Manufacturing Science

Module-5
Press work
 Introduction
 Sheet metal work is generally regarded as the
working of metals generally below 5mm.
 Sheet metal working is associated with press
machines and press working.
 In sheet metal work the knowledge of geometry,
Measurement and properties of metal is most
essential
 Material used-Black iron, Galvanised iron,
Stainless steel, copper, Aluminium, Tin plate,
Lead etc.
1: Bed:
The bed is the lower part of the press frame that serves as a table to
which a Bolster plate is mounted.
2: Bolster Plate:
This is a thick plate secured to the press bed , which is used for
locating and supporting the die assembly. It is usually 5 to 12.5
cm thick.
3: Die Set:
It is unit assembly which incorporates a lower and upper shoe, two or
more guide parts and guide part bushings.
4: Die Block:
It is a block or a plate which contains a die cavity
5: Lower Shoe:
The lower shoe of the a die set is generally mounted on the bolster
plate of a press. The die block is mounted on the lower shoe, also
the guide post are mounted on it.
6: Punch :
The punch is directly or indirectly moved by and fastened to the
press ram or slide.
7: Upper Shoe: -
This is the upper part of the die set which contains guide
post bushings.
8: Punch Plate:-
The punch plate or punch retainer fits closely over the body
of the punch and holds it in proper relative position.
9: Back up Plate:-
Back up plate or pressure plate is placed so that intensity of
pressure does not become excessive on punch holder.
The plate distributes the pressure over a wide area and
the intensity of pressure on the punch holder is reduced
to avoid crushing.
10: Stripper:-
It is a plate which is used to strip the metal strip from
cutting a non-cutting Punch or die. It may also guide
the sheet.
Basic Types of Sheet Metal Processes
1.Cutting
◼ Shearing to separate large sheets
◼ Blanking to cut part perimeters out of
sheet metal
◼ Punching to make holes in sheet metal
2.Bending
◼ Straining sheet around a straight axis
3.Drawing or Forming
◼ Forming of sheet into convex or concave
shapes
 Sheet Metal Working (operation)

Metal cutting operations

Metal forming operations
Shearing - Separating material into
two parts 1.Bending
Blanking - Removing material to use 2.Drawing
for parts 3.Embossing
Punching - Removing material as
4.Coining(Squeezing)
scrap
➢Piercing 5. Stretch forming
➢Slotting
➢Perforating
➢Notching Stresses induced Operations
➢Nibbling Shearing Shearing, Blanking, Piercing,
➢Lancing Trimming, Shaving, Notching,
➢Slitting Nibbling
➢Parting
➢Cutoff Compression Coining, Sizing, Ironing,
➢Trimming Tension and Drawing, Bending, Forming,
➢Shaving compression Embossing
Metal cutting operations
 Cutting processes are those in which a piece of sheet
metal is separated by applying a great enough force
to cause the material to fail.
 performed by applying a shearing force, and are
therefore sometimes referred to as shearing
processes.
 the shear stress in the material will exceed the
ultimate shear strength and the material will fail and
separate at the cut location.
 tools are a punch and die or upper and lower blades,
the tool above the sheet delivers a quick downward
blow to the sheet metal that rests over the lower tool.
 A small clearance is present between the edges of
the upper and lower tools, which facilitates the
fracture of the material.
Blanking Punching
 In this process, the  Punching can be
piece removed, used to produce
called the blank, is holes and cutouts of
not scrap but rather various shapes and
the desired part. sizes.
 Blank size = die size
 Clearance on punch  Hole size = punch
 Shear on die alone size
 Clearance on die
 Shear on punch
alone
 Piercing - The typical  Slotting - A punching
punching operation, operation that forms
in which a cylindrical rectangular holes in
punch pierces a hole the sheet.
into the sheet. Sometimes
described as piercing
despite the different
shape
 Perforating -
Punching a close  Notching - Punching
arrangement of the edge of a sheet,
a large number forming a notch in
of holes in a the shape of a portion
single operation. of the punch.
 Nibbling - Punching a
series of small
overlapping slits or holes
along a path to cutout a  Lancing - Creating a
larger contoured shape. partial cut in the
This eliminates the need sheet, so that no
for a custom punch and material is removed.
die but will require The material is left
secondary operations to attached to be bent
improve the accuracy and form a shape,
and finish of the feature. such as a tab, vent
 Slitting - Cutting  Parting - Separating a
straight lines in part from the
the sheet. No remaining sheet, by
scrap material is punching away the
produced material between parts
 Cutoff -
Separating a
 Trimming - Punching
part from the
away excess material
remaining
from the perimeter of a
sheet, without
part, such as trimming
producing any
the flange from a drawn
scrap. The
cup.
punch will
produce a cut
line that may be
straight, angled,
or curved.
 Shaving - Shearing away minimal material
from the edges of a feature or part, using a
small die clearance. Used to improve
accuracy or finish. Tolerances of ±0.001
inches are possible
Dies and its Types Tool and Die Material :
Tool steels, Carbides are used for high
Types of dies: production rates.

