Sheet Metal Blanking

KDM is a leader in the processing of sheet metal through our automated blanking machine.

What is Sheet Metal Blanking

Blanking is a popular manufacturing process of sheet metals in which a metal workpiece is eliminated from a metal strip when it’s punched. The metal blanking process is often performed with carbide or hardened steel tools. The process is suitable to work with different metals including carbon steel, aluminum, and stainless steel.

During the blanking operations, the behavior of dies and punches (working parts) depends on the yield strength, tensile strength, and thickness of materials. Sheet metal blanking allows producing specialized parts that reduce cost and waste.

If you need mass production for your sheet metal fabrication project, KDM’s metal blanking technique is a cost-effective solution. We use high-quality machines and tools to avoid cracks and burrs for all punched-out pieces. KDM performs different blanking methods for your fabrication projects. These methods include compound die casting, continuous strip blanking, progressive die stamping, square sheared blanking, and cutoff.

KDM Sheet Metal Blanking Components

aluminum sheet metal blanking
Aluminum Sheet Metal Blanking
stainless steel sheet metal blanking
Stainless Steel Sheet Blanking
Steel Sheet Metal Blanking
Steel Sheet Metal Blanking
3 Products Found.

Sheet Metal Blanking: The Ultimate Guide

If you have any question about sheet metal banking process, you will find the answer right here.

Whether you want to learn about the application, quality control or actual process – everything is right here.

Take a look:

What Is Sheet Metal Blanking?

This is the process where a workpiece of geometric shape is created through punching a sheet metal.

It is a method of fabrication where the punched material is the final product.

What remains from the Sheet of Metal is discarded.

This process makes it possible to create various shapes of an object.

The piece that is punched out from a large Sheet of metal is called a blank.

The tools used for blanking are made from very hard steel

During the blanking process a metal punch is gorged into a die that cuts the part from a larger sheet of metal.

Another of sheets can be blanked at a go.

sheet metal blanking

sheet metal blanking

The blankets require smoothening of the edges.

This is because blanking causes deformation along the edges.

Although this process seems cheap and fast in producing a large numbers of pieces that are identical, the blanks edges may have burrs and crack.

Inorder to avoid these drawbacks, use high quality tools.

Corrections can also be done by having the blanks post processed.

Sheet Metal Blanking Vs Sheet Metal Punching
  • Blanking is a metal fabrication processes where metal work pieces are removed from the primary metal.

What remains is discarded or recycled and reused.

  • On the other hand punching is also a process of fabrication that involves forming holes on the sheet metal.

sheet metal blanking

sheet metal blanking

The material removed is discarded or recycled and reused.

  • The two process are often confused.

This is because they both involve removing a metal piece from the primary sheet metal.

  • In blanking the end product is the metal that is removed or punched out from the metal sheet.

In punching the end product is the original sheet where holes have been punched out.

  • Another difference arises from when managing waste.

In blanking the manufacturing optimizes by producing as many blanks as possible.  In punching the manufacturer maximizes by punching very small amount of material from the original sheet metal to reduce wastage.

  • Both methods are cost effective.

Both can be useful for medium or high volume order.

sheet metal punching

sheet metal punching

 The scrap metal from both processes can be recycled and reused

  • Both are methods metal fabrication where a punch and die are used.
Advantages Of Sheet Metal Blanking
  • The process of blanking is common in metal sheet manufacturing industries.

This Is due to its ability to produce highly specialized parts that reduce cost and wastage.

  • Blanking can perform long production runs.

This makes it fast and cost-effective as it can help produce a large number of identical parts.

Blanked parts

  • Blanked parts reduce the net weight of the primary sheet, therefore, reducing the cost of shipping.
  • There is less setup and parts management in the blanking process because the material is continuously fed into the machine.
  • The process is economical since metal pieces can be customized to suit specific customer needs.
  • Blanking helps manufacturers to reduce wastage

This is because the original sheet metal can be recycled and reused.

Industrial Application Of Blacking Sheet Metal

Blanking sheet metal is commonly used in the automotive industry and metal fabrication industries

This is due to the blank ability to adapt to the final shape part.

