A W ’ S P R E S S T O O L T E C H N O L O G Y

Fine blanking and Forming in One Pass

New technology uses multiple tooling modules Fed by a CNC-controlled part-transfer

system to consolidate all operations, including in-tool debarring, into one pass. The result
is Production of net-shape 3D parts.

The ability to combine fine blanking, forming and other stamping functions
into a single pass through the press allows rapid production of net shape complex 3D
parts while eliminating secondary operations. That’s the promise of FFS (Forming,
Fine blanking and Stamping) technology from Fein tool System Parts, in use at the
company’s facility in Nashville, TN. The technology, geared to high-volume
precision component production, uses multiple tooling modules fed by a CNC-
controlled part-transfer system to consolidate all operations, including in-tool
deburring, into one pass through a unique 500-ton hydraulic press. FFS makes use of
Fein tool’s flexible tooling concept, incorporating low-cost simple-maintenance
stamping modules in addition to forming and fine blanking modules that provide
excellent edge quality and dimensional accuracy for critical part features, according to
company officials. With FFS technology, Fine tool can eliminate secondary
operations Such as Bending, Milling, Grinding, Broaching, Drilling and Deburring as
Well as associated work-in-process handling costs.

Produces Complex Parts

Ideal for intricate automotive components such as racks, clutch plates, safety
components and seat-recliner hardware as well as electrical and medical parts, FSS
can produce ferrous and nonferrous parts to thickness of 5 mm. The process
reportedly holds dimensional accuracy to ±0.025 mm and flatness to 0.025 mm across
25 mm for parts from 150 to 200 sq. mm unlike conventional stamping, fine blanking
applies multiple forces that support the part against the ram’s stroke and sandwich the
material in compression to eliminate lateral movement. This controls deformation and
die break to maximize part quality and edge finish. Fine blanking does not tear blanks
from the material, but instead cold-extrudes them.
When combined with traditional forming and stamping, as in FSS, the process
incorporates multiple tooling modules that enable fine blanking and forming
procedures such as coining, bending, piercing, and in-tool deburring, while a CNC-
controlled transfer system delivers parts to succeeding modules. To ease maintenance,
FSS technology design allows individual removal of modules without disassembly of
the entire tooling system. Also, modular design allows use of common modules on
families of parts.

Proving itself onthe Shop floor

Proving its worth, FFS recently produced complex seatbelt-retractor housings
quicker than conventional methods would allow, according to Fein tool officials. The
U-shaped component, a housing for a seat-integrated seatbelt mechanism, holds a
spool and ratchet element, which retracts the seatbelt and absorbs the full load of a
passenger during an accident. Made of high strength low-alloy steel, the part had been
produced as a traditional fine blanked component requiring separate operations for
fine blanking, belt sanding for burr removal, washing/drying to remove sanding
debris, offset bending and U-bending. The old process, requiring multiple machinery
and handling stages, produced about six parts/min. An unfortunate byproduct, the

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process often brought corrosion buildup while components waited for secondary
operations or tool repair.

Part Production Increased

Fein tool applied its FFS concept to this part, value-engineering it to
incorporate all necessary operations and some cost-saving new features to produce a
net-shape part with each stroke of the FFS press. Using modular tooling stages, which
provide complete separation of each operation, FFS delivers 15-finished parts/min.
while eliminating handling, corrosion and scrap problems endured with the previous
method. The parts exit the press ready for immediate delivery for electroplating and
assembly.
The FFS technology integrates in tool deburring technology, which eliminates
secondary belt sanding along with associated handling and washing. Instead of belt
sanding to eliminate slight burrs induced during fine blanking, a tool module is used
to restrict the part, essentially coining or pushing the burr back into the part, leaving a
clean edge while maintaining critical tolerances, difficult to do when belt sanding.
Besides speeding production, FFS brought an optimized design for the seatbelt
housing, eliminating components previously required for housing assembly. The
original part design called for a semi-pierce with a reinforcing washer spin-riveted
onto the side of the part to improve retention of the spool in the housing. Fein tool
engineers developed a special coining operation that produces a locking profile that
simulates the effect of the washer. This eliminated an assembly step and reduced part
costs for the customer.

