Pros and Cons of Punching and How it Works

Punching is a common metalworking method used to make metal parts. For punching and shaping holes in sheet metal, it is one of the best and most accurate methods.

In this article-Pros and Cons of Punching and How it Works, we’ll take a look at punching, including how it works, how it looks, and how it fits into the metal stamping process.

What Is Punching in Metal Stamping?

When using metalworking techniques, punching is used to punch and shape holes in sheet metal. This method can be used for other materials as well. A punching machine with a punch and die is used to make precise and repeatable holes in the sheet metal. The metal can then be used to make other parts.

Metal stamping is a metalworking method that uses different techniques to create metal parts on sheet metal. After metal stamping, a method can be used to create shapes or holes in the metal sheet. This is then further processed by other methods (such as bending, embossing, or flanging), which is punching.

Key Features of Sheet Metal Punching Operations

• Punching and Dies: The punching tool presses into the sheet metal located above the die recess. This cuts the sheet metal to form the desired hole or shape.
• Press: Punching requires a lot of force. Hydraulic or mechanical presses that can generate several tons of pressure are therefore required.
• Fast Production: Punches move up and down quickly, so the work is done quickly. Today, punching machines can make more than 100 punches per minute.
• Tool and Die Sets: There are different types of common punches and dies. They can be used to make holes of different sizes, louvers, slots, notches, and custom shapes.
• Deburring: The cutting action can create raised burr edges at the top of the holes. We can remove these with a deburring process.
• Precision: Modern CNC turret punch presses use a system to track the position of the sheet and the tool. This ensures a precise and consistent hole pattern.
• High Tonnage: To cut and shape thick materials such as steel plates without breaking them, you need to use a punch press with the highest-rated tonnage.

What Is the Difference Between Punching and Stamping Sheet Metal?

When working with sheet metal, punching and stamping are two common methods of forming metal. The main purpose of punching is to make holes or shapes in sheet metal. The main purpose of stamping is to perform one or more processes on a sheet of metal to make a finished product.

During the stamping process, different tools are used to cut and shape the sheet metal into specific parts. As part of the stamping process, punching is often used to help create the final product. Metal stamping also includes other steps such as punching, bending, flagging, and embossing.

How Does Punching Work?

Punching begins with the installation of tools and gears. A punch, usually made of high-speed steel (HSS), and a die make up the tool. As the punch passes through the metal, the die holds it up and helps punch the hole. These are mounted on the punching machine according to the size, shape, and location of the desired hole.

The sheet metal is then placed on the machine table and secured in place with clamps or fixtures. The machine is then turned on and holes are punched into the material using a mechanical or hydraulic press. The punch goes through the material and forms the hole or shape as it is pushed by the press. The punch leaves a piece of metal behind, and the piece is removed from the die before the next piece of metal is punched.

After punching, some post-processing steps may be performed on the metal piece to ensure that the edges of the hole are smooth.

What Is the Purpose of Punching In Metal Stamping?

Punching is used to punch and shape holes in sheet metal for further processing into metal parts. Punching is favored by many manufacturers because it is very accurate and fast. And it doesn’t cost much when it comes to high-volume production.

Metal stamping can be used on many different types of metal, making it very flexible and useful in many different areas and situations. The process is repeatable and consistent and is very efficient. It is therefore the best choice for making holes and shapes in large quantities.

What Are the Uses of Punching Holes In the Metal Stamping Process?

Metal stamping manufacturers use punching when they need to make a large number of holes in sheet metal. One of the main reasons they use punching is that it is an inexpensive way to make large quantities of items. Punching machines are fast and automate the job, making them a great way to punch holes and create shapes in sheet metal. When producing large quantities, this efficiency can make up for the cost of buying tools and setting up a factory.

Punching is also highly accurate and repeatable, which is important in areas where limits need to be tightly controlled. The automotive industry often uses punching for chassis and body parts. In the construction industry, punching is used to manufacture structural components such as brackets, roofing and cladding panels, and HVAC components. In the medical field, punching is also used to manufacture parts for medical equipment, furniture, and medical device boxes.

Does Electrical Stamping Use Punching?

Yes, perforations are used in electrical stamping. In electrical stamping, punching is often used to cut motor parts that are quite complex in form. Thin sheets of metal are cut so that the parts fit together perfectly. Next, the parts are stacked and joined together in a process called lamination. Punching is the best way to do this because the design and quality of these parts have a big impact on the working performance of the motor.

