CHAPTER 4 :

TOOL AND DIE

(PART 1)

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 OBJECTIVE :
4.1 Discuss Die cutting operations
a. The fundamentals of Die-cutting operation including
i. Plain blanking
ii. Piercing
iii. Lancing
iv. Cutting off and parting
v. Notching
vi. Shaving
vii. Trimming
b. The cutting action in punch and Die operations
c. Relation between Die clearance with the cutting
action in punch and Die operations

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 Cutting and forming operations performed on
relatively thin sheets of metal.
 Thickness of sheet metal = 0.4 mm (1/64 in)
to 6 mm (1/4 in).
 Thickness of plate stock > 6 mm.
 Operations usually performed as cold working.

Thickness= 0.4 to 6 mm (1/64 to 1/4 in)

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i. Plain blanking
 The operation of punching, cutting, or shearing a piece out
of stock to a predetermined shape. Die cutting of the outside
shape of a part.
 A shearing operation that creates a hole in sheet metal by
separating an interior section. The removed piece of metal is
the desired section.

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 ii. Piercing
 A shearing operation that creates an open hole in sheet metal by
separating an interior section. The removed metal section is discarded
scrap.
 Another term for a punching operation. For various manufacturers, the
term "piercing" refers to a punching operation that does not produce a
slug, or it is used in a more general sense.

Scrap Product

Product

Blanking Piercing 5
iii. Lancing:
 Combines bending and cutting along a line in the work
material, leaving a bent portion or tab attached to the
work material.
 A shearing operation that cuts an interior section of the
metal without removing the section. A lancing operation
leaves an opened metal tab.

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iv. Cutting Off & Parting
Cutting off:
 A shearing operation that performs a single cut in
order to separate a piece of metal from the original
stock. Each cut separates a new part.
 Achieves complete separation of the work material by
cutting it along straight or curved line.

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iv. Cutting Off & Parting
Parting:
 A shearing operation that performs two cuts
simultaneously in order to separate a piece of metal
from the original stock.
 A parting operation produces metal scrap along with
the part.

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 Notching: cuts off various shapes from the edge of the
workpiece material (a blank or a part).

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vi. Shaving
 Secondary shearing or cutting operation in which the surface
of a previously cut edge of a workpiece is finished or smoothed
(punch and die clearance is small).
 The shaving operation removes a small amount of material from
the edges of the part to improve the edges finish or part
accuracy.

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vii. Trimming
 The outer perimeter of the formed part or flat sheet metal is cut
away to give the piece part the desired profile. The excess
material usually is discarded as scrap (see Figure below).
 Trimming dies cut away excess or unwanted irregular features
from a part, they are usually the last operation performed.

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 Shearing of sheet metal between two
cutting edges:
 (1) just before the punch contacts work;
 (2) punch begins to push into work,
causing plastic deformation;

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Shearing of sheet metal between two cutting edges:
(3) Punch compresses and penetrates into work causing a
smooth cut surface;
(4) Fracture is initiated at the opposing cutting edges which
separates the sheet.
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 Distance between punch cutting
edge and die cutting edge:

Depends on hardness and

thickness of materials

 Typical values range between

4% and 8% of stock thickness

 Die size determines blank size Db

 Punch size determines hole size Dh (will be reviewed in detail)
 c = clearance

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