Holds Tight Tolerances

Perhaps the most vital part features are a U-shaped bend and two large 37-
mm-dia. center holes that retain the seatbelt spool. During an accident, the spool
receives the load from the passenger and attempts to pull out of the holes on either
side of the U-bend. The previous method required hand loading the part onto a
separate press to receive the U-bend, causing variations in critical U-bend width,
leading to rework. Now, the FFS CNC controlled transfer system accurately delivers
the part to the U-bend tool module and repeatedly produces the bend to 1.6CPK. FFS
holds the U-bend outside width to 60 mm ±0.1 mm, and the two 37-mm-dia. holes to
±0.2 mm, reportedly providing excellent edge finish and achieving the customer’s
highest specification.
Fein tool identifies small holes used to fasten the housing’s cover as
incorporating one of the most unique features on the redesigned housing. Originally
straight-through holes with a washer around each hole to aid assembly with push-pins
used to hold a cover, the new design integrates a counter bore—inside each hole—and
lead-in/ chamfer on the holes to receive and securely hold push-pins. A unique
coining operation produces the difficult shoulder feature inside the holes, holding
shoulder position tolerance of ±0.04 mm, and ±0.07 mm on the 5-mm hole diameter.

Where are fine-blanked parts required?

Originally fine-blanked parts were primarily used in the office machine

industry. However, it is used in practically every sector of the press work industry.
The following examples listed only indicate the most important areas of fine-blanking
application.

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Office machines:
Typewriters, Calculators, Franking machines, Addressing machines,
Accounting machines, Cash registers.
Household appliances:
Sewing machines, Irons, Washing machines, Mixes, Meat grinders, Coffee
machines etc.
Leisure tank devises:
Ski bindings, Ice and roller skates, Fishing equipment, Pocket knives.
Communication techniques.
Telephone and telex (teletype machines), Radio and Television.
Watch and Clock industry.
Watch and mechanisms, Watch straps.
Cinema and photographic appliances.
Movie and still cameras, Film and slide projectors, Lenses.
Sound reproduction:
Tape-recorders, Record players, dictating machines.
Automobile industries:
Door locks, Carburetors, Gearboxes, Reclining sheet adjustors, Break shoos,
Disk-brakes, Window-wiper drives, Electrical installations, etc

Electrical industry:
Plug in contacts, lead connectors, switching mechanisms.
Measuring and regulation equipment:
Electrical and water meters, Scales, etc
Aircraft industry:
Breaks, etc
General machines and Equipment application:
Industrial sewing machine, Textile machines, Drilling machines, Grinding
machines, Power saws, Drive and control chains, valve plates, Cooling units, Electro
magnetic clutches, Drive and Switching devises, Electrical apparatus, etc

Production Possibilities for Fine-Blanked Parts

Constructional details concerning the configuration of fine-blanked parts.
o Radii on sharp corners.
o Thickness of Sections.
o Hole diameters and slot width.
o Tooth forms.
o Needle-form protrusions.
o Bends.
o Offsets.
o Counter sinks.
o Marking, Semi-piercing, Coining.
Fine-blanking Tolerances
Surface quality of the sheared edges.
Angle Accuracy of the sheared surfaces.
Flatness of the piece-parts.
Die-roll (pull-down).
Burr.
o Linishing (belt sanding).
o Tumbling.

