Chapter

Chapter 6
6

SCRAP
SCRAP –– STRIP
STRIP

LAYOUT
LAYOUT FOR
FOR BLANKING
BLANKING
SCRAP – STRIP LAYOUT FOR BLANKING
Scrap Layout:
In designing parts to be blanked from strip material,
economical stock utilization is of high importance. The
goal should be at least 75 per cent utilization. A very
simple scrap-strip layout is shown in the next slide

Scrap Allowance:
A scrap-strip layout having insufficient stock between the
blank and the strip edge, and between blanks, will result
in a weakened strip, subject to breakage and thereby
causing misfeeds. Such troubles will cause unnecessary
die maintenance owing to partial cuts, which defect the
punches, resulting in nicked edges. The following
formulas are used in calculating scrap-strip dimensions
for all strips over 0.8 mm. thick
 SCRAP – STRIP LAYOUT FOR BLANKING

t = specified thickness of the material B = 1.25 t when C is less than 64 mm

B = 1.5 t when C is 64 mm or longer C = L + B, or lead of the die
This Fig shows: Single scrap-strip layout: t is the stock thickness;
B is the space between part and edge of strip; C is the lead of the
die, i. e., the distance from a point to the corresponding point on
the next point; L is the length of the part; H is the part width; W is
the width of the scrap strip.
Allowances for one-pass layouts
 SCRAP – STRIP LAYOUT FOR BLANKING

Minimum Scrap-Strip Allowance: If the material to be blanked is 0.6

mm thick or less, the formulas above should not be used.
Instead, dimension B is to be as follows:
Strip width W Dimension B
0 - 75 mm 1.3 mm
76 – 150 mm 2.4 mm
150 – 300 mm 3.2 mm
Over 300 mm 4.0 mm
Allowances for one-pass layouts
 SCRAP – STRIP LAYOUT FOR BLANKING

View A
For work with curved outlines, B = 70 per cent of strip thickness t.

View B
For straightedge blanks: where C is less than 64 mm, B = t, where C
is 64 mm to 200 mm, B = 1.25 t, where C is over 200 mm, B = 1.5 t.
Allowances for one-pass layouts
 SCRAP – STRIP LAYOUT FOR BLANKING

View C
For work with parallel curves, use the same formulas as for view B.

View D
For layouts with sharp corners of blanks adjacent, B = 1.25 t.

Allowances for one-pass layouts

 SCRAP – STRIP LAYOUT FOR BLANKING

View A
Single-row layout intended for two passes through the die B = 1.5 t
View B
Double-row layout of blanks with curved outlines: B = 1.25 t
View C
Double-row layout of parts with straight and curved outlines B = 1.25 t

Allowances for one-pass layouts

 SCRAP – STRIP LAYOUT FOR BLANKING

Percentage of Stock Used

If the area of the part is divided by the area of the scrap strip used, the
result will be the percentage of stock used.

If A = total area of strip used to produce a single blanked part, then

A = Pitch x Strip Width, and a = area of the part = L H.
If P = 11.5 mm and W = 32 mm then A = 11.5 X 32 = 368 mm²
If L X 9.5 mm and H = 27 mm then a = 29.5 X 27 = 256.6 mm²
Percentage of stock used:

