Chapter 4

Introduction to Die
Cutting operation

The Fundamentals of
Die-cutting Operations
Plain Blanking
Piercing
Lancing
Cutting off and Parting
Notching
Shaving
Trimming

Die-cutting Operations

Plain Blanking

Die-cutting Operations

This operation
consists of
simple hole
punching

Piercing

Die-cutting Operations

This is a
combined
bending and
cutting operation

Lancing

Die-cutting Operations

CUTOFF

PARTING

Cutting off and Parting

Die-cutting Operations

NOTCHING

SHAVING

Notching and Shaving

Die-cutting Operations

Trimming

Cutting Action in Punch and Die Operations

The punch contacts the
work material supported by
the die and a pressure
buildup occurs. When the
elastic limit of the work
material is exceeded, the
material begins to flow
plastically
(plastic
deformation). The punch
penetrates
the
work
material, and the blank, or
slug, is displaced into the
die
opening
a
corresponding amount. A
radius is formed on the top
edge of the hole and the
bottom edge of the slug, or
blank, as shown in Fig.

Cutting action progression when blanking and piercing metal

Cutting Action in Punch and Die Operations

Fig. Shows the
characteristic
appearance of the
edges of parts
produced by
blanking and
piercing operations
in detail. The edge
radius (or rollover) is
produced during the
initial stage of
plastic deformation.
The edge radius is
more pronounced
with soft materials.
Characteristic appearance of edges of parts produced by piercing and blanking

Die-cutting Operations
Die Clearance
Clearance is defined as the intentional
space between the punch cutting edge and die
cutting edge. Clearance is always expressed as
the amount of clearance per side. Theoretically,
clearance is necessary to allow the fractures to
meet when break occurs. The amount of
clearance depends upon the kind, thickness and
hardness of the work material.

Die-cutting Operations

The effect of clearance

Too little clearance: Fracture do not meet
Correct clearance: Fracture do meet

Die-cutting Operations

Punch and Die clearance

Die-cutting Operations
Punch and Die clearance

Die-cutting Operations
Angular Clearance
A small amount of draft is provided
below the die opening to prevent blanked
parts or slugs from stacking inside the entire
width of the die wall. The draft is commonly
referred to as angular clearance and is
expressed in degrees per side.

Die-cutting Operations
Angular clearance is
necessary to prevent
backpressure caused by
blank or slug buildup
especially when the
punches or die block are
fragile. Recommended
angular clearance varies
from to 2 per side,
depending upon the
material and the shape of
the work piece. Soft
materials and heavy-gage
materials require greater
angular clearance. Larger
angular clearance may be
necessary for small and
fragile punches.

The use of angular clearance

Cutting Force
The cutting force formula is EXAMPLE: A 5 cm. square hole is
to be pierced in mild steel, which is
F = Spt
0.15 cm. thick.
Solution
where
S = 3.875 tons / cm.2 (for for M. S.
F = cutting force
from Table)
S = shear strength of stock p = 5 + 5 + 5 + 5 = 20 cm.
material
t = 0.15 cm.
p = perimeter or length of Then
cutting edge
F = Spt
t = thickness of material
F = 3.875 x 20 x 0.15 = 11.625 tons

Use of formula

Die-cutting Operations
Stepping punches
Single shear on punch
Single shear on die
Double shear on
punches
Shear Angle

Double shear on
punches

Method of reducing cutting forces

Stripping

Fixed type stripping

Stripping

Spring loaded type stripping

Stripping Force
The stripping force formula is
Lst = K x A
where
Lst = Stripping force in Kgs.
K = Stripping constant in
kgs./cm2
A = Area of cut surface in
cm.2
By experiment
K = 105 for sheet metal < 0.16 cm.
K = 148 for sheet metal > 0.16 cm.

EXAMPLE: A 5 cm. square hole is to

be pierced in mild steel, which is 0.15
cm. thick.
Solution
p = 5 + 5 + 5 + 5 = 20 cm.
t = 0.15 cm.
Then A = 20 x 0.15 = 3.0 cm.2
Lst = K x A
Lst = 105 x 3.0 = 315 kgs.

Use of formula

PUNCH AND DIE MOUNTING

(Std. Die Set)

Rear pillar cast iron standard die set

PUNCH AND DIE MOUNTING

(Std. Die Set)

Center pillar cast iron standard die set

PUNCH AND DIE MOUNTING

(Std. Die Set)

Four pillar all steel standard die set

PUNCH AND DIE MOUNTING

(Std. Die Set)

Diagonal pillar all steel standard die

PUNCH AND DIE MOUNTING

PUNCH AND DIE MOUNTING

(Std. Die Set)
When selecting and ordering die sets, the die area can be
determined by use of full-size templates obtainable from the
manufacturer and marked to correspond with the catalog
number. When ordering, the following information must be
specified:
1) Quantity and catalog number
2) Type and length of bushing
3) Overall length and type of guide pins, based on shut height
and length of stroke
4) Diameter of shank or no shank
5) Thickness combinations if other than those listed in the
catalog (special thicknesses generally furnished at extra cost).