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Construction of Fine-Blanding Tools

The design and construction of fine-blanking tools can be best compared to the
conventional type of compound tools. The fine-blanking tool is, however, more rigid.
The major differences between a fine-blanking tool and a conventional press tool are:
The spring elements providing force for stripping the skeleton strip and for
ejecting the blanked piece-parts are not required. These forces are transferred
by the pressure pins, which are actuated directly from the hydraulics in the
machine.
The clearance between punch and die plate has a total dimension (I.e. relative
to the diameter) of approximately 1% of the material thickness to be worked.
In conventional press tools the clearances is approximately 5-10%.
Due to the reduced clearance the guidance and centering of the main punch
relative to the die plate must be more exact.
The ‘vee-ring’ which, follows the outer periphery of the piece pert form, is
machined on the surface of the guide plate and is imbedded in to the material
to be worked through the hydraulics in the machine. This prevents material to
flow away from the main punch and there by prevents fracture occurring over
the sheared surface.
The main punch from the outer piece-part form is at same time ‘die plate’ for
inner configurations. The inner form slugs do not fall through the main punch.
They are ejected upwards out from the punch with ejector pins actuated by the
hydraulics in the machine after the blanking operation is completed.
These punch inner forms do not run through whole of the height of the punch,
which enables the punch base to be far more rigid. Because of this rigid punch
base, pice-part with many complicated inner forms laying close to each other
may be produced in one operation, without the danger of punch breakage
occurring.

In Fine-Blanking two tool systems may be used.

Tool with sliding (moving) punch.
Tool with fixed punch.

Fine-Blanking Tool with sliding punch

In order that Fine-Blanked components may be produced with minimum
difficulty, an exact centering of the punch to the die plate is require. This centering
only be guaranteed when the main punch is correctly located and guided.
In the so, called ‘Sliding punch’ type of fine-blanking tools both the die plate
and guide plate (pressure plate) are fixed in die-set bolster (die shoes). The punch is
guided through a bore in the lower die-set bolster and the guide plate. The punch
movement is always equal to the material thickness being worked. If the largest punch
dimension exceeds the punch height the exact centering location require, can no larger
be guaranteed.
From this it may be noted that the ‘sliding punch’ tool system is applied mainly to
small and medium sized parts

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Fine blanking tools with fixed punch

Using this type of tool construction the punch is screwed and dowelled to the
die-set bolster the punch is guided through the stripper plate which also functions as
the pressure plate caring the ‘vee-ring’. For this reasons it is essential that the stripper
plate is securely retained and for this purpose is guided over the die-set pillars (guide-
pins).
This basic tool design system is best suited for:
Large, long and narrow parts.
Asymmetrical parts were there is a danger of side pressures occurring.
Parts with many inner forms were a sliding punch arrangement would
not trove strong enough due to the positioning of the ejector pin bridge
in the punch base.
Thick parts which require an exceptionally stable tool design and were
high pressures are to be used in such cases a special adopter ring is
used to give extra support die-set (and thereby also to the punch). The
‘vee-ring’ and ejector pressures are transferred over pains.
Tools with sliding punches are automatically centered in the machine through
the punch base. Fine-blanking tools with fixed punches have to be centered relative to
the adopter rings in order that the pressure pin position corresponds. This is achieved
most easily by introducing two dowel pins in to lower adopter ring and a slot through
the bottom die-set bolster (die-shoe).
Basically it can be stated that for larger parts with complicated forms tools of
fixed punch design are better suited than sliding punch tools. The maintenance and
setting of these tools, however, taxes somewhat longer. As opposed to the sliding
punch tool, where the punch has always to remain in the lower half of the die-set, the
fixed punch may be set in the upper die-set bolster and the piece-part is ejected from
below. This system is applied generally when a removal arm has to be used (large,
heavy parts or multi-punch tools) and also for progressive fine-blanking tools.

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Preparation for the Design of a Fine-blanking tool

Calculation of the required pressures
o Calculation of the blanking (shearing) pressure

The most important factor for determining the type of machine to be used is the
shear pressure. In practice the formula used is as follows:

F = L x S x ƒş x 0.9
F = Blanding or shearing pressure (tones or kp)
L = Total of outer and inner shear periphery lengths (in. or mm)
S = Material thickness (in. or mm)
ƒş = Tensile strength (t./sq. in. or kp/mm2)

It will be noted that instead of ƒş (shear strength) 90% of ƒş (tensile strength) is

given. The reason for this is that the shear strength (ƒş) is only rarely given by
material suppliers.

