Blanking Tool Shear Geometry to Prevent Blank Surface Damage
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Solution Overview
Problem
Conventional blanking tools for forming containers often scratch or blemish the blanks during the cutting process due to high points engaging the product area, leading to defects in the finished products.
Innovation Solution
A blanking tool with a six-point shear design where the contact surfaces are machined to engage only the scrap web area, avoiding contact with the product area and using a grinding wheel to shape the contact areas similarly to the web, thus preventing damage to the blanks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional blanking tools with multi-point shear are used to cut blanks from sheet material, then the cutting function is achieved, but the high points on the shear engage and damage the product area of the blanks causing scratches and blemishes
Solution Approach 1:
The shear is designed with non-uniform contact surfaces where only specific localized areas (high points) engage the material. These contact surfaces are strategically positioned to contact only the web material between blanks, while the product areas remain untouched. This local differentiation of contact quality resolves the contradiction by enabling cutting function through selective engagement.
Solution Approach 2:
The contact surfaces of the shear are segmented into distinct functional zones: contact areas that engage the web material and non-contact areas that preserve the product areas. This segmentation allows the shear to perform cutting through distributed contact points while preventing damage to the blank surfaces by isolating contact to specific segments.
2Productivity
If the shear contact surfaces engage the web material for effective cutting, then the cutting efficiency is improved, but the load distribution becomes uneven causing increased wear on the stock plate
Solution Approach 1:
The contact surfaces are designed with specific geometric parameters including angle ranges (30-60 degrees from vertical), area distributions, and positioning relative to the shear edge. These parameter optimizations enable effective cutting while distributing loads more uniformly across the stock plate, reducing peak stresses and extending tool life.
Solution Approach 2:
The shear design incorporates dynamic load distribution through multiple contact points that engage the web material at different locations. This dynamic engagement pattern distributes the cutting load across multiple areas of the stock plate rather than concentrating it at single high points, thereby improving both cutting efficiency and durability.
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
A blanking tool is provided for cutting blanks from a sheet of material. The sheet of material includes a product area where the blanks are located, and a web area, which is the area between the blanks. The blanking tool includes a shear having first and second opposing sides, an outer diameter, and an inner diameter. A plurality of contact surfaces are disposed on the second side of the shear. The contact surfaces engage only the web of the material. A tooling assembly is also disclosed, which includes first and second tooling coupled to first and second opposing portions, respectively, of a press and being structured to cooperate to engage the sheet of material therebetween. The blanking tool is coupled to the first tooling, and the shear of the blanking tool cooperates with a portion of the second tooling to cut the blanks from the material.