Journal of

Materials
Processing
Technology
ELSEVIER Journal o f Materials Processing Technology 48 (1995) 59-68

Punchless Punching of Thin Sheet Metal by Ultrahigh Pressure Gas

For Circular Hole

Makoto M u r a t a ~,Yasushi Uede b and Hideo Suzuki a

~ D e p a r t m e n t of Mechanical and Control Engineering

bG r a d u a t e Course of Mechanical and Control Engineering
University of E l e c t r o - c o m m u n i c a t i o n s
Chofugaoka 1 - 5 - 1 , C h o f u - s h i Tokyo 182, J a p a n

INDUSTRIAL SUMMARY

Traditional p u n c h i n g of s h e e t m e t a l is performed by punches and dies. If t h e thickness of the

s h e e t m e t a l is less t h a n 0.1mm, t h e clearance b e t w e e n t h e p u n c h and die has to be less t h a n
0.005ram. As t h e clearance decreases, the punches and dies tend to suffer d a m a g e and w e a r
away, a n d t h e e x t r e m e accuracy of the installation b e t w e e n punches and dies is necessary. As
t h e hole d i a m e t e r becomes smaller, t h e punch tend to be broken because of t h e reduction of
p u n c h rigidity. We h a v e studied a n e w punching method for the thin s h e e t m e t a l using
ultrahigh p r e s s u r e gas without punch. In this paper, the punching process of circular holes for
t h e s h e e t is discussed experimentally. The workpieces are thin m e t a l sheets of a l u m i n u m and
copper. The t h i c k n e s s e s a r e 0.05 and 0.10ram, and the d i a m e t e r s of t h e holes r a n g e from
1.0ram to 5.0mm. The punching m e c h a n i s m was clearly explained. The prediction of the
m i n i m u m p r e s s u r e required to p u n c h t h e holes of given sizes could be calculated according to
t h e s h e e t thicknesses and mechanical properties. The predicted p r e s s u r e for p u n c h i n g agree
well with e x p e r i m e n t a l results for t h e hole sizes. The cut edge of punched holes have a large
s h e a r droop and small fracture surface with a good degree of accuracy in size. The d i a m e t e r s of
p u n c h e d holes a r e a little small for dies diameters. The differences b e t w e e n punched and dies
d i a m e t e r s a r e about 0.025ram in spite of t h e material, thickness and hole diameters. The
p u n c h i n g of t h e thin s h e e t m e t a l was worked easily w i t h high accuracy by our newly i n v e n t e d
punchless p u n c h i n g method using ultrahigh p r e s s u r e gas.