The exact shear pressure is influenced by the following factors:

o Condition of the edges of the cutting elements (punch and die plate)
o Size of punch-die clearance
o Shear speed
o Geometric form of the part
o Metallurgical structure of the material
o Type and amount of cutting lubricant
o Surface finish of the cutting elements
o Tolerance of the material being worked

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HEAT TREATMENT TECHNIQUES FOR THE MANUFATURE OF fine

blanking TOOL

Hardening and Tempering the Cutting Elements

High alloy tool steels

(chrome steels with approximately 12%Cr) in an electrically heated furnace

Hardening using an electrically heated furnace requires great care in the method of
operation applied. Correct hardening in such furnaces requires packing the elements
to be hardened in a container together with refined coke and small pieces of charcoal,
and then proper heating before quenching.
These are basic requirements, which must be followed. The more precisely the
pre-heating can be controlled to the stage where austeniting takes place, the more
complete and even will be the formation of the hardened structure, i.e. the martensite
structure. A rough austenite grain has a small degree of influence on the possible dept
of hardness, but on the other hand causes rough ‘needle form’ and brittle martensite.
In most cases, for this reason, a fine grained austenite structure must be recommended
in order to obtain a relatively tough but fine and evenly distributed martensite
structure. The size of the austenite grain in the structure is to a large degree dependent
upon the speed with which the transformation is made. Concerning the types of steel
listed the limit of the first heating zone is reached at approximately 1470 0F (8000C). It
is advantageous to pre-heat evenly at this temperature for some 3 hours as other wise
apart from other factors-great tension and change in dimension can occur.
Finally the heat is brought quickly to the hardening temperature fulfilling the
requirements described to give a fine austenite grain. The finer the austenite grain
achieved the less will be the expected change in volume during the cooling-
transformation period, which follows. For this reason it is necessary in air hardening
that a very high degree of dissolution of the chrome and carbon in the austenite is
reached. This is, heating must take place at the high temperature given for air
hardening to prevent too high a chrome-carbon separation during cooling in the air.
Contrary, for oil hardening too high a temperature should not be chosen to best
prevent the formation of stable austenite. A too stable austenitic structure prevents the
formation of from reaching strongly enough and to the degree required at the
increased quenching speed in oil. This causes an increased degree of residual
austenite to be formed, which is coupled proportionally with a decrease in hardness
and also changes in dimension.

Tempering
The tempering operation and the transformation of the material structure thus
caused can become very complex dependent on the alloy elements in the steel.
The tool steels containing chrome are tempered between 340 and 930 0F (170-
5000C) relative to the hardness necessary. Tempering after hardening not only causes
a change in hardness, but also a change in volume. When hardening ejectors, for
example, changes in dimension can be corrected without difficulty by tempering.
Concerning punches, not only are accurate dimensions required but also the
hardness must lie within a certain range. Here the method mentioned above for
changing the volume of the part (i.e. dimensions) is seldom used. Higher hardening
temperatures, and longer periods for holding the heat constant, generally cause the
elements to show a smaller volume in the hardened state. By lowering hardening

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temperatures and shortening periods at constant temperatures the volume tends to

increase. By measuring the punch both before and after hardening it can be seen
whether an increase or a decrease in punch volume during hardening, so that when
tempering at 4000F (2000C) after hardening a certain shrinkage can occur to bring the
punch to size. Knowing the reaction of the tool steel in use during hardening and
tempering enables cutting elements to be hardened with a minimum of dimensional
change and maintain the requirements which have to be met for fine-blanking tools.

High speed steel in salt baths

The heat treatment of high speed steel gives rise to great difficulty due to the high
temperatures necessary and the loss of carbon on the surface of the material
(oxidation). In order to eliminate the danger of loss of carbon content a planed and
even program of heat treating must be followed. This work must be carried out with
the greatest attention to detail. For obvious reasons it is not possible to insert the high
speed steel directly into a high temperature salt bath. Pre-heating in various stages is
necessary.