Punching is also used in other areas of electrical stamping, mostly in conjunction with other metal stamping methods. Other uses for punching include the manufacture of connectors and parts for data transmission and telecommunications, as well as electronic parts for the aerospace and automotive industries.

What Metals Can Be Used for Punching?

Hole punching can use steel, brass, copper, aluminum, bronze, and a combination of other metals. Which metal you choose depends on many factors, such as the quality you need, the cost, and the purpose of the punched part.

Also, keep in mind that the gearing and tooling required for punching also depends on the metal chosen. For example, the strength and thickness of the material will affect how the tool is made and the material used.

Advantages and Disadvantages of Sheet Metal Punching

Sheet metal punching is a very flexible and fast production process. In addition to its speed, precision, reproducibility, and low cost, it has other advantages. However, you should also be aware of the disadvantages of sheet metal punching. This way you can better choose the manufacturing process that suits your needs.

What Are the Advantages of Punching?

• Speed and Efficiency: This manufacturing process is fast and effective. It can be used to quickly produce large quantities of parts.
• Versatile: There are many tools and dies that can be used to manufacture products of different shapes and sizes.
• High Precision: CNC punching machines with automatic tool changers are highly precise. Holes and other shapes can be produced with minimal error.
• Repeatability: The process can be used to repeatedly manufacture many identical parts. It can be fully or semi-automated.
• Cost: Punches and dies are not expensive compared to other methods. Manufacturing high-quality products using this method is a cost-saving approach.
• Minimal Secondary Processing: Cut edges usually do not require any additional finishing.
• Less Waste: Precision punching makes the most of the material while minimizing waste.
• Wide Range of Materials: Mild steel, aluminum, stainless steel, and other metals up to 1” thick can be punched.
• Low Labor Costs: Automated punching machines do not require a lot of direct operator involvement.

What Are the Disadvantages of Punching?

• Noise: Punching produces a loud repetitive sound. This can have an impact on the surrounding environment.
• Metal Shavings and Dust: A lot of dust and metal shavings are produced. This can be a problem if there is no good ventilation when punching.
• Safety: The process can be dangerous if not done properly. Always follow the safety rules when using sheet metal punching tools.
• Burrs: The edges of the punched holes need to be deburred, which can be an additional step.
• Upfront Costs: Purchasing punching equipment requires a significant investment.
  Skills Required: An experienced coder is often needed to optimize the punching sequence.
• Occasional Jams: The process can get stuck when the material does not feed properly or the tool is damaged. This is usually caused by human error. As such, it is not a common occurrence.

Steps in Metal Sheet Punching

There are various methods of metal sheet punching, depending on the type of operation and the tools or machines used. However, generally speaking, the steps are as follows:

• Design: The engineering drawing shows all the holes, cuts, and shapes required. It also shows their position and dimensions.
• Programming: Programming the numerical control punching machine determines the sequence of the tools and tasks. Today’s CAD/CAM tools make programming much easier.
• Set Up: The required punches and dies are placed in the turret of the punching machine in the sequence of the design. Then the clamping, lubrication, and spacing are checked to ensure they are correct.
• Load: The sheet metal is placed on the punching machine, aligned with the stops and back gauge. Clamping devices hold the material in place.
• Set Up: Punch speeds, stroke depths, and other settings are selected according to the thickness of the material and tool.
• Run: The automatic punching machine punches holes in the sheet metal in the set tool sequence, punching all the design markings into the sheet.
• Check: The punched parts are checked to ensure that the size and position of the holes and any defects are correct.
• Deburring: The deburring method removes the rough top edge burrs produced by punching.
• Unloading: The finished punched parts are removed from the loader and the skeleton scrap is removed.

Although punching holes in metal sheets is a fairly straightforward process. However, it is important to follow safety rules and use the correct methods to ensure a smooth and safe process. We need to have the right tools and ensure that the parts are fixed in place precisely. In addition, by ensuring that the process is closely monitored, we can produce consistently precise punched parts.

How to Choose a Metal Stamping Service That Can Use Punching?

There are a number of things to consider when choosing metal stamping services that use punching techniques. First, you should consider your needs and whether the service provider has the skills and tools needed to get the job done.

Cost and waiting time are also very important considerations. To find the best provider, it is best to ask for quotes from several companies and compare them. Finally, make sure the provider meets quality and safety standards by asking about their licenses and whether they adhere to industry standards.

Yonglihao Machinery has years of experience in precision metal fabrication, perfecting the needs of most of our customers. If you have metal fabrication needs, contact us. We have a professional service team that can answer all your questions.