Advantages of Using Free Falling Objects in the Blanking Process

Oct 13, 2025 by vinooalluri.com 149 views

Analysis of the Results of Making Aluminum Coins with the Blanking Process Using the Burden of Free Falling Objects

Introduction

Making aluminum coins is a process that has been widely used for various applications. The traditional method of making aluminum coins involves using a press machine, which is known as the blanking process. In this process, plates are placed between a pair of cutting devices, namely pons and molds, to produce a product called blank. The blanking process is not only used to produce aluminum coins but also various shapes of plates such as rings, rectangles, ovals (ellipses), and other complex shapes. The size and quality of the desired coin surface are determined by several factors, such as the distance between the pons and the mold (clearance), the speed of slaughtering, the size of the cut force, the type of coin material, and the type of material cutting tool.

The Traditional Blanking Process

In general, the cutting process is carried out using a manual, mechanical, pneumatic, or hydraulic load system with low speeds between 20 to 40 m/minute. However, in this study, the burden of impacted free falling objects is used as an alternative. This system is designed based on JIS or SNI standards, where objects are dropped from a height of 0.5 to 2.5 meters, so the speed of the object falls (and cutting speed) ranges from 3.13 to 7.0 m/s.

The Use of Free Falling Objects in the Blanking Process

This study uses an aluminum plate that is dotted with a thickness of 2 mm and a nominal diameter of 22 mm coins. Five pons used variations of clearance to molds, ranging from 2% to 10% of the thickness of the plate. Each pons produces five coin samples, which are then measured the size and quality of the surface using a digital microscope. Measurement of impact force due to free falling objects is done using a load cell equipped with an impact force gauge software.

Results and Discussion

The results showed that the 8% leeway produced the size of the aluminum coin that was closest to the size of the mold. Smaller leeway requires a larger impact force. The smallest coin diameter produced is 22.020 mm, while the largest diameter is 22.036 mm. The coin size tolerance for a diameter of 22 mm is 0.06 mm, so the diameter of the largest coin allowed is 22.06 mm. Therefore, all sizes of coins produced can be accepted.

Research also shows that the mass and height of the free falling object affect the speed of cutting, the shape of the coin surface, and height of the burr, but does not affect the size/diameter of the coin. The impact force is influenced by the mass and height of the load fall. The measurement results show that the measured impact force is smaller at 3.8% to 5.78% compared to the theoretical impact force.

Conclusion

Overall, this study shows that the use of the burden of free falling objects can be an effective alternative for the blanking process in making aluminum coins. This method produces coins with a size that matches the standard and good surface quality. In addition, this method can also help reduce the use of energy and greenhouse gas emissions and emissions, because it does not require the use of a hydraulic system that requires large electrical energy.

Future Research Directions

This research can be further developed by exploring other parameter variations, such as the type of pons and mold material, as well as more complex coins. In addition, research can also be directed at the development of the automation system for the blanking process using the burden of free falling objects.

Advantages of Using Free Falling Objects in the Blanking Process

Produces coins with a size that matches the standard and good surface quality
Can help reduce the use of energy and greenhouse gas emissions and emissions
Does not require the use of a hydraulic system that requires large electrical energy
Can be used as an alternative to traditional blanking process

Limitations of Using Free Falling Objects in the Blanking Process

Requires careful control of the mass and height of the free falling object
May not be suitable for producing complex coins
May require additional equipment and software for measurement and control

Future Applications of the Blanking Process Using Free Falling Objects

Production of coins for various applications, such as currency, tokens, and medals
Production of complex shapes and designs
Development of automation systems for the blanking process
Exploration of other parameter variations, such as the type of pons and mold material.
Q&A: Analysis of the Results of Making Aluminum Coins with the Blanking Process Using the Burden of Free Falling Objects

Frequently Asked Questions

Q: What is the traditional method of making aluminum coins? A: The traditional method of making aluminum coins involves using a press machine, which is known as the blanking process. In this process, plates are placed between a pair of cutting devices, namely pons and molds, to produce a product called blank.

Q: What is the blanking process? A: The blanking process is a method of cutting metal sheets or plates into desired shapes and sizes. It involves placing the metal sheet between a pair of cutting devices, namely pons and molds, and applying a force to cut the metal into the desired shape.

Q: What is the burden of free falling objects? A: The burden of free falling objects is a method of cutting metal sheets or plates using the impact of free falling objects. In this method, objects are dropped from a height of 0.5 to 2.5 meters, so the speed of the object falls (and cutting speed) ranges from 3.13 to 7.0 m/s.

Q: What are the advantages of using free falling objects in the blanking process? A: The advantages of using free falling objects in the blanking process include producing coins with a size that matches the standard and good surface quality, reducing the use of energy and greenhouse gas emissions and emissions, and not requiring the use of a hydraulic system that requires large electrical energy.

Q: What are the limitations of using free falling objects in the blanking process? A: The limitations of using free falling objects in the blanking process include requiring careful control of the mass and height of the free falling object, may not be suitable for producing complex coins, and may require additional equipment and software for measurement and control.

Q: What are the future applications of the blanking process using free falling objects? A: The future applications of the blanking process using free falling objects include production of coins for various applications, such as currency, tokens, and medals, production of complex shapes and designs, development of automation systems for the blanking process, and exploration of other parameter variations, such as the type of pons and mold material.

Q: What are the results of the study on the blanking process using free falling objects? A: The results of the study on the blanking process using free falling objects showed that the 8% leeway produced the size of the aluminum coin that was closest to the size of the mold. Smaller leeway requires a larger impact force. The smallest coin diameter produced is 22.020 mm, while the largest diameter is 22.036 mm. The coin size tolerance for a diameter of 22 mm is 0.06 mm, so the diameter of the largest coin allowed is 22.06 mm.

Q: What are the implications of the study on the blanking process using free falling objects? A: The implications of the study on the blanking process using free falling objects are that it can be an effective alternative for the traditional blanking process in making aluminum coins. It produces coins with a size that matches the standard and good surface quality, and can help reduce the use of energy and greenhouse gas emissions and emissions.

Common Misconceptions

Misconception: The blanking process using free falling objects is a new and untested method.
Reality: The blanking process using free falling objects has been studied and tested, and has shown promising results.
Misconception: The blanking process using free falling objects is not suitable for producing complex coins.
Reality: The blanking process using free falling objects can be used to produce complex coins, but may require additional equipment and software for measurement and control.

Conclusion

The blanking process using free falling objects is a promising method for making aluminum coins. It produces coins with a size that matches the standard and good surface quality, and can help reduce the use of energy and greenhouse gas emissions and emissions. However, it requires careful control of the mass and height of the free falling object, and may not be suitable for producing complex coins. Further research is needed to fully explore the potential of this method.