Blanking benn la ci liggéey yi gëna am solo ci estampage wen. Dafay soppi tóol bu plat wala stock serpentin ci pàcc yu wuute - ñu leen di woowe blank - ci dagg macceer bi ci contour bu tëju jëfandikoo punch ak matris. Yaa ngi defar ay bracket, ay enclos, ay jokkoo electrik, wala ay pano oto, anam wi ñuy raxasee mbir yi mooy defar fundaasioŋ ngir geometrie pièce yi, kalite boor yi, ak liggéey yi ñuy def ci wàllu forme.
Gid bii dafay wax ci mekaniku blanking, nimu wuute ak perforation, pexe blanking yi gëna am solo yi jàppandi, jëfandikoo jumtukaay pexe, ay jafe-jafe yu bari ak seeni saafara, ak xayma tonnage yi nga soxla ngir tànneef pres.
Lan moy anam wi ñuy jaar ba noppi?
Ci tëggin metal, blanking mooy jëfandikoo cisage bi ñuy dagg wàll wiñ bëgg ci tool bi, daal di daanu ci piyees bi jeex. Mbir yi ko wër — yax wala lënd — dafay nekk mbalit. Lii mooy màndarga biy tàqale blanking ak punching (piercing), fu dindi slug bi nekk scrap te darab bi tëye pax mi.
Ni Shearing di doxee
Su punch bi wàccee ba noppi laal tóol bi, cisage bi dafay jaar ci ñeenti fase yu wuute:
- Elastic deformation — Mbir mi dafay gëna xëcc tuuti ci suufu catu punch bi; amagul coppite ci jëmm ju nara yàgg.
- Deformaasioŋ plastik - Punch bi dafay dugg ci biir macceer bi, daal di tàmbali dagg bu lakk (bu nooy) ci wet wi gëna jege punch bi.
- Fracture — Xar-xar yi dañuy bawoo ci punch bi, dagg catu dagg yi, daal di tasaaroo ci biir. Fu ñaari zone fracture yi daje, matériel bi dafay tàqaloo.
- tàqalu - Blank bi dafay fomp ubbikaayu matris bi. Pin ejector yi wala stripper yi dañuy tëye cër bi wala yax bi mu génn.
Section transversale biy génn ci wàll wi amul dara dafay wane ñeenti zone yu am màndarga: rollover (bande cisaillement ci kaw), burnish zone (bande verticale bu nooy), zone de fracture (surface angle bu dëgër), ak burr (bët bu woyof, ñaw ci catu suufu suuf).
Clearance: Parametre bi gëna am solo
Die clearance - gap bi am ci digganté punch bi ak dagg bi ñuy natt ci wet bu nekk - dafay saytu ci saasi kalite boor bi, kawewaayu burr bi, ak dundu jumtukaay bi.
| Diggante bu nekk ci wet gi (% ci yaatuwaayu macceer bi) | Résultat typique |
|---|---|
| 3–5 % | Fit bu dëgër; rollover bu néew; wear punch bu gëna mag; jëfandikoo ci blanking bu jaar yoon |
| 5–8 % | Standard ci asiye yu bari; rasio lakk bu baax |
| 8–12 % | Diggante bu gëna yaatu; rollover bu gëna mag ak burr; tonnage bu néew; |
| > 12 % | Burr bu ëpp ak deformaasioŋ; duñu ko nangu ci liggéey bi |
Regle bu mag: Ngir asiye bu woyof (ba 3 mm ci yaatuwaay), jëfandikoo 5–7 % ci wet gu nekk. Ngir aluminium, 6-8 %; ci asiye inox, 7-10 %. Xoolaatal saa yu nekk tegtali yiñ tëral ci macceer bi te natt ci misaali blank yi balaa ngay tàmbali defar jumtukaayi liggéey bi.
Burr yoon ci blanking mën nañu ko seetlu: burr bi dafay forme saa yu nekk ci scrap side — wàll wi jàkkarloo ak punch bi. Ci blanking, burr bi mingi ci suufu catu blank bi jeex (ci wetu matris bi). Sudee dañu soxla benn boor bu amul burr ci kaw benn surface, jubalal wàll wi ci matris bi ci anam woowu.
Blanking vs. Punching (Piercing): Lan mooy wuute gi?
