Chapter I

Shearing Processes
M. L. L. P. J. Ledel

1.1 Introduction
Processes of shearing (or cutting without stock rem oval) belong to the
group of metal working processes used to make parts from standard sheet,
strip and coiled strip material. Shearing is a mechanical operation performed
mainly by exerting heavy pressure on the stock. This pressure is usually sup-
plied by an eccentric press whilst the shape is imparted by punches. The
application and development of these techniques have gained considerable
impetus from the vast expansion of industrial production and consequent
demand for products in more or less large quantities, which demand has also
led to higher standards of product quality and accuracy of size and shape. A
further stimulus was and is being given to this development by rapid advances
in mechanisation and miniaturisation. To meet the more and more exacting
requirements it has been necessary to adapt the processes and methods of
production, as weIl as the measuring and test systems, machines and materials
and the design of punches and other tools employed.
One important factor calling for due consideration is efficiency, governed
very largely by the total run of the particular product as weIl as its quality,
precision and material. It is upon these factors that the choice of production
method depends.

A. Davidson (ed.), Handbook of Precision Engineering

© N. V. Philips’ Gloeilampenfabrieken, Eindhoven 1974
2 HANDBOOK OF PRECISION ENGINEERING

Another essential is to take the functional requirements of the product into

account and try to design this with the inherent possibilities ofthe prospective
production method in mind.
Shearing as discussed in this chapter means the process of severing material
by means of two tools moving relative to each other. Punching, blanking and
piercing and cutting-off are specific forms of shearing. The object of the shear-
ing process is to enable those with the necessary knowledge of it and of all the
different punches and dies (or any other tools involved) to decide how best to
make a product at the least possible cost.

1.2 Shearing technology

1.2.1 Punching
Punching is the process of shearing usually closed contours from a sheet of
material (2) by means of a punch (I) and die (3) (see figure 1.1a).
A punching operation can be said to have three phases. It starts with the
punch exerting enough pressure on the material to cause elastic deformation.

2- --f'","-

Fig. 1.1 Punching sheet material.

a. Open punching tool. b. The punching process.
1 = blanking punch; 2 = stock; 3 = die; 4 = blank.

Next the punch begins to penetrate, thereby compelling the material to under-
go plastic deformation and thrusting that within the contour into the die
opening, and finally shear occurs and the contour tears out. The material is
thus divided into two parts, namely the blank and the remaining scrap or 'web'
(figure l.lb).
Figure 1.2 illustrates these three phases of the punching operation. 1 In phase
one, section a, the punch begins to exert pressure on the material and when
this is strained beyond the yield point plastic deformation occurs.