Hi. Over the next three days or so, I have to cut hundreds of rectangles from some thin copper sheet (0.004"). Ideally, the shape is basically rectangular, with a couple little tabs sticking out near the four corners (the sheet will be folder over itself, and the tabs will be folded over to help keep the sandwich together). The approximate dimensions are 50 mm x 40 mm (plus the tabs).
I have a CNC mill (PCNC1100), and a bunch of 6061-T6 aluminum stock. Can I make a blanking die and punch out of this and get reasonable results? I'm not too worried about the edge quality (so long as I don't cut myself while working with the blanks) or shape accuracy. Any recommendations for how to undersize the punch relative to the die?
Thanks!