0924-0136/95/$09.50 1995 Elsevier Science S.A. All rights reserved

SSDI 0924-0136(94)01633-C
60 M. Murata et al. / Journal of Materials Processing Technology 48 (1995) 59-68
1.1NTRODUCTION
The n e e d for m a n u f a c t u r i n g techniques
w i t h s h o r t production runs in a variety of
sizes and s h a p e s is increasing while the
reduction of production costs, h i g h - s p e e d
production, and i m p r o v e m e n t in dimensional
a c c u r a c y are t h e m e s which are always in
demand.
Conventional punching of thin s h e e t m e t a l
is performed by punches and dies with
s h a p e s and dimensions of t h e desired holes.
This type of the punching lacks flexibility.
Many punches and dies m u s t be prepared, as
t h e s h a p e s and dimensions for t h e desired
holes are changed. Burrs and cracks occur in
t h e inside part of the punched holes, and the
accuracies of conventionally punched holes
c a n n o t sufficiently comply with industrial
demands, because a clearance b e t w e e n t h e
p u n c h and die of 5~10% of plate thickness is
n e c e s s a r y [1]. It is difficult to p u n c h high
a c c u r a t e holes of small d i a m e t e r s in thin
s h e e t metal. T h e r e is a cost problem in
obtaining t h e exclusive punches and dies for
holes of e a c h shapes and sizes. These
problems m a k e it difficult to accomplish
p u n c h i n g at low cost. For t h a t reason, some
punchless punchings w e r e examined. For
example, t h e r e w e r e a punching of
amorphous alloys using plastic film and
electromagnetic p r e s s u r e [2], punchings of
s h e e t metals directly by electromagnetic
p r e s s u r e [3,4], and punchings of s h e e t m e t a l
by a n explosive [5]. The reference [2] was
adopted only for u l t r a t h i n film such as
amorphous alloys, ref.[3,4] were difficult for
t h e workpieces to produce high pressure,
and ref.[5] was dangerous to work w i t h
because of explosives. For t h a t reason,we
examine t h e punchless punching of thin
s h e e t m e t a l s by ultrahigh p r e s s u r e gas
which is easy to use and can act w i t h very
high p r e s s u r e on the workpieces. A study [6]
of punchless punching by ultrahigh p r e s s u r e
gas was carried out. But, the study only
indicated experimentally t h e possibility of
punchless punching of stainless steel sheet.
We have examined a n e w punching
m e t h o d for thin s h e e t m e t a l using ultrahigh
pressure gas without a punch. The n e w
punching method has t h e following merits:
~1~ By substituting gas for a punch,
clearance b e t w e e n t h e p u n c h and die is not
needed, and burrs or cracks seldom occur.
We can get a satisfactory f r a c t u r e surface
without a second process.
(~ Cross sections are rarely malformed by
h i g h - s p e e d cutting.
@ It is possible to cut the production cost
by half, because we only have to m a k e dies
without punch.
@ W h e n t h e shapes or hole diameters are
changed, we only have to replace t h e dies.
@ The workshop can be k e p t clean as no
lubricate is needed for punching. It is not
necessary to w a s h t h e products after
punching.
@ The process works not only for s h e e t
metal,but also for high polymer materials,
flexible basis and amorphous metals.
In this paper, we report t h e e x p e r i m e n t a l
result of punching circular holes of the
simplest shape. We investigate t h e punching
process, examining t h e dimensional accuracy
of circular holes experimentally, while using
dies of varying diameters. F u r t h e r m o r e , we
examine the minimum pressure for
punching experimentally and analytically. It
is the purpose of this p a p e r to clarify the
possibility and c h a r a c t e r of punchless
punching by ultrahigh pressure gas.
 M. Murata et aL / Journal of Materials Processing Technology 48 (1995) 59-68 61

2.EXPERIMENTAL EQUIPMENT, pressure regulation and pressure is

WORKPIECE AND PROCESS ORDER
Figure 1 shows a block diagram of
punchless punching of a circular hole in thin
sheet metal by ultrahigh pressure gas. The
gas booster system which was used for
punching is also indicated in Fig.1. The
maximum pressure of the system is
200MPa. The press pump(~ is regulated by
air pressure, and the gas pressure is
adjusted by turning the air regulator valve.
Nitrogen gas is used as the press medium,
for safety and ease of handling. The high
pressure nitrogen gas is reserved in a 300ml
reactor(~). The gas press system and reactor
are obstructed after the pressure in the
reactor is boosted to a set pressure.After
that, punching operations are set by
measured by the strain gage transducerS.
Figure 2 shows a photograph of the gas
booster system. Punching is finally
completed by opening the work v a l v e ~ ,
joining the reactor and workbase~) and
adding sudden massive pressure to the
workpiece. The workbase,packing sheet,
workpiece and die with circular hole are
arranged as in Fig.3. We prepared six dies
with holes ranging from 1.0 to 5.0mm in
diameter. They were made of JIS
SKDll(Japanese Industrial Standerds:JIS).
The workpieces shape were 50 square mm
and the materials were aluminum(JIS
A1060) and tough pitch copper sheet(JIS
Cl100), with thicknesses of 0.05mm and
0.1ram. Table 1 shows the main mechanical
properties of these materials.

