Experiment 8
Aim
Demonstration and study of press working and sheet metal operation.
Apparatus Required
1. Sheet metal (Aluminum, Mild Steel, or Copper)
2. Mechanical/Hydraulic press machine
3. Punch and die sets
4. Vernier caliper/micrometer
5. Safety gloves and goggles
6. Marking tools (scriber, ruler, calipers)
7. Hammer and file
Theory
Press working operations encompass a wide range of metal forming processes used in the
manufacturing industry to shape and manipulate sheet metal and other materials. These
operations utilise mechanical or hydraulic presses to apply pressure and force, transforming
raw material into desired shapes and configurations. The versatility and efficiency of press
working operations have made them an integral part of modern manufacturing, contributing to
the production of various components used in automotive, aerospace, electronics, and
numerous other industries. Press working is a manufacturing process in which sheet metal is
shaped using force applied by a press machine and die. Fig. 1 shows various type of sheet metal
operations.
Punching
Punching is a fundamental sheet metal cutting operation that involves the creation of holes or
other geometric shapes in a metal sheet using a mechanical or hydraulic press. It involves the
application of shearing force to create holes and cutouts in different shapes and sizes by driving
a punch through the metal sheet. This process is widely used in various industries, including
manufacturing, automotive, aerospace, and electronics, to create components with precise
cutouts.
Fig. 1. Types of sheet metal operations.
Blanking
Blanking is a common operation in sheet metal forming and manufacturing processes. It is a
cutting process used to produce flat parts from sheet metal stock. The process involves cutting
out a desired shape or profile from a larger sheet of material. The process involves the removal
of a pre-defined part from the sheet metal using a single die and punch, resulting in a flat shape.
Perforating Operation
Perforating is a sheet metal forming process that involves creating holes or openings in a sheet
of metal. These holes can serve various purposes, such as ventilation, decoration, drainage, or
facilitating assembly. The process of perforating is commonly used in industries such as
automotive, construction, electronics, and manufacturing. In short, it involves punching or
stamping slots or holes in a pattern with minimal material wastage.
Shearing Operation
Shearing is a fundamental sheet metal forming process that involves cutting or trimming sheet
metal along a straight line. This process is used to separate a larger piece of sheet metal into
smaller sections, creating the desired shape and size. Shearing is commonly used in various
industries, including manufacturing, automotive, aerospace, construction, and more.
Trimming Operation
Trimming is a sheet metal forming process that involves removing excess material, often in the
form of flash, burrs, or unwanted edges, from a part that has already undergone another forming
operation, such as stamping, punching, or deep drawing. Trimming ensures that the final part
meets the required dimensions, tolerances, and surface quality. It is an important step in
achieving the desired functional and aesthetic characteristics of a sheet metal component.
Notching Operation
Notching is a sheet metal forming operation that involves cutting out a portion of a sheet metal
workpiece to create a specific shape or profile. This process is commonly used to prepare the
sheet metal for subsequent forming operations or to create features such as holes, slots, or
irregular shapes in the material.
Slitting Operation
A slitting operation in sheet metal forming is a process that involves cutting a wide sheet of
material into narrower strips. This operation is commonly used in industries such as
manufacturing, construction, automotive, and more, where narrow strips of sheet metal are
required for various applications. Slitting can be performed on a variety of materials, including
metals like steel, aluminium, and copper.
Procedure
1. Preparation: Select a suitable sheet metal and clean it properly.
2. Marking: Use a ruler and scriber to mark cutting lines as per the required shape.
3. Setup: Install the appropriate punch and die in the press machine.
4. Punching/Blanking: Place the sheet metal on the die and apply force using the press
machine to cut or punch holes.
5. Bending: Position the metal in the press brake and apply pressure to bend it to the
desired angle.
6. Deep Drawing: Place the sheet metal over the die and apply force to stretch it into a
cup or cylindrical shape.
7. Finishing: Inspect the product and remove burrs using a file.
8. Measurements: Use a vernier caliper or micrometer to check dimensional accuracy.
Observations
• Measure and record the dimensions of the punched, blanked, or bent pieces.
• Observe the effect of press force on different sheet thicknesses.
• Note any defects such as burrs, cracks, or uneven bending.
Result
The experiment successfully demonstrated various sheet metal operations, and the obtained
dimensions were compared with the required values.
Precautions
1. Wear safety gloves and goggles during operation.
2. Ensure proper alignment of sheet metal before applying force.
3. Use appropriate punch and die sets to prevent tool damage.
4. Do not exceed the machine’s load capacity.
Conclusion
Press working is an essential manufacturing technique used for shaping sheet metal into desired
forms. The experiment provided hands-on experience in different press operations,
emphasizing accuracy, efficiency, and safety in the process.