Types of Die Construction

Single Station Dies

Progressive dies
Transfer dies
Compound dies
Combination dies
Rubber Pad Blanking
Fine blanking

Types of Die Construction

Each single station die
performs one operation and a set
of dies for a lamination can be
mounted in one press or different
presses.
Simple
laminations
usually are produced in one
operation. More complex parts
may require several operations.
Fig. shows a typical sequence for
the production of stator & rotor
laminations in four operations.
These are
1.Stock blanked & pierced,
2.Stator lamination notched,
3.Rotor lamination separated
from stator lamination and
4.Rotor lamination notched.

Sequence of operations

Single Station Dies

Types of Die Construction

Progressive Die
Progressive dies perform two or more operations at different
stages every time the ram descends. The stock strip is
advanced through a series of stations that perform one or
more distinct die operations on the work piece. The strip
must move from the first through each succeeding station to
produce a complete work piece. Thereafter a complete work
piece is produced with each stroke of the ram
The distance from one station to the next must be the same.
The station-to-station distance is also the same as the
advance distance. The advance distance, called advance for
short, is the distance the strip moves in order to relocate
(register) at each successive station.

Types of Die Construction

1.

Stock strip

2.

Die stop activating pin

3.

Primary die stop

4.

Blanking punch

5.

Piercing punch

6.

Punch plate

7.

Stripper plate

8.

Die block

9.

Die set

10. Button stop

11. Pilot pin

Simple Progressive Die

Types of Die Construction

Transfer Die
Transfer dies are used for piercing in applications generally
similar to those for which progressive dies are used. A
number of operations are done in successive stations of the
transfer die. Piercing, blanking, cutoff, lancing, notching,
forming and drawing can be done in transfer dies. The
method differs from progressive die operation in that the
work piece does not remain attached to the strip for feeding,
but is fed from station by transfer by mechanical fingers,
levers or cam. Transfer dies are particularly suited to the
making of parts that would be difficult to connect to the
stock skeleton with carrier tabs.

Types of Die Construction

Compound Die

A compound die differs from a progressive die in that it

performs two or more cutting operations during one stroke of
the press at one station only. In order to do this, both the upper
and lower member of the die set carry punching and blanking
elements, which are directly opposed to each other. In other
words, the piercing punches act in the opposite direction with
respect to the blanking punch. A simple compound die in a
closed position is shown in Fig. in the next slide. Note that the
blanking punch also serves as the piercing die. The sidewalls
adjacent to the cutting edges of the blanking-die opening are
straight because the blank does not pass through the die. The
blank is return-ejected by the knockout mechanism that is
actuated at the return stroke of the press.

Types of Die Construction

Compound Die

Types of Die Construction

Combination Die
A die in which a cutting operation is combined
with a noncutting operation is referred to as a
combination die. The cutting operations may
include blanking, piercing, trimming, and cutoff
and are combined with noncutting operations,
which may include bending, extruding,
embossing, and forming. Fig. in the next slide
shows a typical combination die that draws and
blanks a shell.

Types of Die Construction

Combination Die

Types of Die Construction

Rubber Pad
A This methodBlanking
of blanking employs a rubber pad in the punch

holder and a punch in the die shoe (See fig.in the next slide). It
operates on the principle that when rubber is compressed, it
transmits the pressure in all directions. The rubber is confined in
a cavity in order to exert full force against the part. This type of
blanking, referred to as the Guerin process, is generally limited
to the blanking of aluminum alloy up to a maximum of 1 mm.
thick. The minimum hole diameter or width of cutout is
approximately 50 mm., and at least 38 mm. trim is necessary for
external cuts.

Types of Die Construction

Rubber Pad

Types of Die Construction

Fine Blanking Die
Fine blanking is basically a method of blanking or piercing parts
without die break. This is done by controlling metal flow in the
shearing area. A knife-edge or impingement ring, is pressed into
the metal outside the cutting line and the metal outside this line
is restrained by application of great force. With the metal
virtually unable to move in ward and a punch-to-die clearance
between 0.0075 mm. and zero, a clean smooth-edge cut can be
made regardless of stock thickness. A triple-action hydraulic
press is required to get the holding or gripping action, controlled
punch speed, and counter pressure on the part necessary for
successful fine blanking.

Types of Die Construction

Fine Blanking Die

Types of Die Construction

Advantages of the Fine
Blanking Die

1)

Automatic manufacturing

2)

Elimination of secondary operation

3)

High production

4)

Continuous good quality

5)

Reduced space requirement for the production line

6)

Less material handling