Term yi dañuy faral di jaawatle, waaye wuute mekanik bi jub na:
| Melokaan defar | Blanking | Punching (Piercing) |
|---|---|---|
| Goal | Defar piyees biñ dagg muy piyees bi jeex | Defar pax ci darab bi; |
| Useful part | Piyees biy daanu ci matris bi | The sheet that remains on the die |
| Profil die | Shaped to the part outline | Round or shaped to the hole geometry |
| Punch profile | Dafa topp liñu bind ci wàll wi (dafa gëna ndaw ndax dafa am lijaasa) | méngoo ak jëmmu pax mi |
| Dellu gannaaw | Yax (web) bi des ci band bi | The punched-out slug |
| Application typique | blancs plats, brackets, garnitures, shims | Pax yu ñuy fikse, ay bërëb ngir ngelaw, ay daggukaayu dugg |
Ci tëggin die progressive, ñaari liggéey yooyu dañuy faral di am ci benn strip ci stasioŋ yu wuute - blanking ci stasioŋ bu mujj bi, punch ci yi njëkka am.
Xeetu pax mi: Benn méngale
Du bépp jëfandikoo blanking mooy joxe benn njariñ. Tanneef ci anam wi ñu koy defee mingi aju ci toleransu piis yi, li ñuy laaj ci kalite bi, bariwaayu liggéey bi, ak njëg yu bari yi.
Conventional Blanking (Standard Blanking)
Xeetu liggéey bi gëna bari. Benn punch kese mooy dagg ci biir matériel bi ak clearance buñ miin (5–8 % ci wet bu nekk). zone fracture yi ci wetu punch bi ak die bi dañu daje ci benn angle, daal di sos liiñ bu ñuy gis ci catu dagg bi.
- Muñ: ± 0,1 – 0,3 mm (li gëna bari ci asiye)
- Edge finish: Modéré; zone lakk = 30–50 % ci dëgëraay bi
- Gaawaay: Kawe; 100-800+ SPM ci pres yu gaaw yi
- Njëg: Njëg li yomb; njëg bu gëna ndaw ci pàrti bu nekk ci volume bu bari
- Bi gën for: Piyees yu ñuy jëfandikoo ci anam wu ëpp solo, fu boor bu amul dara nekkul surface bu am solo
Defar bu baax (Blanking bu jaar yoon)
Blank bu baax dafay jëfandikoo benn presse bu am ñatti jëf: benn anneau V (stinger) dafay dugal tol bi ngir moytu matériel bi naaw, benn pad bu ànd ak presion dafay tëye blank bi bu baax, (0.5-1 % ci wet bu nekk). Lépp soo ko boolee mu am catu boor bu mat sëkk, am luy tollu ci 100 % ci lakk, ak rollover bu néew.
- Muñ: ± 0.02 – 0.05 mm
- Edge finish: Xereñ; 90-100 % lakk; hauteur du burr < 0.05 mm
- Gaawaay: Ci suuf; 20–80 waxtu
- Njëg: Njëg lu bari ci jumtukaay yi;
- Bi gën for: Blanc de vitesse, plaques de pignon, composants de siège automobile, pièces qui ne soit de qualité masinée sans opérations secondaires
Progressive Blanking (matris bu dox ndànk tëggin)
Blank bi dañu koy forme ci ay stasioŋ yu bari ci benn matris buy yokk, bu nekk di def liggéey bu amul benn werante (perforer ay pax pilote, notching, forme, ak mujjee blanking). Band bi dañu ko indexe ci kanam ci pitch bu méngoo ak diggante gaaraas yi.
- Muñ: ± 0.05 – 0.15 mm (dafay aju ci gaaraas bi)
- Edge finish: Convention
- Gaawaay: 100-1000+ SPM
- Njëg: Njëg bu rëy; njëgu piyees bu gëna ndaw ci volume yu bari lool (> 100,000 piyees)
- Bi gën for: Piyees yu bari volume; komposant yiy laaj liggéey yu bari ci benn yoon
Tablo buy méngale
| Parametre | Blanking buñ miin | Fine Blanking | Blanking buy yokk |
|---|---|---|---|
| Kalite boor | 30–50 % | 90-100% | 30-50 % lakk (staasioŋ buy fomp) |
| Muñ dimension | ± 0,1–0,3 mm | ± 0,02-0,05 mm | ± 0,05-0,15 mm |
| Burr height | 5–15 % ci yaatuwaayam | < 3 % ci yaatuwaayam | 5–15 % ci yaatuwaayam |
| Xeetu bës | Mekanik/hidraulik | Triple-action hydraulic | Mekanik bu gaaw |
| SPM range | 100–800+ | 20–80 | 100–1000+ |
| Material thickness | 0.3-12 mm | 0.5-16 mm | 0.3-6 mm |
| Njëg li ci jumtukaay yi | Baax–diggi | Haut | Haut |
| Njëg li ci pàcc bu nekk | Low | Diggante-kawe | Dafa tuuti lool (volume bu rëy) |
| volume bi gëna baax | 10,000–500,000+ | 5,000–500,000 | 100000–milioŋ |
Jëfandikoo jumtukaay ak gëna mëna jëfandikoo
Njëg li ci macceer bi dafay nekk 50–70% ci njëgu piyees biñ tampoon. Optimisation layout bu amul dara (nesting) ci strip bi bokk na ci liggéey yi gëna am njariñ ci blanking.