Blanking sheet metal

This ability has attracted a wider range of industries such as:

Transport industry: This used in making vehicle frames, bumpers, doors, military vehicle, rails, shipbuilding and fuel tanks.

The steel metal sheet is also used in making car engines is one that has mechanical strength and is wear resistant.

Construction industry:  sheet metal is used in civil engineering and construction purposes.

The construction industry is one of the largest consumer of world steel.

The applications used in these industry are heavy medium plates and steel sheets.

Medical industry uses stainless steel sheet because it’s easy to clean and maintains a sterile environment.

Machinery and metal parts industries: Product such as steel plates, sheets, pipes and bars are used in the manufacturing of machines

Step-by-step Sheet Metal Blanking Process

The process of blanking in general refers to punching out a metal work spiece from a metal sheet.

The blanking process goes through a series of phases through which the metal sheet undergoes.

First the punch touches the sheet metal causing compression stress on the metal.

The punch then goes through the metal making it elastic and causing plastic deformation.

As the compression increases, shearing takes place and fracture occurs.

Depending on the strength and thickness of the sheet metal the blank is ejected out.

This is the breakthrough phase.

From here the blank has to undergo post process correction interms if removing excess metal.

sheet metal blanking process

sheet metal blanking process

This process can best be described through different specialty types of blanking process.

Nibbling

In this process a number of overlapping slits and notches are created by cutting a contour.

This allows various shapes to be form.

Punches of various shapes and sizes are available.

Rectangular punches are popular because they minimize wastage.

Nibbling is done in the inner or outer side of the material..

The process is commonly used on work pieces that do not require quantities that justify a customized blanking die.

The amount of cuts overlap and the shape of the cutting die determine the smoothness of the edges.

For more accuracy, shapes that have undergone nibbling go through filing and grinding after finishing.

Shaving

This is a finishing process.

Some small quantities of metal is sheared away from the part that is blanked.

The reasons for shaving are:

a). Achieve accuracy of specifications.

b). To remove excess metal from the blank

c). Smoothening the edges and squaring the edges.

Shaving is usually done instrument parts and clicks and watch parts. To accomplish shaving you need to use shaving dies designed for this purpose.

Trimming

This process involves cutting away excess metal from the blank.

Sheet Metal Cutting

Irregular and undesired features are removed from the Sheet.

It’s the last exercise performed on the metal part.

Fine Blanking

In this process the metal produced has tight tolerance.

Three separate forces are used to shear off the blank from the Sheet.

Also, the first force is applied on to the sheet.

The second force is applied under the sheet opposite the punch.

These two forces prevent bending of the sheet therefore producing flatter work pieces.

The third force is the punch which impacts on the sheet and Shears the blank into the door of the die.

This method produces parts that are flat with smooth edges.

These parts are of high quality and do not require finishing.

The method is suitable for high volume production.

This is because the additional tools used are expensive.

Factors Determining Quality Of Blacking Sheet Metal Parts

When determining the quality of blanking sheet metal parts, consider the specific requirements of the product.

Consider also the challenges in the environment the product may encounter.

The quality of the blanking metal part is determined by the following factors

Blacking Sheet Metal Parts

Process Used

The use of conventional/ traditional blanking process does not produce smooth and parallel edges.

Fine blanking gives you the desired blank edge quality.The metal parts produced are of high quality and do not require finishing.

Characteristics Of The Material Used For Blanking

The material should:

  • Have good plasticity which enables stamping deformation and enhances the quality of the metal parts.
  • Have good surface quality. This means it should smooth free from scratches, cracks and other defects.

This also protects the metal from breaking when punched.

This leads to waste reduction.

  • Have tensile strength. Choose a material that has the ability to resist breaking when it is subjected to compression force during the blanking process.
  • Have the ability to support your appliance adequately.

Stainless steel serve well in products for plumbing.

This is because it is durable and can resist corrosion.

While copper is is preferred in electrical appliances due to its excellent thermal and electrical conductivity.

  • Have pliability in that, the material should be flexible and can easily bend or formed into wires, bars and plate.

