International OPEN ACCESS Journal Of Modern Engineering Research (IJMER) | IJMER | ISSN: 2249–6645 | www.ijmer.com | Vol. 5 | Iss.3| Mar. 2015 | 71| A Review on Factors Affecting the Sheet Metal Blanking Process Prof R.S.Shaikh 1 , R.R.Gaonkar 2 , A. Shaikh 3 , M.Shaikh 4 , S.Shaikh 5 1,2,3,4,5 Department of Mechanical Engg,anjuman-i- islam kalsekar technical campus,mumbai university,India I. Introduction Metal blanking is a widely used process in high volume production of metal components. General guidelines for this process exist but they are not sufficient to overcome the difficulties in designing blanking processes, where requirements for less cycle time and accurate product dimensions become more demanding. The design of blanking processes in industrial practice is still based largely on experimentations and it is often governed by time-consuming and expensive trial and-error iterations caused by limited, mostly empirical, knowledge of these processes. 1.1 Characteristics of the blanking process include  Its ability to produce economical metal work pieces in both strip and sheet metal during medium or high production processes,  The removal of the work piece from the primary metal stock as a punch enters a die.  The production of a burnished and sheared section on the cut edge.  The production of burred edges.  The control of the quality by the punch and die clearance.  The ability to produce holes of varying shapes – quickly. 1.2The blanking process has some downside effects., these include:  Generating residual cracks along the blanked edges,  Hardening along the edge of the blanked part or work piece, and  Creating excess roll-over and burr if the clearance is excessive. The most common materials used for blanking include aluminium, brass, bronze, mild steel, and stainless steel. Due to its softness, aluminium is an excellent material to be used in the blanking processes . Blanking process can be considered to include series of phases in which sheet metal undergoes deformation and separation... Therefore, appropriate modellingand understanding of the blanking process could be beneficialto reduce the lead-time and to control the product specifications, especially the shape of a blanked (sheared)edge.The behaviour of the blank material during the blanking process can be divided into five stages. During the start ofthe process, the sheet is pushed into the die and the blank material is deformed, first elastically. The processcontinues and the yield strength of the blank material is reached, first at the outer fibbers and later at all the fibbers in the zone between the punch and the die. Normally, the material underneath the punch is subjected to thinning.The plastic deformation causes rounding of the edge of the blank. During this stage, or possibly as early as during the plastic deformation stage, damage initiation followed byte nucleation and growth of cracks takes places. In most of the conventional blanking situations, ductile fracture occurs after ABSTRACT: Metal blanking is a widely used process in high volume production of sheet metal components. The main objective of this paper is to present the study model to predict the shape of the cut side. The study investigates the effect of potential parameters influencing the blanking process and their interactions. Different methodology like use of simulation software’s (e.g. abacus,ansys),FEM,DOE tech are applied. Finally, the factors affecting blanking process observed are Clearance ,tool wear, Sheet Thickness, Material properties . Keyword: Clearance, tool wear, Sheet Thickness, .