Pexe yu am solo
- Row nesting — Piyees yi ñu boole ci rang yu jub ci yaatuwaayu strip bi. Yomb naa defar; jëfandikoo gi 55–70 %.
- Staggered nesting - Ligne yu wuute offset ci genn-wàll pitch. Yokk jëfandikoo gi 5-15% ci kaw rang nesting ngir wàll yu rectangle wala yu gudd.
- Nid rotation — Piyees yi dañu leen wëlbati ci wàll yi gëna baax (30°, 45°, wala ñu defaree ko) ngir yokk limu piyees yi ci strip bu nekk. jëmm yu jaxasoo yi ñoo gëna am njariñ ci jëfandikoo gii.
- Common-line blanking — Wàll yi dendoo bokk benn liiñ bu dagg, dindi lënd bi ci seen biir. Mën na yokk 10-20% jëfandikoo, waaye dafay laaj jëmmal jumtukaay bu jaar yoon, te mën na yokk wear die ci boor bi ñu bokk.
- Scrap-free (skeleton-free) blanking - Jëfandikoo ngir strip yu wéy yu am pàcc yu nuróo (lu melni, kontakt kuuraŋ) fu skeleton bi di gëna néew wala di dindi.
Ni ñuy xaymaa jëfandikoo jumtukaay
Jëfandikoo jumtukaay (%) = (Tolluwaayu barab bu amul dara ci band bu nekk / Barab bu amul dara ci strip bu nekk) × 100
Wala lu mu méngoo:
Jëfandikoo (%) = (Limu bërëb yu amul dara ci tracé bu nekk × Benn barab bu amul dara) / (Yaatu band × Pitch) × 100
Jëfandikoo 70–85 % mën nañu ko amee ci geometrie yu bari yu am nesting bu jaar yoon. Lu weesu 60% dafay laaj ñu defaraat jumtukaay bi wala jëmmal.
Tegtal yu am solo
- Teela boole ingenieur yiy liggéey ci jumtukaay — ab tweak bu ndaw ci geometrie (yokkum benn rayon, defar benn koñ) mën na ubbi lënd bu gëna am njariñ.
- Xalaatal yaatuwaayu bobine bi, yaatuwaayu bobine bi. mm, 1000 mm) mën nañu joxe njëg yu gëna xéewale yaatuwaayu fente yuñ defaree.
- Jëfandikool losisel buy lëkkale (lu melni, Sigmanest, Lantek, AP100) ngir jëmm yu jafee xam ngir jàngat fukki-fukki wàll yu gaaw ci jubluwaay.
Ay jafe-jafe ak saafara yu bari
Ba ci liggéeyum blanking buñu defar bu baax mën na jur ay jafe-jafe. Tablo bi ci suuf dafay wax ci jafe-jafe yi gëna bari, li ko waral ak li ñu wara def ngir saafara jafe-jafe yi.