Exhaust valve
Gas outlet !1 [~
Gas inlet valve
Voltmeter
I [ !lGas inlet
Nitrogen cylinder (~Press I Gas outlet
cylinder I valve
Amplifier ~--~
Air inlet Pressur~
[- .B gauge
Air compressor: .......... VAir inlet Press Velve t~tnrsdn ciarge ~
L.~valve

Valve A
QAir ope~ied
h y d r o pump ~ I I
I~ork b.sel
Reservoir
................... ~ ~.r~re~,
_~. n ~~, b~..?
,^~t, ........................ alve Work valve

Work block
Fig.1 Block diagram of system of punchless punching of a circular hole
in thin sheet metal by ultrahigh pressure gas.
62 M. Murata et aL / Journal of Materials Processing Technology 48 (1995) 59-68

We used a tool microscope to measure the

dimensions and determine the accuracies of
the punched holes diameters.

workl
pack
she~

Fig.2 Photograph the ultrahigh pressure gas Fig.3 Schematic illustration workpiece set
punching system. up.

die ~t
~~~~1
workpiece

Fig.4 Measured position of the

dimensional accuracy of diameter.

Table 1
Mechanical properties of workpieces
(JIS: Japanese Industrial Standard)

Material Ultimate tensil Elongation

estrength[MPa] percentage[%]
A1umiaum 132.0 43.0
(.]IS AI060-H18)
Tough pitch copper 268.7 48.4
(JIS C1100-H)
 M. Murata et al. / Journal of Materials Processing Technology 48 (1995) 59--68
& E X P E R I M E N T A L RESULT AND
INVESTIGATION
3.1.Punching m e c h a n ; - m
Figure 5 shows a photograph of t h e
surfaces and cross sections of t h e
workpieces, w h e r e circular holes w e r e
p u n c h e d in 0.1ram copper s h e e t and w h e r e
t h e p u n c h i n g p r e s s u r e was changed in each
photo. Figure 5(a) shows a photo of the
scrap surface on t h e die side and Fig.5(b)
shows a cross section of t h e punched holes
n e a r positions (a). These photos show the
initial s t a g e of t h e process at a low p r e s s u r e
(9.8MPa), a n d t h e final stage of t h e process
at a high p r e s s u r e (12.2MPa). T h a t is, w h e n
gas p r e s s u r e is added to t h e surface of t h e
workpiece, a bulge formation occurs in the
die's hole, and t h e workpiece is s h e a r e d a t
(a)Die-side (b)Cress section
Copper(J-IS C 1 1 0 0 - H ) , t = 0 . 1 ( m m ) , d = 5 ( m m )
Fig.5 Bulge deformation of workpiece.
63
t h e die's cutting edge. T h e s e are t h e
features of this punching process using gas.
Punched circular holes h a v e a cut end with
a large s h e a f i n g droop, but w i t h little burr.
In Fig.5(b) at 14.7MPa and Fig.6(a) which
was magnified (Fig.5(b)) t h e same thing is
also shown. In addition, t h e deeproot
necking parts which w e c a n see in Fig.6(b)
show t h a t t h e b r e a k i n g p h e n o m e n a of t h e
workpiece by this process is different from
t h e conventional method,since t h e s h e a r i n g
of t h e blanking is done a t t h e dies cutting
edge, and t h e p a r t of punched hole's outline
is formed by having t h e m a t e r i a l drooped
and pulled w i t h bulging deformation. As a
result of this, t h e punching occurs.
Figure 7 shows a model of this punching
process. With t h e addition of pressure, a
bulge deformation occurs in t h e part
(a)Part of punched hole.
(b)Part of s h e a r i n g deformation.
Fig.6 Microphotography of cross section of
workpieces.
64 M. Murata et aL / Journal of Materials Processing Technology 48 (1995) 59-68

equivalent to t h e b l a n k and a t cutting edge Figure 8 shows t h e photo outline of a

A a s h e a r i n g deformation occurs. The
