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Discussion on Smooth Blanking Process of Sheet Metal

October 13, 2022

Based on my years of practical work experience, the following specifications are summarized for these two common blanking methods:
1 CNC blanking operation standard
1.1 General regulations on the thickness of plates by numerical control blanking
(1) Ordinary Q235 plates are generally 1mm, 1.2mm, 1.5mm and 2mm thick. (If there are large batches of special parts, the material thickness can be extended to 3mm, but the mold with corresponding specifications needs to be opened)
(2) Due to the size limit of the worktable of TruPunch1000 equipment, the overall dimension of the CNC blanking plate must be less than 1100mm (W) * 2450mm (L)

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(3) When formulating the production process flow, the general rules for plates are as follows: iron plates and aluminum plates that meet the above conditions should be digitally punched as much as possible, and stainless steel plates should not be digitally punched even if they meet the above requirements (due to the molding characteristics of stainless steel, the requirements for molds are very high).

1.2 General provisions of CNC blanking on workpiece profile
(1) The shape shall not have an arc greater than R5, and the open angle shall be 45 ° and 90 °;
(2) The process that must be completed by CNC punching: shutter, rolling rib, punching rib, rolling rib, punching convex tapping hole. (Corresponding molds are generally required)

1.3 General provisions for the contour of workpieces that cannot be CNC blanking
(1) Φ Round hole, hexagonal hole and special shaped hole below 15
(2) Waist hole less than 5mm.
1.4 Notes for drawing of digital punch
NC blanking has a certain impact on the front and back of the plate, which determines the aesthetics of the product. If the drawing conversion is not good, there will be burrs on the front, which will seriously affect the appearance and extend the grinding time. Digital blanking requires that the drawing is the front of the part, to avoid burrs on the front. If there are negative marks, they can be ignored.

2 Operation standard of laser cutting
Laser cutting, no need to add additional mold, high processing accuracy. However, the energy consumption is large and the unit labor cost is high. In order to reasonably use the laser cutting machine and improve its service life, the following operation standards are established:
2.1 Cutting capacity
(1) Iron plate thickness ≤ 10mm (if it is necessary to cut 12mm-16mm plates, try cutting to determine)
(2) Thickness of stainless steel plate ≤ 6mm (if it is necessary to cut 8mm to 12mm plates, try cutting to determine)
(3) The thickness of aluminum plate to be cut shall be ≤ 8mm (if it is necessary to cut 10mm to 16mm plates, it shall be determined by trial cutting)
(4) Boundary dimension of cutting plate ≤ 2000mm * 4000mm
(5) Requirements for cutting aperture:

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2.2 Some points for attention during laser cutting
(1) Whether to use laser cutting depends on the economic value of different customers' products.
For products with high economic value, more attention should be paid to laser cutting, otherwise less attention should be paid.
(2) Consider whether laser cutting is applied according to the shape characteristics and quantity of the expanded drawing.
Products with simple appearance shall not be cut by laser as far as possible; For products with large batch and single variety, laser cutting is not required.

(3) For workpieces with complex shapes, laser cutting is considered.
(4) For the parts that must be combined with laser and digital punch, the safety distance between the clamp and the punch shall be considered (the safety distance is 100mm), and the distance from the part edge to the hole edge shall be less than the safety distance, so as to ensure that the distance from the part edge to the hole edge is more than 100mm. Programmers need to consider the allowance, and pay attention to cutting after several strokes.

2.3 Requirements for unfolding drawing for laser cutting
(1) The laser mark is on the front of the drawing.
(2) The tread plate must be placed on the reverse side.
2.4 Special process of laser cutting
2.4.1 Knock out hole
It is convenient for customers to knock down easily, and the other surfaces are not deformed (unless the customer has specific requirements). The knock down hole is reserved for connection of 2mm, which cannot be too large; The number of reserved connection points shall be determined according to the size of knockout holes;

2.4.2 Laser marking line
In order to facilitate bending and welding positioning by bending workers, manual scribing by workers is reduced and improved.
For product accuracy and production efficiency, technicians should strengthen the use of laser marking. The following specifications are formulated for reference on what conditions and how to add stamps.
(1) Laser marking of welding nails and drilling and tapping: the welding nails must be positioned with a circle and a cross line. The length of the cross line is 3mm * 3mm, and the circle size is the outer diameter of the boss at the bottom of the welding nails;
(2) Counterbore: the contour of the counterbore shall be marked with a laser marking line, which is convenient for the operator to process in place at one time;
(3) Drilling: the hole diameter smaller than the plate thickness shall be positioned with cross lines, and the length of laser line marking line shall be 3mm * 3mm;

(4) Bending line laser positioning line: it is determined according to the throat depth of the bending machine. When the bending size is larger than the throat depth or the bending sideline is in a deformed state and it is difficult to lean against the stop, it is considered to add a laser marking line. The length of the laser marking line is generally 20~50mm, which is convenient for the bending operator to identify; Under special circumstances, consider slotting when the reverse side needs to be bent, and the laser slotting incision is generally 0.5-2mm long;
(5) Rolling circle achieved by bending method: it is required to mark the line from the starting point to the end point of the rolling circle, with a length of 10-20mm, and the middle part is evenly marked every 8-10mm, except for those with a special mold or being rolled by the rolling machine (R85 arc is pressed out by a special mold, but the starting point needs to be marked);
(6) The side line is very small or irregular: when the stop cannot be used for measurement, the laser marking line shall be engraved;
(7) Perforation positioning: when the front side needs to be marked and the reverse side still needs to be positioned, perforation positioning is required at this time;
(8) Positioning of welding parts: the arc and special-shaped parts that are difficult to measure shall be positioned by laser marking during welding.