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35.3.1 Blanking Paper-Base Laminates When parts are designed to have shapes other than rectangular and the volume is great enough to justify the expense of building a die, the parts are frequently punched from sheets

(6.26)

by using a blanking die A blanking operation is well adapted to paper-based materials and is sometimes used on glass-based ones In the design of a blanking die for paper-based laminates, the resilience, or yield, of the material previously discussed under Piercing applies The blanked part will be slightly larger than the die that produced it, and dies are therefore made just a little under print size depending on the material thickness Sometimes a combination pierce and blank die is used The die pierces holes and also blanks out the finished part When the configuration is very complex, the designer may recommend a multiple-stage die: The strip of material progresses from one stage to the next with each stroke of the die Usually in the first one or two stages, holes are pierced, and in the final stage, the completed part is blanked out.

The quality of a part produced from paper-based laminates by shearing, piercing, or blanking can be improved by performing the operation on material which has been warmed Caution should be exercised in heating over 100 F because the coefficient of thermal expansion may be high enough to cause the part to shrink out of tolerance on cooling Paper-base laminates are particularly anisotropic with respect to thermal expansion; that is, they expand differently in the x and y dimensions The manufacturer s data on coefficient of expansion should be consulted before a die for close-tolerance parts is designed Keep in mind that the precision of the manufacturer s data is probably no better than 25 percent 3532 Blanking Glass-Based Laminates Odd shapes that cannot be feasibly produced by shearing or sawing are either blanked or routed Glass blanking is always done at room temperature.

Assuming a close fit between punch and die, the part will be about 0001 in larger than the die which produced it The tools are always so constructed that a part is removed from the die as it is made It cannot be pushed out by a following part, as is often true when the material has a paper base If material thicker than 0062 in is blanked, the parts may have a rough edge The life of a punch, pierce, or blank die should be evaluated with reference to the various copper-clad materials that may be used One way to evaluate die wear caused by various materials is to weigh the perforators, or punches, very accurately, punch 5,000 pieces, and then reweigh the punches Approximately 5,000 hits are necessary for evaluation, because the initial break-in period of the die will show a higher rate of wear.

Also, of course, the quality of the holes at the beginning and end of each test must be evaluated Greatly enlarged microphotos of the perforator can be used for visual evaluation of changes in the die 3533 Shearing When copper-clad laminates are to be sheared, the shear should be set with only 0001 to 0002 in clearance between the square-ground blades (Fig 353) The thicker the material to.

be cut, the greater the rake or scissor angle between the top and bottom shear blade The converse also is true:The thinner the material, the smaller the rake angle and the closer the blades Hence, as in many metal shears, the rake angle and the blade gap are fixed; the cutoff piece can be twisted or curled Paper-base material can also exhibit feathered cracks along the edge that are due to too wide a gap or too high a shear angle That can be minimized by supporting both piece and cutoff piece during the shear operation and decreasing the rake angle Epoxy-glass laminate, because of its flexural strength, does not usually crack, but the material can be deformed if the blade clearance is too great or the shear angle is too large.

As in blanking, the quality of a part produced from paper-based laminates by shearing can be improved by warming the material before performing the operation 3534 Sawing Paper-Base Laminates Paper-base laminates are much harder on sawing tools than are the hardest woods, and therefore a few special precautions are necessary for good saw life Sawing paper-based laminates is best accomplished with a circular saw with 10 to 12 teeth per inch of diameter at 7500 or 10,000 ft/min Hollow-ground FIGURE 354 Commonly used saw tooth designs for saws give a smoother cut; and because of the paper and cloth laminates At left, two successive teeth abrasive nature of laminated materials, car- on a 15 alternate-bevel saw At right, two successive teeth on a 30 ft alternate-corner-relieved (AC-30) saw bide teeth are an excellent investment (See Fig 354 for tooth shape.