t h i c k n e s s in hole B corresponds to t h a t at
cutting edge A, w h i c h gets t h i n n e r being
pulled. The results a r e s h o w n in (d). And the
blanked disks a r e domed.(i.e, this process
c a n n o t be used for blanking.) This machine
needs to finish t h e process (a) to (d) about
0.1second.
circular hole t h a t was punched in 0.1ram
copper s h e e t by a die 2 m m in diameter. In
this photo, (a) is t a k e n from die side and (b)
is t a k e n from t h e press side. For t h e reasons
mentioned above, we can see little shearing
droop in (a), i t is well punched. On t h e o t h e r
hand, we can see a large s h e a r i n g droop in
(b), and it shows a black ring as in the
photo, with a width of 0.08ram.

(a)Before p u n c h i n g (b)Bul~ e deformation s t a r t

(c)Shearing (d)After p u n c h i n g

Fig.7 P u n c h i n g process.

(a)Die side

(b)Pressure side

Fig.8 P h o t o g r a p h of outline of t h e punched hole.

 M. Murata et aL / Journal of Materials Processing Technology 48 (1995) 59--68 65

3.2.Accuracy of punched hole d i a m e t e r regardless of the punching pressure

We have described how accuracy is changes.
affected by the punching mechanism. Here, The relationship b e t w e e n the diameters of
A d for the index of the punched hole dies hole and widths of e values for different
accuracy is adopted, and A d is indicated as thicknesses of aluminum s h e e t are indicated
follow. in Fig.15. These are t h e average e values for
various pressures. The e value at 0.05mm in
A d = d 0(diameter of die's hole) thickness is 0.03mm, and at 0.1mm in
- d ( i n t e r n a l d i a m e t e r of punched hole) thickness is 0.06mm. The later e value is
twice as much the former. Figure 16 shows
Figure 9 shows the relationship b e t w e e n the s a m e relationship as in Fig.15 with
p r e s s u r e p and punched hole accuracy A d copper sheet. The values of e in copper are
for different thicknesses t of aluminum. The equal to those in aluminum for the s a m e
die hole d i a m e t e r is 3.0ram. The pressure is thicknesses. If the thickness is doubled, the
changed from 5 to 120MPa. The accuracy is value of e becomes about twice as m u c h in
c o n s t a n t in spite of the p r e s s u r e change. aluminum and copper. This can be explained
Although t h e holes are punched by various by the punching process indicated in Fig.7.
pressures, t h e diameters of punched holes
do not vary and are smaller than those of 0.1
Copper(JIS C1100)
t h e die holes. The relationship b e t w e e n -t(mm) 0.05 0.1
p r e s s u r e and hole accuracy in copper is []
s h o w n in Fig.10. The p r e s s u r e varies from E
20 to 120Mpa.The accuracy is the s a m e as Ao.o5
in Fig.9.
<3 ~ID r~D Ell
The effects of various dies hole diameters
on the accuracies of punched hole diameters ~D ND
in aluminum s h e e t are s h o w n in Fig.11. The do=3!mm)
accuracies are the m e a n values at various 0 ,50 100 150
punching pressures. The thicknesses of p(MPa)
aluminum s h e e t are 0.05 and 0.1mm. The Fig.9 Relationship b e t w e e n pressure p and
value of accuracy is about 0.025ram and the accuracy of d i a m e t e r of punched hole Ad
dispersion is 0.01mm. Figure 12 shows for different thickness t of aluminum.
effects similar to those in Fig.11 in copper
sheet, but the accuracy is about 0.02ram and
the dispersion is 0.01ram. The accuracies 0.1
