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Technology


Tool Design & Tool Manufacturing

Majestic Auto Limited designs and manufactures all the tools for captive use in-house. The tools are designed to ensure the required percision with extended tool life.

The proper tool design is the key to fine blanking process.

  • More strokes thus more number of components per cycle of die grinding. 
  • Lower idle time in terms of tool break down.
  • Lower maintenance cost.
  • This results into increased productivity and standardisation of products.
  • Competitive cost.

In-house Tool Design & Tool Manufacturing reduces the gestation period to start mass production to meet the critical time schedules. 

Our design & manufacturing equipments includes:

  • CAD-CAM stations for tool design
  • Jig Boring, Grinding & Milling Machine (Waida Japan)
  • Wire Cut EDM (Agie Switzerland)
  • Spark Erosion EDM (Electrical)
  • Optical Profile Grinder (Waida Japan)
  • Profile Projector



FINE BLANKING (PROCESS FEATURES)

Fine blanking is a specialized form of blanking where there is no fracture zone while shearing. It is a sheet metal forming process which compresses and shears the metal strip simultaneously so as to achieve smooth edge with grinding finish. Dedicated hydraulic presses with triple action are used  to produce ‘net shape’ finished parts in just one operations, or press stroke, with one or more steps of the material inside the tool. The tools used are progressive and complex. Unlike Conventional Blanking, counter-pressure is applied on the component that allows the part to be sheared with straight edges and particularly good flatness and tolerances that do not require secondary  operations, such as grinding or milling. Fine Blanking has die clearances one-tenth of those used for Conventional blanking, which helps eliminate tearing on the cut edge of parts. This technology is particularly relevant for the production of high-strength two-dimensional components and has been successfully gaining applications in the automotive sector, where quality and tolerances are paramount.







Fine blanking is a hybrid metal forming process combining the technologies of stamping and cold extrusion. Its unique characteristics mean parts that would otherwise require extensive machining after stamping to complete the design can often be produced to the desired shape and size. Its ability is to pierce small holes and create thin web sections often eliminates the need for costly secondary drilling and machining operations. Throughout the fine blanking process pressure is constantly applied to both sides of the part achieving flatness unmatched by conventional stamping. 

 

Positional Accuracy and Repeatability
As a result of the construction of fine blanking tool;  close tolerances can be consistently achieved from first part produced to the end of the tool life.

The process has the capability to make
Small and big holes which are relative to material thickness enables fine blanked parts to be more cost effective than fully machined parts and conventionally blanked parts that require secondary machining.

Cleanly Sheared and Straight-Cut Edges
This enables fine blanked parts to achieve very tight dimensional tolerances throughout the thickness of the part. The straight-cut edges also provide excellent functional surfaces.

Rolled Stock Strength
Fine blanked parts are made from rolled steel, which makes them inherently stronger than powder metal  and cast components. Often this added strength enables engineers to design smaller, lighter fine blanked components than would be designed for Powder Metal or casting.

Excellent Flatness
As a result of the counter pressure applied throughout the blanking cycle, we can achieve excellent flatness. This often eliminates the need for secondary process of grinding or coining. A part requiring grinding also requires extra thikness on the surface thus more material. Fine blanking eliminates the grinding requirement which leads to saving of extra raw material as well as the secondary operation of grinding.

Design Freedom
Fine blanking can create intricate parts with many features including forming, bends, coining, countersinks, counter bores and much more.

This is achieved through multistation Fine Blanking progressive tools