PIERCING

Piercing is a shearing process where a punch and die are used to create a hole in sheet metal or a plate. The
process and machinery are usually the same as that used in blanking, except that the piece being punched out
is scrap in the piercing process.

Fig. Difference between Blanking & Piercing operation

RULES FOR PIERCING

(A) The outside edge of the blank adjacent to this punched hole should not bulge because the web (material
between the edge of the hole and the outside contour of the blank) is equal to the material thickness “t”.
(B) In this case, the edge of the blank will bulge slightly (measurable but hardly visible) because the web is
less than the stock thickness. In this instance, the web is equal to 2/3 of the stock thickness “t”.
(C) The bulge is noticeable because the web is much less than the material thickness, only 1/3 of “t”.
(D) With no web, the punched hole, which is tangent with the edge, will break through.
(L) In this instance, we punched the hole undersize and redrilled to size without deburring to illustrate the
small burr that will occur from redrilling. This burr will occur on the drill side or, in this instance, on the
burr side of the blank.
(M) Here, too, the same narrow web (1/2 of “t”) exists, but the hole was drilled through to avoid bulging.
Drilling is, of course, much slower than punching and in addition there is a burr on the opposite side, which
may or may not be objectionable.

(N) As in the explanation (M), this hole was also drilled through; and in addition was deburred on the far
side by lightly countersinking. Two operations are needed and either one is slower than punching, so the
costs increase to several times the price of the punched holes in explanation (A), (B), (C), and (D), or the
punched and redrilled hole in the explanation (L).
(E) This No. 3 (medium fit) tapped hole was produced in three operations: punch, tap, and remove burr. (For
a No. 4 class fit punch undersize, redrill to remove the breakage from punching, tap and remove burr is
required.)
(F) This No. 3 (medium fit) tapped hole was produced in two operations: punch and tap. If the burr from the
tapping is acceptable, the production cost would be lower than the procedure outlined in the previous
explanation (E).
(W) (V) & (U) These holes were punched in the flat blank before forming.
(I) This notch was too narrow and too long to include in the blank and was therefore punched after blanking.
This notch may require tools and will require an extra operation which will increase the cost in comparison
to the adjacent notch (H)

Guidelines for Piercing Operation:

When it comes to piercing operations, which involve creating holes or openings in materials, there are
several design guidelines to consider. These guidelines aim to ensure efficiency, accuracy, and safety in the
piercing process. Here are some key considerations:
 Material selection: Choose the appropriate material for the piercing based on its properties, such as
thickness, hardness, ductility, and machinability. Consider factors like the material's ability to
withstand deformation and cutting forces during the piercing operation.

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 Hole design: Design the hole shape, dimensions, and location according to the desired purpose and
requirements. Consider factors such as hole size, tolerance, position, and any necessary post-piercing
operations. Optimize the hole design to achieve the desired functionality and accuracy.
 Tool selection: Select the appropriate tooling for the piercing operation. Consider factors such as the
material being pierced, hole size, and desired edge quality. Choose between punches, dies, drills, or
other piercing tools based on your specific requirements.
 Tool geometry: Optimize the tool geometry to achieve efficient and accurate piercing. Consider
factors such as punch diameter, clearance, cutting edge geometry, and die design. The tool geometry
should promote effective material displacement and minimize burrs or shearing defects.
 Cutting forces: Calculate or estimate the cutting forces involved in the piercing operation. Ensure
that the selected tools and the machine used can withstand these forces without excessive
deformation or failure. Consider factors such as material thickness, tensile strength, and shearing
resistance.
 Lubrication: Apply appropriate lubrication between the tooling and the material being pierced to
reduce friction and improve the piercing process. Lubrication helps prolong tool life, reduce wear,
and improve hole quality. Choose the lubricant based on the material being pierced and the specific
piercing conditions.
 Support and stability: Provide adequate support and stability to the work piece during the piercing
process. Consider the work piece size, shape, and rigidity when designing the support system. Proper
support prevents work piece deflection, minimizes vibrations, and ensures accurate hole placement.
 Safety considerations: Prioritize safety during the piercing operation. Implement safety protocols,
such as proper guarding, personal protective equipment (PPE), and safe work practices. Consider the
potential hazards associated with tool handling, material deformation, and machine operations.
 Chip and slug management: Develop a plan to manage chips or slugs generated during the piercing
process. Consider methods for effective chip evacuation and slug removal, including appropriate
equipment and waste disposal procedures. Proper chip and slug management contributes to process
efficiency and safety.
 Quality control and inspection: Implement quality control measures to ensure the accuracy and
integrity of the pierced parts. Regularly inspect and measure critical dimensions, hole quality, and
tolerances. Use appropriate measuring instruments, such as calipers, micrometers, or optical
measurement systems, to verify part conformance.