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Blanking

Blanking is a manufacturing process where pieces are punched out of sheets or strips of raw material into specific shapes, called blanks. Blanking can be done on metals like steel, aluminum, and plastic using hardened steel or carbide tools. While blanking provides a quick and cost-effective way to mass produce identical parts, the punched edges may have burrs or cracks, though high-quality tools and post-processing can avoid these issues. Different blanking methods include compound, continuous strip, progressive die, and cutoff blanking. Common materials used for blanking include carbon steel, stainless steel, and aluminum due to their strength, hardness, and cost-effectiveness.

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23 views4 pages

Blanking

Blanking is a manufacturing process where pieces are punched out of sheets or strips of raw material into specific shapes, called blanks. Blanking can be done on metals like steel, aluminum, and plastic using hardened steel or carbide tools. While blanking provides a quick and cost-effective way to mass produce identical parts, the punched edges may have burrs or cracks, though high-quality tools and post-processing can avoid these issues. Different blanking methods include compound, continuous strip, progressive die, and cutoff blanking. Common materials used for blanking include carbon steel, stainless steel, and aluminum due to their strength, hardness, and cost-effectiveness.

Uploaded by

k.prasad
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© © All Rights Reserved
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Blanking

 Manufacturers use blanking to punch pieces in specific shapes from


sheets or strips of raw material. The punched-out piece is called the
“blank,” hence the term “blanking.”

 Blanking is most often performed with tools made from hardened steel or
carbide, which work on metals like aluminum, carbon steel, stainless
steel, and even plastic.

 Blanking has many benefits, but manufacturers must take some


considerations into account before embarking on a full course of metal
blanking. Although this process is a quick and cost-effective way to
produce a large number of identical pieces, these punched-out pieces may
have burrs or cracks on the edges. However, these drawbacks can be
avoided by using high-quality tools, and they can be corrected by post-
processing the blanks.

Fig. Difference of Blanking & Piercing


Fig. RULES FOR METAL BLANKING

(K) This is a sharp corner as it comes out of the die for this thickness, temper
and type of material.

 Material that is thicker, or of lower shear strength, will have more


pull-down on the die side.
 Material that is thicker, or of lower shear strength, may have more
burr on the punch side.
 Material that is thicker, or of higher shear strength, will have more
breakage toward the punch side.
 Corners can be sharp if material thickness is 1/16” or less – over
1/16”, allow corner radii “r” equal to ½ material thickness.
 1/16 “r” in general is a good idea to extend die life.

(O) This is a corner with a radius equal to ½ the stock thickness. This radius can
be included in the blank at no additional cost for tools or operations.
(R) This is a slight step with a sharp internal and external corner included in the
contour of the blank. Pull-down on the die side and breakage on the burr side
prevents better definition. Thickness, temper and type of material will vary the
results similar to explanation (K) above.
(H) This notch is wide enough relative to its length and material to include in
the blanking die. The blanking die cost would be a little higher, but would be
cheaper than the possibility of notching tools, plus the extra operation.
(U) The same explanation as (H) above, applies to the two relief notches on
either side of this form.
Different Types of Blanking Methods:
While the fundamentals of the blanking process are simple, they have many
variations, which we describe below:

Compound Die Stamping

This type of blanking is used to precisely manufacture complex steel parts. In


this process, workers or automated equipment feed a steel strip through the
stamping machine, which punches out a blank every three seconds. This simple,
precise, and fast technique enables firms to produce steel components in bulk.

Continuous Strip Blanking

As implied by the name, continuous strip blanking continuously feeds metal


substrates through a machine. This allows punching machines to produce
uniform end products around the clock, with each product having the same
characteristics of those before and after it. This process is a great way to
develop coins, bottle caps, and medallions.

Progressive Die Stamping

Progressive die stamping uses coiled strips of thin flat metal as its base material.
In this process, progressive die machines sequentially stamp, trim, and bend
workpieces to make the finished parts, which exit the machine in conjoined
strips. After performing this task, the machine separates individual parts from
the strip, which results in the creation of several identical parts.

Square Sheared Blanking

Square sheared blanking is a fine process that uses specialized clamping tools to
produce square-edged and contoured blanks. This process is a great way to
create panels, casings, and any other component that requires a uniform square
shape.

Cutoff

This process combines metal cutting and metal blanking procedures to create
highly specialized blanks. When cutoff blanking, manufacturers blank metal
sheets and then cut the metal at the sheets, allowing the production of long, flat
pieces.
Best Materials to Use When Blanking:

Carbon Steel

Metalworkers use carbon steel to make industrial equipment and household


tools like knives because of this material’s exceptional strength and hardness.
Carbon steel’s hardness varies depending on the amount of carbon present
within it, and the higher the carbon content, the harder the alloy is.

Carbon content in carbon steel ranges from 0.8% to 2.11%, and the typical
value is about 1.5%. Carbon steel is more cost effective than other materials of
comparable hardness, thus making it a popular raw material to use as a
substrate.

Stainless Steel

Stainless steel has low carbon content but a large amount of chromium, which
ranges from 10% to 30% of the final material. This chromium content makes
stainless steel highly resistant to corrosion and heat.

Stainless steel may also incorporate other metals like aluminum, copper, and
titanium to enhance various attributes, and even nonmetals like phosphorous
and sulfur can be used to improve resistance to certain types of corrosive
substances. Stainless steel is thus a versatile alloy that can take on a variety of
uses depending on its composition.

Aluminum

Aluminum’s softness and flexibility make it very suitable. In fact, aluminum is


the most common metal used to create industrial and household products
because of this material’s low cost, ease of extraction, and properties like
lightness, durability, and recycling potential.

For these reasons, many applications in the automotive, aerospace, energy, and
packaging industries use aluminum in large quantities. Aluminum is a very cost-
effective way to produce high volumes of components.

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