Aluminum(JIS A1060) !
and dispersions of aluminum and copper are
t(mm) 0.05 0.1
t h e s a m e for thicknesses of 0.05 and 0.1mm. o
Figure 13 and 14 s h o w t h e relationship E
b e t w e e n t h e punching p r e s s u r e and the Ao.o5
width e (as s h o w n in Fig.4) of the shearing <3
droop, and e is observed from a
perpendicular view point over t h e hole
surface. The e value of aluminum is a little do=3(mm)
smaller t h a n t h a t of copper, and t h e y have 0 50 100 150
constant values in spite of various p(MPa)
pressures, because the punching Fig.10 Relationship b e t w e e n pressure p and
phenomena, which are caused by drooping accuracy of d i a m e t e r of punched hole A d
and shearing of materials, are the same for different thickness t of copper.
66 M. Murata et aL I Journal of Materials Processing Technology 48 (1995) 59--68

0.1
Aluminum(JIS A1060)
t(mm) 0.05 0.1 0.1
o
E E
go.o5 E
<3 "6"0.05 t=0.1 (mm)
~ do=3(mm)
Materials AI Cu
Ii
o ' ~, ' 4 ' 6 0 . . . . . .5O
. . . 16o'" T5o
do(ram) p(MPa)
F i g . l l Relationship b e t w e e n d i a m e t e r of Fig.14 Relationship b e t w e e n p r e s s u r e p and
dies hole do and average of accuracy of s h e a r droop width e for different workpiece
d i a m e t e r of punched hole A d for different materials at a thickness of 0.1mm.
thickness t of aluminum.

0.1
.Copper(JIS C1100) 0.15
-Aluminum(J IS A1060)
.t(mm) 0.05 0.1 t(mm) 0.05 0.1
[] o
E 0.1
E E
~0.05 g
<3 0 0
[] 0.05
[] O0 0 0 0 0

h I I ~ I
0 2do(mm) 6 o -6
d(mm)
Fig.12 Relationship b e t w e e n diameter of Fig.15 Relationship b e t w e e n d i a m e t e r of
dies hole do and average of accuracy of dies hole do and the average s h e a r droop
d i a m e t e r of punched hole A d for different width e for different thickness t in
thickness t of copper. aluminum.

0.1~
0.1 t=0.05(mm) Copper(JIS C1100)
do=3(mm) do(mm) 0.05 0.1
[]
[] ~-o.1
E
"~0.05 mmmm []
[] %O~Oo
,6~Jo 0.05 [] [] [] [] []
Materials AI Cu []
[]
0 . . . . . . .50 %0 .... 150 n

p(MPa) ' 2 d(mm) ~ '~

Fig.13 Relationship b e t w e e n p r e s s u r e p and Fig.16 Relationship b e t w e e n d i a m e t e r of
s h e a r droop width e for different workpiece dies hole do and the average s h e a r droop
materials at a thickness of 0.05mm. width e for different thickness t in copper.
 M. Murata et aL / Journal of Materials Processing Technology 48 (1995) 59-68 67

3.3~llnlmum punching pressure pressure.

Concerning economy or preservation of The p u n c h i n g p r e s s u r e p is t h e m i n i m u m
dies continually hit by sudden, and massive p r e s s u r e for punching in case of a n equality.
high p r e s s u r e gas, it is not appropriate t h a t The s h e a r i n g resistance is normally applied
t h e r e a c t o r p r e s s u r e is needlessly boosted. 0.8 times of tensile strength. If t h e punching
tks previously shown, the accuracy of holes does not incur a loss of punching force by
p u n c h e d w i t h gas is almost c o n s t a n t with friction b e t w e e n die and p u n c h unlike o t h e r
gas p r e s s u r e change. It is i m p o r t a n t for the conventional punching,the punching is
design of p u n c h i n g machines t h a t the caused only by s h e a r i n g force. T h e n , t h e
m i n i m u m p u n c h i n g pressure is calculated. s h e a r i n g resistance is hal/ of t h e ultimate
We d e t e r m i n e h o w m u c h p r e s s u r e is needed, tensile s t r e n g t h s in this paper, and the