First pre-heating stage

The first pre-heating operation is not carried out in a salt bath but in the air.
Generally an electrically heated air circulating furnace is used for this purpose. Pre-
heating is carried to approximately 9300 F (5000C). At this temperature there is no
danger that high speed steel will oxidize and cause surface carbon to be lost. The
elements to be heated should be left in the furnace until they are warmed through. A
long pre-heating period can have no bad influence on the work places.

For the second pre-heating stage

Only a salt bath can be used. Electric are furnaces with automatic temperature
controls are required. Experienced has shown that the second pre-heating is best made
at 1470-16500F (800-9000C). If the temperature of16500F (9000C) is not exceeded,
and the duration of pre-heating is not excessive, there is no danger of oxidation
occurring. The elements being hardened remain in the bath until they have been
completely warmed through. Remaining in the bath for a slightly longer period than
necessary can cause no harm as the high speed steel oxidizes very slowly at these low
temperatures.

Third pre-heating stage

For large parts, and especially tools with major variations in sectional thickness, a
third pre-heating at approximately 20000F (11000C) is recommended.

Heating to hardening temperature

To heat the high speed steel to the hardening temperature, which lies between
approximately 2200 and 23700F (1200-13000C), salts are available which vary in
certain respects and require different use of the furnace and methods of operation
employed. Temperature measurement, i.e. temperature regulation, can best be made
using thermal elements within the furnace. The hardening operation is made with the
following apparatus: The pieces to be hardened are either hung from wire, placed on
retaining platforms or set in baskets which are carried through the various baths. The
material used to support the high speed steel must be a low carbon mild steel. Carbon
free steels would melt or cause oxidation of the high speed steel. High speed steel
elements being hardened which come in to contact with the heating electrodes of the

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furnace, when these are under power, can cause melting or areas becoming
overheated. Corners or edges of parts coming into contact with each other in the bath
can also cause this.

Immersion period
The period of time the high speed steel should remain immersed in the high
temperature bath is generally relative to the shape of the elements, the intensity and
length of time taken for pre-heating, and the fall in temperature experienced when
placing the element in the high temperature bath.

Quenching
After the high speed steel elements have been held at the hardening temperature
for the correct period they must be quenched. Only quenching (cooling) in a salt bath
at 930-10800F (500-5800C) may be applied. Air cooling (except on parts with thin
sections) causes loss of carbon (oxidation) on surfaces and cleaning problems.
Cooling in oil leads to unnecessary changes in shape and dimension, Cracking and
cleaning problems. The parts are generally kept in the quenching bath until they have
cooled to the temperature of the bath. They can remain in the bath for a longer period
as this causes no unfavorable effects to the elements. The high speed steel parts are
then hardened in the air. The pieces may not belied on the floor or on a table as one
side would cool more quickly and cause cracking, also the salt dropping from the
pieces will be wet and cause corrosion. The pieces should hang freely in a steel or
aluminium container and cool slowly. After cooling completely the parts should be
tempered immediately.

Tempering
This can be carried out most suitably in a salt bath furnace, generally in two
stages, one immediately following the other, each taking ½ to one hour at 1000-
10800F (540-5800C) with complete cooling between both operations. High speed steel
which has been sufficiently hardened may not become softer through tempering but
will rather become 1-3 points higher on the Rockwell scale. Air circulation furnaces
may also be used for tempering. Here, however, there is a danger that the tool
elements and also the furnace may corrode if the salt is not completely removed from
the parts being hardened. Also this type of furnace requires longer heating up and the
temperature can not be held as constant as in a salt bath. It must also be noted, that
some salts in the high speed steel tend to attack the steel during tempering so this that
this method of tempering can only be used where the complete part is to be ground or
sand blasted.

