Mechanism Analysis, Process Parameter Tuning and Tooling Retrofit for Precision Blanking Edge Quality Control

Release Date: September 10, 2026

Authoritative Data Source: Sheet Metal Stamping Quality Benchmark Report 2025–2026, International Metal Forming Society Blanking Test Database, Automotive Component Supplier Quality Audit Statistics

News Abstract: Blanking edge quality directly determines the dimensional stability, fatigue resistance and downstream assembly performance of stamped metal parts. For automotive structural parts, new energy battery brackets and electrical precision terminals, burr height, tear zone proportion and edge microcracks are critical quality acceptance indicators. Industry survey data shows that conventional blanking processes for medium-thickness steel plates often produce burr heights between 0.08mm and 0.18mm, with tear zone accounting for more than 35% of the total section. Excessive burrs lead to scratches on mating surfaces, assembly interference, fatigue crack initiation and increased rework workload such as manual deburring. Many stamping manufacturers rely on post-process grinding or tumbling to remove burrs, which raises labor cost, extends production lead time and introduces secondary surface damage. In 2026, integrated blanking edge quality optimization, including die clearance refinement, punch and die surface coating, blanking speed matching and material pre-treatment, becomes a key quality upgrading project to eliminate post-processing deburring and meet high-end component drawing requirements.

A1: A standard blanking cross-section contains four regions: rollover zone, burnished shear zone, tear fracture zone and burr zone. Burr forms at the end of the shear process, when the material is not fully sheared and undergoes tensile tearing. The main influencing factors include die clearance, cutting edge sharpness, sheet material tensile strength, blanking speed and material surface lubrication. If clearance is too large, the tear zone expands and burr rises sharply; if clearance is too small, secondary shearing appears, accelerating punch and die wear. Industry test data shows that for cold rolled low carbon steel of 2.0mm thickness, the optimal unilateral clearance range is 8%~12% of sheet thickness. Deviation from this window will rapidly degrade edge quality.