| Defect | Melokaan | Sabab bu njëkk bi | Saafara |
|---|---|---|---|
| Burr bu ëpp | Bët bu ñaw, yéeg ci catu amul dara | Daggukaay yu màgget; clearance bu ëpp; | Delloosi punch bi ak matris bi; wàññi li ñuy génne; jëfandikoo jumtukaay bu gëna dëgër asiye wala revêtement |
| Rollover (die-side rollover) | Depression courbe ci catu dugg bu amul dara | Yoon bu ëpp; macceer bu doywul; | Serreer bu baax; yokk dooley tëyekaay bu amul dara; yokk V-ring ngir lëndëm bu baax |
| Rugosité zone de fracture | Bande de fracture bu jagged, bu jaxasoo | Clearance bu dëgër lool (xar-xar yi daje wuñu bu baax); | Gëna baax wëlbatiku jubluwaayu pàcc bi méngoo ak wàllu rolling bi |
| Xar ci catu | Xar-xar yu radié ci wàll wi | Matériel buy yàqu; burr wet ci suufu tension ci formaasioŋ bi ci topp; | Deburr laata ngay forme; oriental wet burr ci zone kompresioŋ; jëfandikoo blanking bu baax ngir boor yu am solo yi |
| Coppite ci dimension | Dayo bu amul dara bu wuute ci liggéey bi | Wear jumtukaay; deflection de presse; | Defar jumtukaay yiñ nara toppatoo; xool bu baax njubluwaay bi; xool njubteg feeder bi |
| Twist / bow | Dañuy wëréelu wala ñuy wëlbatiku ginaaw buñu ko noppee | Yokkateg bu tolloowul; geometrie ponch asymétrique; | Delloosi ponch bi ak matris bi xool ndax jumtukaay yi dañu méngoo; |
| Slug pulling | Scrap slug retracts into die on upstroke | Aspiration ci suufu perforateur; dooley stripper bu doywul; | Yokk ay portu dindi aspiration; yokk pressu ressort stripper; |
| Galling | Material smearing on punch/die surface | lëkkaloo gi am ci digganté jumtukaay bi ak pièce bi ñuy liggéey; lubrication bu doywul; jumtukaay bu jaarul yoon | Defal ay revêtement TiN/CrN; jëfandikoo jumtukaayi karbure; yokk debit lubrifiant |
| Die chipping | Fractures yu ndaw ci boor daggukaayu matris | coono impact; dëgëraay asiye bu jaarul yoon; | Jëfandikool asiye bu gëna dëgër (lu melni, D2 ba M2 dem); yokk dugg taper ngir dee; |
Xayma tonage ngir raxas
Xayma bu baax tonnage pres bi war lu am solo la ngir tann pres bi gën te moytu jafe-jafe tonnage yu néew wala yu ëpp (defektu piyees, yàqu-yàqu ci pres, wala energie bu yàqu).
formul standard
Force de blanquement (ton) = (Périmetre × Épaisseur × Force de cisage) / 2000
Fan:
– Perimeter = guddaayi kontur biñ dagg yépp (pouce)
– Yaatu = épaisseur de matériel (pouces)
– Force de cisage = force de cisaillement (PSI)
– 2000 = facteur de conversion (2000 lbs = 1 tonne)
Weersu Metrik
Blanking force (kN) = Perimeter (mm) × Thickness (mm) × Shear strength (MPa) / 1000
Force de cisaillement Valeurs de référence
| Matériel | Tensile strength (MPA) | Force cisage approximative (MPa) |
|---|---|---|
| Asie bu woyof (AISI 1008–1020) | 300–420 | 250–350 |
| Acier inoxydable (304) | 515–620 | 400–500 |
| aluminium 5052-h32 | 228–275 | 150–185 |
| Aluminum 6061-T6 | 290–310 | 200–220 |
| Cuivre C11000 | 210–380 | 170–250 |
| C26000 en cuivre | 300–400 | 220–300 |
Tip: Resistance de conservation. × dooley traction ci wen yu bari yu ductile.
Yokk benn marge de sécurité
Deel faral di yokk 20–30 % ci facteur de sécurité ngir xam:
- Coppite ci màndarga yi (tàngoor-ci-tàngoor)
- Jumtukaay bu dëgër diggante ñaw
- Strip feeding misalignment causing partial cuts
- Liggéeyu forme ci benn yoon (sudee boole ci fomp)
misaalu xayma: Defar ab blank bu 100 mm × 50 mm bu am 2 mm ci asiye bu woyof (force ci cisaillement = 300 MPa):
Perimetre = 2 × (100 + 50) = 300 mm
Doole = 300 x 2 x 300 / 1000 = 180 kN
Ak 25% ci wàllu kaaraange: 180 × 1,25 = 225 kN ≈ 23 tonne
Wàññi tonnage: Angle cisage
Yokk benn angle cisaillement (rake) ci punch bi wala matris bi dafay gëna xëcc liiñ biy daje ci macceer bi, wàññi tonnage bi gëna mag ci tasaare dagg bi ci diir bi. Angle cisage bu 1°–3° ci wet bu nekk (muy tollu ci 5–15 % ci dëgëraay bi ci kanam punch bi) mën na wàññi tonnage bu mag bi ci 30–50 % te du yàq geometrie bu amul dara.
Jëf yi gëna baax ngir defar ay weñ
- Xaarandil wàllu burr bi ci nataal bi. Ndax mën nañu xam yoon wi burr bi di jaar ci blanking bi, yokk ko ci rëdd bi.
