Sheet metal cutting — reducing punching/shearing force: During blanking or piercing, how can the cutting force required on the tool be effectively reduced without compromising part accuracy?

Introduction / Context:
Blanking and piercing operations require high instantaneous force to fracture the sheet. Tooling strategies can lower peak tonnage while maintaining edge quality and die life. One proven method is to introduce shear either on the punch or the die face.

Given Data / Assumptions:

• Conventional punch–die set with proper clearance.
• Material thickness and strength are moderate.
• Objective: reduce peak press load.

Concept / Approach:
Providing shear means beveling or stepping the punch or die face so that contact engages progressively rather than simultaneously across the full perimeter. This increases the penetration distance over which fracture occurs, reducing peak force (tonnage) while keeping total work similar. Sharp edges and hardness are important for life and quality but have negligible effect on peak force compared with adding shear.

Step-by-Step Solution:
Introduce punch shear angle α so engagement initiates at one point/line.Force–displacement curve spreads over longer stroke, lowering maximum force.Maintain clearance to preserve edge quality.Result: lower required press capacity without changing part dimensions.

Verification / Alternative check:
Press load calculations show peak force roughly proportional to perimeter * thickness * shear strength; effective shear reduces the instantaneous engaged thickness.

Why Other Options Are Wrong:
Sharper edges reduce burrs but not peak tonnage substantially.

Hardness of tools/dies affects wear, not fundamental cutting force.

Press speed has limited influence on static peak force for ductile metals and may degrade edge quality.

Common Pitfalls:
Applying excessive shear that causes part rollover; neglecting to support the sheet leading to distortion.

Final Answer:
providing shear on tool