(A): According to type of press operation:

classified as cutting dies and forming dies.
1: Cutting Dies:
These dies are used to cut the metal. They utilize the
cutting or shearing action. The common cutting dies
are : blanking dies , perforating dies , notching dies ,
trimming , shaving and nibbling dies.
2: Forming Dies:
These dies change the appearance of the blank without
removing any stock. Theses dies include bending,
drawing dies etc.
(B) According to the method of operation:
1: Simple Dies:
Simple dies or single action dies perform single operation for each stroke of the press
slide.
2: Compound Dies:
In these dies, two or more operations may be
performed at one station. Eg. Washer
Compound dies are more accurate and economical in
production as compared to single operation dies.
3: Combination Dies:
In this die also , more than one operation may be
performed at one station. It is different from
compound die in that in this die, a cutting operation is
combined with a bending or drawing operation, due
to that it is called combination die.
4: Progressive Dies:
A progressive or follow on die has a series of operations.
At each station, an operation is performed on a work
piece during a stroke of the press.
 6.Transfer dies 7. Multiple dies

 It is similar to  These dies are also called

progressive dies, where as gang dies.
the stroke is fed  It produces two or more
progressively from one workpiece at each stroke
station to another. of the press.
 In transfer dies, already  Number of simple dies
cut blanks are fed and punches are ganged
mechanically from together, to produce more
station to station. parts at each stroke of the
press.
 Clearance Analysis
 The die opening must be sufficiently larger than
the punch to permit a clean fracture of the metal.
 The difference in dimensions between the mating
members of a die is called Clearance.
 When correct clearance is used, a clean break
would be appear as a result of the extension of
the upper and lower fractures towards each other.
With an insufficient clearance additional cut would
appear before the final separation.
 Ductile material require smaller clearance and
longer penetration of the punch compared to
harder material.
Clearance Analysis(continued…..)
If the clearance is less than
(a) the optimum value ,
then
• Three piece configuration
is produced (1)Hole in
sheet (2) Blank (3) Hole
component
If the clearance is more than
(b) the optimum value
,then
• Penetration is more
 Clearance Analysis(continued…..)
 In piercing operation, where  In blanking operation,
the hole in sheet metal is to be where blank is the desired
accurate and the slug(o/p) is part, the die opening size is
wastage, the punch is made to same as blank size and the
the hole size. The die opening punch size is obtained by
size is obtained by adding a subtracting the clearance
clearance to the punch size. from die opening size.
Clearance Analysis(continued…..)
 Clearance is a function of type, thickness and
temper of work material, harder materials requiring
larger clearance than soft materials.
o Generally ,the clearance is calculated by using
following relation,
C= 0.0032 .t.√τ,
Where, τ is the shear strength of the sheet metal

C= 5% t if t<= 2mm
C= 10%t if t>2mm
Clearance Analysis(continued…..)

Angular clearance:
• Angular clearance is provided below the straight portion of
the die surface.
• Angular clearance is provided to enable the blank to clear the
die easily and fall freely out of the die block.
• If the angular clearance is not provided, the punched blank
would remain stuck in the die block.
• It is generally, ¼° to ½° per side but mostly up to 2° is provided.
 Centre of Pressure
 When the irregular shape blank is to be cut, then the
summation of shear forces about the centre line of press
ram are not symmetrical.
 Hence ,bending moments will be introduced in the press
ram because of which undesirable deflection and
misalignment are produced.
 So to avoid this, centre of pressure of the shearing action
of the die must be found.
 While laying out the punch position on the punch holder,
centre line of press ram should pass through the centre of
pressure of the blank.
 This centre of pressure is centroid/centre of gravity of the
line perimeter of the blank.
 It is not the centroid of the blank area.
 Procedure to calculate centre of pressure

 Draw the outline of the part

 Place X and Y axes in a convenient position.
 The outline of the part is divided into convenient
line element and numbered as 1,2,3…….and so on
 The length l1 ,l2 ,l3, etc. of these line element are
calculated.
 The centroid of these line element is also
calculated
 The distance of centroid from the X and Y axes is
determined.Let x1,x2,x3 and y1,y2,y3 be the
distance of centroid of the line elements from the Y
and X axes respectively.
Element length x y lx ly
1 8 4 0 32 0
2 2 8 1 16 2
3

∑l= 36 ∑lx= ∑ly=

192 100
Procedure to calculate centre of pressure
(continued…..)