a  256.5 
=  = 70% approx.
A 368

Allowances for one-pass layouts

EVOLUTION OF A BLANKING DIE

•Die Set Selection

•Die Block Design

•Punch Design

•Stripper Design

•Stock Stops
EVOLUTION OF A BLANKING DIE
Part to be blanked
 EVOLUTION OF A BLANKING DIE
Die Set Selection
A commercially available standardized two-post die set with
150 mm overall dimensions side-to-side and front-to-back allows the
available 76 mm. wide stock to be fed through it. It is large enough
for mounting the blanking punch on the upper shoe (with the die
mounted on the lower shoe) for producing the blank shown in the
previous slide, since the guideposts can be supplied in lengths of from
100 to 225 mm.
Since the stock, in this case was available only in a width of 76
mm the length of the blanked portions extended across the stock left a
distance between the edges of the stock and the ends of the blank of 6
mm or twice the stock thickness; this allowance is satisfactory for the
3.2 mm stock.
 EVOLUTION OF A BLANKING DIE
Die Block Design
By the usual ‘rule-of thumb’ method, die block thickness
should be a minimum of 20 mm for a blanking perimeter up to 75 mm
and 25 mm for a perimeter between 75 and 100 mm. For longer
perimeters, die block thickness should be 32 mm. Since the perimeter
of the blank is approximately 178 mm a die block thickness of 38 mm
was specified, including a 6 mm grinding allowance.
There should be a margin of 32 mm around the opening in the
die block; its specified size of 150 x 150 mm allows a margin of 45
mm in which four M10 cap screws and dia. 10 mm dowels are located
at the corners 20 mm from the edges of the block
 EVOLUTION OF A BLANKING DIE
Punch Design
The shouldered punch (57 mm) long is held against a 6 mm
thick hardened steel backup plate by a punch plate 20 mm thick)
which is screwed and doweled to the upper shoe. The shut height of
the die can be accommodated by a 32-ton (JIC Standard) open-back
inclinable press, leaving a shut height of 240 mm. For the conditions
of this case study, shear strength S = 42 kg/mm², blanked perimeter
length L = 178 mm approx. and thickness T = 3.2 mm.
From the equation P = S L T
The pressure P = 42 kgs. X 178 mm X 3.2 = 23.92 tons.
This value is well below the 32-ton capacity of the selected press.
The shut height is 178 mm less the 1.6 mm travel of the punch into the
die cavity.
 EVOLUTION OF A BLANKING DIE
Stripper Design
The stripper that was designed is of the fixed type with a channel or slot
having a height equal to 1.5 times stock thickness and a width of 80 mm to allow for
variations in the stock width of 75 mm. The same screws that hold the die block to
the lower shoe fasten the stripper to the top of the die block.
If, instead of 3.2 mm stock, thin (0.8 mm) stock were to be blanked, a
spring-loaded stripper would firmly hold the stock down on top of the die block and
could, to some extent, flatten out wrinkles and waves in it.
A spring-loaded stripper should clamp the stock until the punch is withdrawn from
the stock. The pressure that strips the stock from the punch on the upstroke is
difficult to evaluate exactly. A formula frequently used is
Ps = 2.5 x L x t kgs.
Where Ps = stripping pressure, in kgs., L = perimeter of cut, in mm.
t = stock thickness, in mm.
 EVOLUTION OF A BLANKING DIE
Stock Stops
The pin stop pressed in the die block is the simplest method for
stopping the hand-fed strip. The right-hand edge of the blanked
opening is pushed against the pin before descent of the ram and the
blanking of the next blank. The 4-8 mm depth of the stripper slot
allows the edge of the blanked opening to ride over the pin and to
engage the right-hand edge of every successive opening.
The design of various types of stops adapted for manual and
automatic feeding is covered in a preceding discussion.
EVOLUTION OF A BLANKING DIE
Die Design

A Blanking Die
EVOLUTION OF A PROGRESSIVE BLANKING DIE

•Part Specification
•Scrap-Strip Development
•Press Tonnage
•Calculation of the Die
•Calculation of Punches
•springs
•Piloting
•Automatic Stops
EVOLUTION OF A PROGRESSIVE BLANKING DIE
Part Specification

Linkage case cover

 EVOLUTION OF A PROGRESSIVE BLANKING DIE
Product study
Step 1, Part Specification
1. The production is of medium class; therefore a second-class die
will be used.
2. Tolerances required: Except for location of the slots, all
dimensions are in fractions. The slot locations, though specified in
decimals, are not very close. Thus a compound die is not
necessary; a two or three-station progressive die will be adequate.
3. Type of press to be used: Available for this production are presses
of 5-ton, 8-ton, or 10-ton capacity, with a shut height of 175 or
200 mm.
4. Thickness of material: Specified as 32 mm standard cold rolled
steel.
EVOLUTION OF A PROGRESSIVE BLANKING DIE
Step 2, Scrap-Strip Development

