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Precision Blanking Edge Quality Upgrade Project: Burr & Cross-Section Optimization

2026-09-12

Precision Blanking Edge Quality Upgrade Project: Burr & Cross-Section Optimization for New Energy Battery Bracket Stamping

Tear zone ratio on blank cross-section: 36.2%
Assembly defect rate caused by edge burr: 0.87%

3. Optimize press blanking stroke speed from 32 strokes/min down to 24 strokes/min for blanking phase, avoiding high-speed impact tearing.

Core Quality, Cost & Productivity Indicators	Before Blanking Edge Quality Upgrade	After 12-Month Stable Operation	Quantified Comprehensive Improvement
Maximum blank edge burr height	0.14 mm	0.028 mm	-80.0%
Tear zone ratio on blank cross-section	36.2%	11.5%	-68.2%
Edge microcrack detection rate	2.13%	0.31%	-85.4%
Relative deburring labor workload	100%	12.6%	-87.4%
Edge-related scrap rate	1.68%	0.22%	-86.9%
Punch & die insert service life	115,000 strokes	196,000 strokes	+70.4%
Assembly defect rate from edge burr	0.87%	0.11%	-87.4%
Monthly cost of deburring labor + edge scrap loss	USD 12,860	USD 2,740	Monthly saving USD 10,120

A2: DLC diamond-like carbon coating has low friction coefficient and high hardness, reducing cold welding and material pickup between steel sheet and cutting edge. Before coating, high-strength steel material adhered to punch and die edges, forming built-up edges which scratched blank surfaces and accelerated edge blunting. DLC coating reduced metal pickup, slowed down abrasive wear and delayed edge dulling. In mass production verification, coated inserts maintained stable burr height for far more strokes before requiring regrinding, cutting mold maintenance frequency and downtime caused by die swap.

Q5: What preventive maintenance system was built to keep burr within specification in long-run mass production?

A5: The factory implemented three-tier control. First, hourly on-line sampling for burr height measurement and visual cross-section check by operators. Second, daily quality team audit and SPC chart update to detect upward trend before burr exceeds control limit. Third, mold maintenance pre-warning: once burr height approaches threshold, arrange insert regrinding and recoating during planned shutdown, instead of waiting for mass scrap. This preventive mechanism avoids sudden quality drift and ensures stable edge quality over long production batches.

Case Comprehensive Conclusion & Industry Outlook

This 12-month mass production verification demonstrates that blanking edge quality optimization is a high-value quality improvement project for precision stamping manufacturers. Many factories rely on post-process deburring as a routine fix, which brings high labor cost, unstable quality and hidden reliability risks. By fine-tuning die clearance, applying advanced surface coating, matching blanking speed and building SPC edge quality monitoring, stamping enterprises can greatly reduce burr height, shrink tear zone, cut deburring workload and lower edge-related scrap. With the increasingly strict reliability requirements of new energy and automotive industries, controllable blanking cross-section quality will become one of the mandatory core quality indicators for high-end stamped component suppliers.

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