- Waxtu toppatoo jumtukaay ci limu stroke yi. Wear bu boor bi dafay dem ndànk; 50,000 ba 200,000 yoon yu nekk (dafay aju ci macceer bi ak coating bi) moo gën ñuy xaar ay njuumte yuñ mëna gis.
- Jëfandikool jumtukaay yuñ raxas ngir macceer abrasif. TiN, TiAlN, ak CrN coatings mën nañu yokk dundu jumtukaay bi 2–5x suñuy blanke asiye inox, alloy bu woyof bu am doole (HSLA), wala stock galvanisé.
- Kontrôle serpentin bu plat. Band ondulé wala cambred dafay indi clearance bu jaarul yoon ci dagg bi, loolu mooy indi burr bu bari ci kawewaay ak dayo bu amul dara. Niveau strip bi balaa gaaraasu blanking bi su ko jaree.
- Xool diisaay bu amul dara ni proxy kalite. Pesé benn misaalu blank ci shift bu nekk, dafay gaaw, te du yàq dara, ngir xam ndax amna derivation dimensionnel wala wear ci jumtukaay bi.
Laaj yu ñuy faral di laaj
Lan mooy wuutale blanking ak dagg ci tóol?
Blanking liggéey la bu ñuy jëfandikoo ngir dagg piyees biñ perfore mooy piyees biñ bëgg, tol bi ko wër nekk scrap. Dagg, baat la bu gëna yaatu, lu ci melni fomp, dóor, dagg ak dagg. Ci blanking, ubbite matris bi dafa méngoo ak jëmmu piis bi; ci punching (piercing), matris bi méngoo ak jëmmu pax mi, ba noppi sànni slug bi.
naka lañuy xaymaa limu amul dara?
Liggéeyukaay bi ñu ngi koy xayma ci pursàntaasu yaatuwaayu macceer bi, ñu natt ko ci wet bu nekk diggante ponch bi ak catu daggukaayu matris bi. Ci misaal, ak asiye bu dëgër 2 mm ak 6 % ci wet gu nekk, bërëb bi mooy 0.12 mm ci wet gu nekk. Formul bi mooy: Yaatu ci wet bu nekk = Yaatu macceer bi × (Yaatu % / 100). Valeur yiñ gëna xam mingi tollu ci diggante 3 ba 12 %, lépp di aju ci li ñuy laaj ci macceer bi ak ci kalite bi.
Lu ñuy jëfandikoo blanking bu baax?
Blanking bu baax dañu koy jëfandikoo sudee piis bi dafa soxla cisage bu mat, daanaka amul benn burr te amul ñaareelu usine. Application yiñ gëna xam ñooy blanks engrenage yi, plaques pignon yi, composants recliners siège automobile yi, ak pièce yu plat yu xarañ yi nga xamni kalite boor bi dafay indi jafe-jafe ci fonction bi wala ci montage bi. Blanking bu woyof dafay defar boor yu am 90–100 % burnish ak burr yu kawe yu néew 0.05 mm.
naka may wàññi gaawaayu burr ci blanking?
Ngir wàññi kawewaayu burr: (1) ñaw wala wecci punch bu yàgg ak boor yi, (2) gëna xéewale clearance ba 5-7% ci wet bu nekk ngir gëna bari ci asiye yi, (3) jëfandikoo coated wala carbure tooling ngir tëye boor bi gëna gudd, (4) fexe matériel bu baax tëye-ci suuf ngir moytu blaring tol bi ak blank) aplikaasioŋ bi dafay laaj burr bu jege-zero.
Ban tonnage pres laa soxla ngir blanking?
Xaymal tonnage bi nga jëfandikoo formul bii: Doole = (Perimetre × Yaatu × Dooley cisage) / 1000 (ci kN, metrik) wala / 2000 (ci tonne, imperial). Deel yokk 20 ba 30 % ci facteur de sécurité. Ci misaal, soo bëggee raxas benn wàll bu 100 mm × 50 mm ci weñ bu woyof bu 2 mm, fàww nga soxla lu tollu ci 225 kN (23 ton). Pres bi dafa wara am guddaay bu doy, yaatuwaayu lall bi, ak gaawaay bi doy ngir liggéey bi nga soxla.
Soxla piyees yu amul dara yuñ defaree ci say leeral? Jokkoo ak piyeesu estampoŋ wen ngir waxtaane seeni bëg-bëg ci wàllu blanking — daale ko ci prototype ba ci defar lu bari, ak jumtukaayi biir kër ak defar bu sertifiye kalite.