 The distance of centre of pressure from each axis

is determined by using following
X = l X1+l2 X2+l3X3 +……..
1

l + l2 + l3 +……..
1

Y = l Y1+l2 Y2+l3Y3 +……..

1

l + l2 + l3 +……..
1

Where, X = distance of centre of pressure in x-

direction and
Y = distance of centre of pressure in y-
direction
 Cutting forces
 While cutting operation, as punch moves downward
into the material, it need not require to penetrate
completely in to the stock thickness to affect the
complete rupture of the part.
 The distance which the punch enters into the stock to
cause rupture is called as penetration, and generally
it is given in terms of the percentage of the stock
thickness.
 The percentage penetration depends on the material
being cut and thickness of the material.
 When a hard and strong material is being cut, very
little penetration of the punch is necessary to cause
fracture.
 The percentage penetration also depends on the
sheet thickness, being smaller for thicker sheets and
greater for thinner sheets.
 Cutting forces (continued…..)
Stock thickness, 25 20 15 12. 10 8 6 5 3 2. 1. Below
t(mm) 5 5 6 1.6
Percentage % of t 25 31 34 37 44 47 50 50 62 67 70 80

 The maximum force required to cut a material is

given by,
Fmax = Sheared area * Shearing strength
= A * τS , N
1. for circular blank Fmax is given by,
Fmax = A * τS = πDt * τS , N
Where, D is blank diameter in mm,
t is stock thickness in mm,
τs is shearing strength in N/mm²
Cutting forces (continued…..)
 2. For rectangular blank Fmax is given by,
Fmax = 2 (L+ b )t * τs , N
where, L is length of the blank in mm,
b is width of the blank in mm,
• Energy in press work or work done to make a cut is given by,
E= Fmax * Punch travel
= Fmax * K * t
Where , K is the percentage of penetration required to cause the rupture.
• But the actual cutting force is less than maximum force, which is
given by,
F= Fmax * K * t where, F is the actual force
( K * t + I) I is the shear on the punch or die.
1. Find the total pressure, dimensions of tools to produce a
washer 5 cm outside diameter with a 2.4 cm diameter hole,
from material 4 mm thick, having a shear strength of 360
N/mm2. Also find out blank and punch sizes if clearance is
10% of stock thickness.

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2. Estimate the blanking force to cut a blank 25 mm wide
and 30 mm long from a 1.5 mm thick metal strip, if the
ultimate shear stress of the material is 450 N/mm2. Also
determine the work done if the percentage penetration is 25
percent of material thickness.

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3. A hole of 60 mm diameter is to be produced in steel
plate 2.5 mm thick. The ultimate shear strength of the plate
material is 450 N/mm2. If the punching force is to be
reduced to half of the force using a punch without shear,
estimate the amount of shear on the punch. Take
percentage penetration as 40%.

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4. A washer with a 12.7 mm internal hole and an outside diameter of
25.4 mm is to be made from 1.5 mm thick strip of 0.2 per cent
carbon steel. The ultimate shearing strength of the material of the
washer is 280 N/mm2. (a) Find the total cutting force if both
punches act at the same time and no shear is applied to either punch
or the die. (b) What will be the cutting force if the punches are
staggered, so that only one punch acts at a time. (c) Taking 60%
penetration and shear on punch of 1 mm, what will be the cutting
force if both punches act together.

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 Methods of reducing cutting forces
 For cutting operation it has been assumed that,
bottom of the punch and the top of the die block lie
in parallel planes.
 But, due to this, very high punch force is exerted for
a very short time on the material resulting in shock
or impulse condition.
 Hence ,to reduce cutting forces and smooth out the
stock impact of heavy loads, following methods are
used:
1)Shear :
• The working faces of the punch or die are ground off
so that, it does not remain parallel to the horizontal
plane and remains inclined, this inclination angle is
called as Shear.
• It reduces the shear area and the cutting force.
• If shear=0 i.e. the cutting edges are parallel hence,
the required force is maximum.
Methods of reducing cutting forces(continued….)
2)Staggering of punch:
• For staggering, [punches are arranged so that it
does not enter the material until the punch before it
has penetrate through.
• Hence, the cutting load may be reduced up to 50%.
 Strip layout
In the blanking die-set design, the first step is to prepare blanking
layout i.e. position of the workpiece in the strip and their
orientation with respect to each other, this called as strip
layout.
Factors which affect the strip layout
1)Economy of material:
a. As per this arrangement ,it can be worked at single row, single
pass with single punch.
b. By feeding material, there is
increase in material utilization up to
some extent
c. It is a single row, double pass strip, strip
Will have to be passed through the dies once,
Turned over and passed through dies second
Time, this is the maximum utilization of the
Material and reduction in scrap.
Economy of material
strap-strip layout in blanking
 Bending operation
 Bending is the forming of solid parts,
where angle or ring-shaped work pieces
are produced from sheet or strip metal.
In bending, the plastic state is brought
about by a bending load.