as follows. If p a r t of t h e scrap is sheared by Tresca condition can be applied. Figure 17
t h e c u t t i n g edge of t h e die, t h e equation of shows t h e m i n i m u m pressure required to
balance b e t w e e n the part of scrap and the p u n c h circular holes w i t h diameters for
part of s h e a r i n g is given as equation (1). different thicknesses in a l u m i n u m sheets.
Each black and w h i t e points show the
zr d0Zp experimental values in Fig.17. The
zrdotk~ - (I) experimental values a g r e e well with t h e
4
Equation (I) is rewritten as follows: calculated curve. The m i n i m u m pressures
decrease as t h e punched hole d i a m e t e r s
4k,t increase. W h e n t h e s h e e t thickness increase
p _~ (2) doubles, t h e m i n i m u m pressure needed is
do
almost twice as m u c h as in Fig.17. Figure 18
Where k , [N/ram 2] is the shearing shows t h e s a m e relationship in Fig.17 with
resistance, d 0[ram] is t h e radius of t h e die copper sheet. The experimental and
hole, t [ m m ] is t h e thickness of the calculated m i n i m u m pressures of copper
workpiece, and p[MPa] is t h e gas punching show t h e same values.
80 80
Aluminum(JIS A1060) ~ Copper(JIS C1100)
t(mm) 0.05 0.1 ~m t(mm) 0.05 0.1
60 Experimental 60 i~ \ \ Experimental []
(13
Calculated . . . . . . . n \, ~\ Calculated . . . . . . .
13_
40 \ 40 ~,[] X \ _
\ \ '\. []'~..
20 '"'?'~"e_ 20 \'-. [] ~ L .
"~.~. C_I ~ i . m
, , -;- ....
0 2 4 6 0 2 4 6
do(mm) do(mm)
Fig.17 M i n i m u m p r e s s u r e p required to Fig.18 Minimum pressure p required to
p u n c h circular holes w i t h d i a m e t e r do for p u n c h circular holes with d i a m e t e r do for
different thickness t in aluminum. different thickness t in copper.
68 M. Murata et al. / Journal o f Materials Processing Technology 48 (1995) 59-68

4.CONCLUSIONS ACKNOWLEDGEMENTS

We investigated experimentally the This work has b e e n realized by m e a n s

punchless punching of thin s h e e t m e t a l by AMADA FOUNDATION found and the
ultrahigh p r e s s u r e gas. The punching authors wish to t h a n k t h e Foundation.
m e c h a n i s m , accuracies of punched hole
diameters, s h e a r i n g droop width and
minimum punching pressures were REFERENCES
examined. The results were concluded as
follows: 1. T.Maeda, Plastic Working, 1972, pp.208,
~) The accuracy of t h e punched holes was Seibundo(in Japanese).
almost always c o n s t a n t in spite of gas 2. T.Sano, Y.Murakosi and K.Matsuno,
p r e s s u r e and die hole d i a m e t e r changes. J.Mater.Process.Technol.,30 - 3,1992,pp.341
~) The cut ends had a large shearing (in Japanese)
droop, but b u r r e d or s h e a r e d surfaces were 3. M.Murata,H.Suzuki,Proc.Jap.Spring Conf.
minimal. Technol.Plasticity,1992,pp.621 (in Japanese)
S h e a r i n g droop of cross section of the 4. T.Aizawa, R.Ueki and T.Kobayashi,
punched hole increased w i t h thickening Proc.42nd Jap.Joint Conf.Technol. Plasticity,
The experimental and calculated 1992,pp.503(in Japanese)
minimum pressure were almost in 5. J.Harding, Proc.2nd Int. Conf. H.E.F.,1972,
a g r e e m e n t . Therefore, the m i n i m u m possible 8.4
p r e s s u r e needed to p u n c h could be 6. I I . ~ . T y T ~ U l K H H X B . B . I ~ o :~ :1
calculated using the aforementioned BjI~y 3 H e q H O--flIT a M H O B O q II
equation. o e l i p o H 3 a o a c T B O,4,1982, pp.16