Blanking and piercing

Blanking and piercing are shearing processes in which a punch and die are used to modify webs.The tooling and processes are the same between the two, only the terminology is different: in blanking the punched out piece is used and called a blank; in piercing the punched out piece is scrap.The process for parts manufactured simultaneously with both techniques is often termed "pierce and blank." An alternative name of piercing is punching.

Characterization of part quality and potential defects

Burrs and die rolls are typical defects of trimmed surfaces. The surface finish will be lower in the so-called fracture zone, i.e. where the material is irregularly stripped away from the matching surface, at the end of the shearing operation. Die roll is a plastic deformation of the sheet edge, which causes permanent edge rounding.

Burr height is typically used as an index to measure tool wear, because it is easy to measure during production.

Process variants

There are various types of blanking and piercing: lancing, perforating, notching, nibbling, shaving, cutoff, and dinking.

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Flanging

the material is bent along a curved line.

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Bending

he material is deformed or bent along a straight line.

Bending is a manufacturing process that produces a V-shape, U-shape, or channel shape along a straight axis in ductile materials, most commonly sheet metal.Commonly used equipment include box and pan brakes and brake presses,and other specialized machine press.Typical products that are made like this are boxes such as electrical enclosures and rectangular duct work.

Process

THE press brake forming, a work piece is positioned over the die block and the die block presses the sheet to form a shape.Usually bending has to overcome both tensile stresses and compressive stresses.When bending is done, the residual stresses cause the material to spring back towards its original position, so the sheet must be over-bent to achieve the proper bend angle. The amount of spring back is dependent on the material, and the type of forming. When sheet metal is bent, it stretches in length. The bend deduction is the amount the sheet metal will stretch when bent as measured from the outside edges of the bend. The bend radius refers to the inside radius. The formed bend radius is dependent upon the dies used, the material properties, and the material thickness.

The U-punch forms a U-shape with a single punch.

Types

There are three basic types of bending on a press brake, each is defined by the relationship of the end tool position to the thickness of the material. These three are Air Bending, Bottoming and Coining. The configuration of the tools for these three types of bending are nearly identical. A die with a long rail form tool with a radiused tip that locates the inside profile of the bend is called a punch. Punches are usually attached to the ram of the machine by clamps and move to produce the bending force. A die with a long rail form tool that has concave or V shaped lengthwise channel that locate the outside profile of the form is called a die. Dies are usually stationary and located under the material on the bed of the machine. Note that some locations do not differentiate between the two different kinds of dies (punches and dies.) The other types of bending listed use specially designed tools or machines to perform the work.

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Stamping (metalworking)

Stamping (also known as pressing) is the process of placing flat sheet metal in either blank or coil form into a stamping press where a tool and die surface forms the metal into a net shape. Stamping includes a variety of sheet-metal forming manufacturing processes, such as punching using a machine press or stamping press,blanking, embossing, bending, flanging, and coining.This could be a single stage operation where every stroke of the press produces the desired form on the sheet metal part, or could occur through a series of stages. The process is usually carried out on sheet metal , but can also be used on other materials, such as polystyrene.

Stamping is usually done on cold metal sheet.

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