The metal ability to withstand plastic deformation under tensile strength.

Aluminium has low ductility while stainless steel has high ductility.

  • Consider the universal rules that apply to conditions and certain materials.

What works well with low carbon sheet metal may not work well with aluminium.

Tools And Die Design Determine The Quality Of The Edge

It is Important to revise the mathematical designs of the die during its development.

This will enable optimal tool design thus desirable edge profile.

d). Finishing of the metal part. There are a variety of finishes that can be used on blanked metal parts.

Finishing enhances the strength and and resistance of the metal to corrosion.

Finishing also makes the metal part to be smoother and attractive.

Common Failure Mechanism During Sheet Metal Blanking

During the process of blanking failure mechanism may occur due to:

  • The behaviour of the punch and die on the sheet metal.

the process of blanking

Interms of its thickness and the strength produced.

  • The ability of the tool to cope with the stress that comes up on the cutting edges.

Due to the above reasons there may arise failures during the blanking process. These are:

  • Abrasive wear is caused by hard parts coming into contact with the tool surface.

Abrasions occur on the on sliding contacts between the sheet metal and the tool.

Important properties of the tool are its hardness, the high volume and hardness of the carbides

  • Galling and adhesive wear.

Both are produced due to compressive stresses and sliding contacts that result in strong friction and high temperatures.

Thus end up producing spots of micro welds that destroy the surface quality of the tool.

Due to the stress, the work material may pull out parts of stick material from the tool surface.

The critical factor here is the friction coefficient, roughness toughness and hardness.

The grade of the tools steel and powder metallurgy stool steel can provide the best solution.

Surface coating can also help in maximizing the sliding abilities.

  • Plastic deformation occurs when the compression stress exceeds the compressive yield strength of the tool steel.

This leads to permanent deformation.

This causes the material to elongate, bend or twist.

In this case the critical parameter is hardness.

  • Chipping and total breakage. High tool steel ductile can prevent the formation and growth of cracks.

The tool should have good levels of impact strength and fatigue limit.

In case it shows signs of breaking, very fine and homogeneous powder metallurgy tool steel is used.

Chipping and cracking are the most destructive failure mechanisms that can occur during blanking.

Material To Choose For Blanking Processes.

The material used in the blanking process could be a sheets of metal or rolls.

Blanking Carbon Steel

Carbon steel is an alloy of iron and carbon.

It is divided into low, medium and high cargo steel.

Used In making industrial   and household equipment.

Has exceptional strength and hardness.

The content of carbon in carbon steel ranges between 0.8% and 2.11%.

It’s cost effective more than other material of the same hardness.

It is used for making knives because of its high content of carbon.This gives the edge retention to the blade.

Blanking Stainless Steel

Has low carbon content.

Has high amounts of chromium of between 10% and 30%.

This forms a passive film which protects the material from corrosion.

Chromium content makes stainless steel to be resistant to corrosion and high temperatures.

It’s an all-round alloy that can be used in various ways depending on its contents.

It can be made into rolls of sheets, plates and bars.

It is used to produce surgical appliances, industrial equipment, cookware and storage tanks.

The material has a cleanability level which makes it better than copper and aluminium.

This explains why it’s popularly used in food processing plants and pharmaceutical industry.

Blanking Aluminum

This material is soft and flexible and can be easily bend.

It is commonly used in the production of industrial and a wide range of household equipment.

It has a low cost, it is easy to extract and fabricate.

Has low weight, it’s durable and can be recycled.

Large quantities of this material are used in industries like packaging, energy and automotive.

Blanking Brass

Blanking Brass

This is an alloy of copper and zinc.

It contains 66% copper and 34% zinc.

This material is popular for its bright gold like appearance.

It is widely used in making utensils.

The melting point of brass is very low.

Brass is durable and has a high workability characteristic.

It is also used in manufacturing applications that are resistant to corrosion such as medal and jewels.

Remember, sheet metal blanking is a versatile process you can use to fabricate a range of sheet metal parts.

For any questions of inquiry about sheet metal blanking, contact us now.

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