Cleaning
Following tempering the parts must be cleansed of the salt. This is done with
fresh water free of all sodas or phosphates, etc. However, a very good cleansing
compound for this purpose is 2-3% diluted Sirilon HS at a minimum of 1800F (800C).
This cleanser completely removes all salt and does not cause any damage or
corrosion to the steel.It has been shown that fresh water removes the salt more slowly
than used water and tends to cause more rusting. Lastly the parts are cleaned with
fresh water and immersed in oil to remove the last degree of moisture. This is to be
recommended especially if the parts are to be held in stock.

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High alloy tool steels in salt baths

The heat treatment of tool steels with 12% chrome content in salt baths can be
made as described above. The austeniting period, and the heating times must be made
to correspond with the form and dimension of the parts being hardened and
maintained relatively accurately.

Construction and Requirement of fine-blanking Presses

Fine-blanking presses are constructed and built to meet requirements of fine-

blanking as explained in the previous pages. These basic requirements are briefly
listed below. For construction details concerning various questions and solutions these
are explained as far as is necessary in the machine description on the following pages.

Triple action press

The requirement for fine-blanking is that the press supplies the three necessary
forces, namely:
1. Shear pressure
2. ‘Vee-ring’ pressure
3. Counter pressure
Regarding the shear pressure, a mechanical (double toggle) or hydraulic drive
system may be used. It is important in either type of press that there is a reduced ram
speed during the shearing operation. During the actual fine-blanking or shearing
action the material outside the shear periphery is firmly clamped by the ‘vee-ring’ and
retained inside the shear periphery by the ejector. The ‘vee-ring’ and counter
pressures provide containment of the material to prevent it following away from the
shear zone during the shear operation. In order to shear various types of material,
material thickness and piece-part forms, these two pressures must be infinitely and
independently variable and adjustable. They must remain constant during the shearing
operation. These requirements for material containment (clamping pressures) are met
by the use of a hydraulic system.

Shear speed
As piece-part thickness increases, and the greater the tensile strength of the
material becomes, the slower the shear speed required to achieve cleanly sheared
surfaces, and prevent excessive heating of the tool cutting element. For this reason the
shear speed of a fine-blanking press must be adjustable. As a rule, fine-blanking press
shear speeds lie between 0.196"-0.590" (5 and 15 mm) per second. On the other hand,
for reasons of economy in manufacturing the press must be able to produce as many
parts per hour as possible. Giving the ram cycle a correctly controlled speed
movement with accelerating phases solves the obvious discrepancy appearing in the
requirements stipulated above.

Ram reversal
Precise control of the ram reversal movement, after the shearing operation is
completed, is another point requiring considerable attention. Contrary to conventional
press work, where the punch may penetrate into the die 0.0039"-0.0079" (0.1-0.2 mm)
the reversal of the ram section in a fine-blanking press must be made in the same
instant that the part is fully sheared. Allowing the punch to penetrate into the die,
results in faster blunting of the tool cutting elements and low production runs.

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Play-free ram guidance

The close clearance between the punch and die in the fine-blanking tool requires an
exact ram guidance to prevent any deflection occurring in the press. If this
requirements is not met or is insufficient, this result in piece-parts of poor quality and
short too life.

Press frame design

Fine-blanking press must be of an especially robust design with sufficient supporting
mass in the press frame to absorb reaction, sudden pressures and all vibration.
Through a symmetrical press frame design undesirable deformation, which could be
caused by the working pressures, are eliminated. As against the «C» type machine
frame of eccentrically placed rectangular columns. Any ‘breathing’ of the press frame
during blanking operation is thus reduced to a vertical stretching of the press frame,
excluding all side pressures.

Tool safety device

In order to use the presses as full automats they must be equipped with a tool safety
device system. When a component or slug remains in the tool zone the machine stops
automatically without exerting pressure and without damaging the press, tool or
piece-part. This devise is an integral part of the machine. Safety device on each tool,
which require specially trained personnel to fit them, are not necessary.

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