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Blanking

Gmetal provides blanking for lower services and stamping parts.

  • GMP Blanking Service
  • GMP Blanking Service

GMP Blanking Service

Gmetal has different blanking services, the following are the main types we offer:

  • CNC Blanking: CNC blanking involves cutting flat metal into custom shapes and sizes using a CNC machine tool programmed with precise instructions. It is an efficient and accurate method of producing metal blanks with stable quality.
  • Laser Blanking: Laser blanking is an advanced and precise sheet metal cutting process that uses laser technology to cut custom shapes and patterns from flat metal.
  • Punching: Punching involves using a tool called a punch to create a hole or shape in a workpiece. It is commonly used in industries such as automotive, electronics, conversation, and manufacturing.
  • Shearing machine: It is an important tool in the metal processing industry and is widely used to cut metal sheets, plates and other materials accurately and efficiently.
  • Saw: A saw is a mechanical device used to cut wood, metal, plastic, and other materials into different shapes and sizes.
The process of blanking

The Process of Blanking

Gmetal provides blanking services. The main processes are as follows:

  1. Material Selection: The first step is to select the appropriate sheet or strip for the specific application. The material can be steel, aluminum or copper, depending on the requirements of the end product.
    Design and Tooling: The next step involves designing the desired shape or profile of the blanked part. Once the design is complete, a specialized cutting tool called a mold is created.
  2. Positioning and Alignment: The metal sheet or strip is then positioned onto the mold, ensuring it is properly aligned for precise cuts. Clamps or fixtures are often used to hold the material in place to prevent movement during the cutting process.
  3. Cutting process: A press or punch is used to apply force to the die, forcing it through the sheet metal. The sharp edge of the die cuts through the material, creating a blanked part in the desired shape. The material that is cut away is called scrap, and the finished part is called a blank.
  4. Scrap Removal: After the cutting process, the scrap is removed from the mold, leaving behind the finished blanked part.
    Finishing and Quality Control: Depending on the application, blanked parts may undergo additional finishing processes, such as deburring or surface treatment, to achieve the desired surface quality. Quality control measures are also taken to ensure that the blanked parts meet the required specifications and tolerances.

The Advantages of Blanking

Precision: Blanking can produce high-precision parts with tight tolerances. Using specialized molds ensures consistent and repeatable shape cutting, producing parts with uniform dimensions.

High Productivity: Blanking is a high-speed process, especially when automated using a punch press. It enables mass production of parts, making large-scale manufacturing cost-effective.

Minimize material waste: The blanking process is designed to minimize waste as it cuts the desired shape from larger sheets or strips. This reduces material waste and lowers production costs.

Versatility: Blanking can be used to produce a variety of flat shapes and profiles, making it suitable for a variety of applications in different industries.

Smooth edges: The cutting edges of the dies used in blanking are sharp and well-maintained, resulting in clean, smooth edges of the blanked parts.

Material flexibility: Stamped parts can be produced from various types of materials, including steel, aluminum, copper and other metals, providing a variety of material options for different applications.

Customization: Blanking allows for customization as different shapes and sizes can be easily achieved by using different molds.

Integration with other processes: Blanking can be combined with other manufacturing processes such as stamping, bending and forming to produce more complex parts and assemblies.

The Advantages of Blanking

Introduction to Blanking

In manufacturing, blanking is a pivotal process where specific shapes are punched out from sheets or strips of raw material, typically using tools made from hardened steel or carbide. This process, suitable for a range of materials including aluminum, carbon steel, stainless steel, yields a piece known as the “blank”. Blanking stands out for its efficiency and cost-effectiveness in mass-producing identical pieces.

Advantages and Considerations of Blanking

While blanking offers rapid production and high uniformity, it’s not without its challenges. One common issue is the occurrence of burrs or cracks on the edges of punched-out pieces, a problem typically mitigated by employing high-quality tools and post-processing techniques.

Blanking Variations and Benefits

The machinery for blanking spans from basic punches and dies to advanced CNC machines, capable of adapting swiftly to product specifications. Its speed and simplicity enable consistent production with minimal part-to-part variation, making it ideal for long production runs in industries like aerospace and automotive manufacturing. Blanking also contributes to material waste reduction due to the recyclability of the primary metal stock.

Punching vs. Blanking: Understanding the Distinction

It’s easy to confuse punching with blanking, as both involve removing material from a base sheet. However, in punching (also known as piercing), the focus is on the pierced sheet rather than the removed material. In contrast, blanking prioritizes the punched-out slugs as the end product.

Beyond Basic Blanking: Diverse Techniques

Blanking’s simplicity belies its versatility. Techniques like Compound Die Stamping, Continuous Strip Blanking, Progressive Die Stamping, and Square Sheared Blanking demonstrate its adaptability to various manufacturing needs, from bulk production of steel components to the creation of uniform parts like coins and bottle caps.

Optimal Materials for Blanking

Gmetal leverages materials like carbon steel, stainless steel, and aluminum for blanking, each offering unique benefits. Carbon steel, with its variable carbon content, is known for its strength and cost-effectiveness. Stainless steel, rich in chromium, excels in corrosion and heat resistance, while aluminum, valued for its lightness and flexibility, is widely used in various industries for its affordability and recyclability.

Understanding Blanking and Punching: A Detailed Analysis of Tool Steel and Process

  • Anatomy of a Die-Cut Edge

The edge of a die-cut piece typically displays four distinct areas: roll-over, burnish, fracture, and burr. The cut surface, particularly in the fracture zone, often appears angled and rough, a characteristic outcome of conventional metal punching.

  • Influencing Factors in Punching/Blanking Operations

The performance of the working parts in punching or blanking, such as punches and dies, is significantly influenced by the material properties (like thickness and tensile/yield strengths) and the tool steel’s capacity to withstand cutting edge stresses.

  • Primary Failure Mechanisms in Punches and Dies
  1. Plastic Deformation: This occurs when the compressive stress surpasses the compressive yield strength of the tool steel. The hardness of the steel is a crucial factor here.
  2. Chipping and Total Breakage:Initiation and growth of cracks are mitigated by the ductility/toughness of the tool steel. Powder Metallurgy (PM) tool steels, with their fine and homogenous microstructure, enhance impact strength and fatigue limit, reducing brittleness.
  3. Abrasive Wear:This happens due to hard particles in contact with the tool surface during sliding interactions. Key properties of tool steel in this context include hardness, carbide volume, and carbide hardness.
  4. Galling and Adhesive Wear:These are caused by compressive stresses and sliding contact, leading to friction and high temperatures, which might result in micro-weld spots. Critical parameters include surface roughness, friction coefficient, and the toughness/ductility of the tool steel. PM tool steels, along with surface coatings, can significantly optimize sliding properties.
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