 Application of the process

 to produce angled parts, sheet profiles,
tubes and workpieces for shipbuilding and
apparatus manufacturing, rings for
various fields of application
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α = bend angle
w = width of sheet
R = inside bend
radius
t = sheet thickness
α′ = 180° - α,
“included” angle
Types of Bending

Two common bending methods are:

◼ V-bending
◼ Edge or wipe bending.
In V-bending the sheet metal blank is bent between a V-shaped
punch and die.

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 2. Edge Bending

Edge or wipe bending involves cantilever loading of

the material.
A pressure pad is used to apply a Force to hold the
blank against the die, while the punch forces the work
piece to yield and bend over the edge of the die.

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Springback in bending
➢When the bending stress is removed at the end of the deformation
process, elastic energy remains in the bent part causing it to
partially recover to its original shape
➢In bending, this elastic recovery is called springback.
➢Springback is defined as the increase in included angle of the bent
part relative to the included angle of the forming tool after the tool
is removed

After springback,
➢ The bend angle will decrease (the included angle will increase)
➢ The bend radius will increase

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Springback Animation

Springback

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Bending die design
To calculate blank length for bending, the length of the
material in the curved section has to be calculated.
The length of the bend area which is more than blank
length before bending is known as bend allowance.

3)Bending force or bending pressure:

 Drawing operation
Drawing is a sheet metal forming operation
used to make cup-shaped, box-shaped, or
other complex-curved, hollow-shaped parts.
It is performed by placing a piece of sheet
metal over a die cavity and then pushing the
sheet into the opening with a punch.
The blank is held down flat against the die
by a blank holder.

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 Drawing operation h/d< 0.5 shallow drawing
h/d>= 0.5 deep drawing

 Sheet metal forming to make

cup-shaped, box-shaped, or
other hollow-shaped parts
 clearance c = 1.1 t
 where t = stock thickness
 In other words, clearance is
about 10% greater than
stock thickness

h
Draw Die design
Blank size calculation:
• Blank size design is the important step in the drawing process.
• While calculating it is assumed that, blank surface area is
equal to the surface area of the finished shell
• When the shell has sharp inside corners , then following
relation is used:

D = (d²+ 4dh )½
Where, D=flat blank dia.
d=finished shell dia.
h=height of the finished shell
(this relation is applicable when d/r ≥ 20,r =radius of bottom corner)
Draw Die design(continued……)

• When d/r is between 15 and 20, the relation

becomes,
D =(d²+ 4dh )½- 0.5 r, and
When d/r is between 10 and 15, then
D =(d²+ 4dh )½- r
The symmetrical-cup workpiece shown in fig., is to be made from
cold rolled steel 0.8 mm thick. Determine shell blank size.
By rule of thumb about 3.2 mm to the blank diameter for each 2.5
cm of cup diameter for trimming operation.

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Draw Die design(continued……)
5)Drawing force:
The force required to draw a shell is given by,
F= π d t σ(D/d –C),N
Where, d=finished shell diameter
t=blank-thickness
σ=strength in tension
D=blank diameter
C=constant varies between 0.6-0.7
6)Blank holding force:
Blank holding force is generally 33-40 % of the drawing
force.
Tests of drawing Feasibility
LDR
 Drawing ratio method For soft--2-2.3
LDR or DR= (dia before drawing)/(dia after Hard material- 1.6-2
drawing) Default-2

DR1=D/d1, d1=D/DR1 ≤ df n=1

DR2=d1/d2, d2=d1/DR2 ≤ df n=2

 Draw Reduction ratio method DRR1=45-50%

DRR2= 30-35%
DRR= (Dia reduced)/Dia before)
DRR3= 20-25%
Above 16%
Defects in Drawing
A number of defects in drawing can occur, which include:
(a) Wrinkling in the flange occurs due to compressive buckling in the
circumferential direction (blank holding force should be sufficient to
prevent buckling from occurring).
(b) Wrinkling in the wall takes place when a wrinkled flange is drawn
into the cup or if the clearance is very large, resulting in a large
suspended (unsupported) region.
(c) Tearing occurs because of high tensile stresses that cause thinning
and failure of the metal in the cup wall. Tearing can also occur in a
drawing process if the die has a sharp corner radius.
(d) Earring occurs when the material is anisotropic, i.e. has varying
properties in different directions.
(e) Surface scratches can be seen on the drawn part if the punch and
die are not smooth or if the lubrication of the process is poor.

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Advantages of Sheet Metal Parts

 Good dimensional accuracy

 Good surface finish

 Relatively low cost

 Economical mass production for large

quantities
THANK YOU

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