B = 1.25t = 1.25 x 3.2 = 4 mm

W = H + 2B = 60 + 8 = 68 mm
C = L + B = 60 + 4 = 64 mm

Scrap-strip development for part

 EVOLUTION OF A PROGRESSIVE BLANKING DIE
Step 3, Press Tonnage
It is now in order to determine the amount of pressure needed. Only the
actual blanking in the fourth stage need be calculated, since the work in the first
three stages will be done by stepped punches.
From Table, the shear strength S of cold rolled steel is 40 kgs/mm². The length L
of the blanked perimeter equals 60 x 4 = 240 mm. The depth of cut (stock
thickness t) equals 3.2 mm.
From the equation P = S L t
P = 40 kgs./mm² x 240 mm x 3.2 mm
= 30,720 kgs. Or 30.7 tons.
An available press only a 30-ton press with a 190 mm shut height and a 50
mm stroke. This press is selected. The bolster plate is found to be 300 mm deep,
140 mm from centerline of ram to back edge of bolster, and 600 mm wide. Shank
diameter is 64 mm.
 EVOLUTION OF A PROGRESSIVE BLANKING DIE
Step 4, Calculation of the Die
The die. The perimeter of the cut equals 240 mm and therefore the
thickness of the die must be 25 nm. The width of our scarp-strip opening is 60 mm
with 32 mm extra material on each side of the opening, it will be 60 mm + 64 mm =
124 mm or 130 mm width. The distance from the left side of the opening in stage 4
to the edge of the opening in stage 1 equals 3 C + 30 + 6 = 192 + 30 + 6 = 228 mm
and plus 62 mm = 290 mm or 296 mm long.
Therefore the die should be 25 x 130 x 296 mm long.
The die plate. As a means of filling in between the die and the die shoe, a
die plate of machinery steel is used. To secure the die plate to the die shoe M12
cap screws and dowels are used. A minimum of twice the size of the cap screw for
the distance from the edge of the die to the edge of the die plate is needed, which
will equal 25 mm. Twice this distance = 50 mm and 50 mm added to the size of the
die will result in a die plate of 25 x 180 x 346 mm. Figure in the next slide shows
the die and die plate fitted together and with the holes, which show the sharpening
portion and the relief portion.
EVOLUTION OF A PROGRESSIVE BLANKING DIE

The fitting of the die and die plate. Note the shear on stage 4,
also the straight edge and the relief at die opening.
EVOLUTION OF A PROGRESSIVE BLANKING DIE
Step 5, Calculation of Punches
Good practice requires 10 per cent of the metal thickness to be
removed from the basic dimension of the blanking punch. This same
value is used on the die opening, since holes are to be pierced in the
blank. The clearance rule will be applied to the die opening in Stages
1, 2, and 3, and to the punch in Stage 4 (see fig.).
For Stage 4: Blank to be 60 mm. square,
Stock thickness = 3.2 mm; 10% = 0.32 mm.
Punch = 60 – 0.32 = 59.68 mm.
Therefore the die opening will equal 60.01 to 60 mm and the
punch will equal 59.68 to 59.67 mm.
EVOLUTION OF A PROGRESSIVE BLANKING DIE

For Stage 2: Slot to be 8 mm wide by 34 mm long .

Die = 8 + 0.32 + 8.32 mm long = 34.32 to 34.33 mm.
Punch will equal 3.99 to 8.00 mm. wide, and 33.99 to 34.00 mm.
long.
The punch and the die opening will have straight sides for at
least 3 mm for sharpening, and then will have a taper relief of about
1½ deg. to the side. Figure 3-43 also shows a 3 mm shear for the die
at Stage 4 and a 3 mm shear for the punches of Stage 2, and also the
stepped arrangement of the punches for all stages.
EVOLUTION OF A PROGRESSIVE BLANKING DIE

Illustrates calculation of clearance. Shear on punches, Die and

Stepped arrangement of punches to reduce cutting pressure.
 EVOLUTION OF A PROGRESSIVE BLANKING DIE

Step 6, springs
A solid stripper plate can be used for this job.
Step 7, Piloting
Figures 3in the previous slide illustrate the arrangement for
piloting. In this case it is direct piloting. However, if the part did not
have a center hole, and the slots and other holes were too small,
indirect piloting would have to be provided.
Step 8, Automatic Stops
Finger stops, illustrated in Fig., will act as stops when a new
scrap strip is being inserted but, after that, an automatic spring drop
stop must be used to halt the scrap strip. Figures in the next slide
illustrate details of the completed drawing of the die.
EVOLUTION OF A PROGRESSIVE BLANKING DIE

Top and front sectional view of completed die.