SHEET METAL OPERATIONS

• BLANKING OPERATION: PIECE PART (BLANK or COMPONENT)

• PIERCING OPERATION: - HOLE OF ANY PROFILE

• NOTCHING OPERATION: SIDE CUTTING OF ANY PROFILE

• SHAVING OPERATION: MAKING UNIFORM, SMOOTH AND PRECISE

OUTER CONTOUR

• TRIMMING OPERATION: MAKING UNIFORM AND SMOOTH OUTER

CONTOUR
• SIDE CAM PIERCING: SPECIAL HOLE MAIKKNG OPERATION IN DRAWN
CUPS

• DINKING OPERATION: FOR FIBRE MATERIAL

• LOVERING OPERATION: PASSAGE FOR AIR TO ENTER

• LANCING OPERATION: PARTIAL TEARING OPERATION

• BENDING OPERATION: FOR SHAPING OF PRE-CUT BLANKS OR SHEETS
IN STRAIGHT AXIS

• FORMING OPERATION: FOR SHAPING IN CURVED AXIS

• CURLING OPERATION: FOR HINGING, PIN GUIDEING PURPOSE

• FLANGING OR EXTRUDING: FOR ORIGINATING THREADS IN SHEET

METAL

• DRAW OPERATION: TO SHAPE FLAT BLANK SHEET METAL INTO CUP

• COINING OPERATION: SOLID BLANK IS SQUEEZED TO REQUIRED
PROFILE

• STAMPING OPERATION: DEPRESSED LETTERS, SYMBOLS, LOGOS ARE

POSSIBLE ON SHEET METALS

• EMBOSSING OPERATION: REQUIRED FOR PLACING SCREWS, FOR

RIVETTING ETC ON SHEET METALS

• BULGING: SWELLENING OF THE IRREGULAR PROFILE ON THE TUBE

SURFACE
 INTRODUCTION TO PRESS TOOLS

Sheet metal components are produced by a device called “Press tool”.

Generally, these tools are Cold working and manufactured to improve the productivity
of the components qualitatively and quantitatively.

APPLICATION OF PRESS TOOLS

Press tools are extensively used for the production of sheet metal components in
mass.

Examples
Most of the products namely, Television, Tape recorder, Radio, Refrigerator,
Automobile Car, Scooter, Motorbike, Watch, Computer etc, consist number of
components made of either plastic or sheet metal.

DEFINITION FOR PRESS TOOLS

Press tool as a device used for producing sheet components in large volume by
applying an external force with the help of a machine tool called “PRESS”.
Press tools are mainly manufactured for high rate of sheet component
production. If the requirement of components is less (less than 1000 numbers), these
devices are not economical.

Hence, press tools are categorized according to the requirement,

CATEGORIES OF PRESS TOOLS

Simple press tool

Medium production press tool

Large scale production press tool

High speed press tool

Precision press tool

Horological press tool (watch component)

SPECIAL PURPOSE PRESS TOOLS

• Cantilever press tool
• Side cam press tool
• Straight cam press tool
• Angular cam press tool
• Curvature cam press tool
TYPES OF PRESS OPERATION
• Cutting press tool
• Non - cutting press tool
• Hybrid press tool
(Cutting and Non-Cutting operation)

TYPICAL SKETCH OF A PRESS TOOL WITH BASIC PARTS

Space for Notes:
 ACTIVITIES OF SHEET METAL INDUSTRIES

Sheet metal industries have a significant role in the present industrial society.
The production of sheet metal components have increased in many folds due to
continuous research and development.

In our country, major activities lies with sheet metal industries only. As per the
present survey, it occupies 55% of the industrial supplies.

Sheet metal industries are classified into many categories.

1. Fabrication industries
• House hold products
• Conventional products
• Commercial products
• Non – precision industrial products
• General engineering products

2. Medium precision industries

• Engineering products of second priority

3. High precision industries

• Aero space products
• High end engineering products
• Products with special material
• Products for research and development
 For any industry to run efficiently 3 M are very important.
1) M = Money
2) M = Machine
3) M = Men

Money and Machine are supported by many agencies and consultancies,

whereas, it is difficult to find skilled man power with good knowledge of both theoretical
and practical.

SIGNIFICANT POINTS

• Most Tool and die makers need 4 or 5 years of classroom instruction and
on-the-job training to become fully qualified.

• Employment is projected to decline because of strong foreign competition

and advancements in automation.

• Despite the decline in employment, excellent job opportunities are

expected.
NATURE OF THE TOOL MAKERS

1. Tool and die makers are among the most highly skilled workers in
manufacturing.

2. These workers produce and repair tools, dies, and special guiding and
holding devices that enable machines to manufacture a variety of products
we use daily — from clothing and furniture to heavy equipment and parts
for aircraft.

3. Toolmakers produce precision tools.

4. They are capable of handling machines that are used to cut, shape, and
form metal and other materials.

5. They also produce jigs and fixtures that hold workpiece while it is bored,
stamped or drilled and handle gauges and other measuring devices.

6. Die makers construct metal forms called “DIES”, that are used to cut metal
in stamping.

7. Tool & Die makers use computer-aided design (CAD) to develop products
and parts.

8. Tool & Die makers set up a test run using the tools or dies they have
made to make sure that the manufactured parts meet specifications.

9. If problems occur, they compensate by adjusting the tools or dies.

 10. They study metalworking processes, such as heat treating and plating.

11. Classroom training usually consists of tool designing, tool processing, blue
print reading.

TRAINING, QUALIFICATIONS AND ADVANCEMENT

1. Even after completing a formal training program, Tool & Die makers still
need years of experience to become highly skilled.

2. Most specialize in making certain types of Press tools, Moulds, or Dies.

3. While a State certification is not necessary to work as a Tool & Die maker,
it gives workers more flexibility in employment and is required by some
employers.

4. Apprentices usually must be at least 18 years old.

5. People entering this occupation also should be mechanically inclined, able

to work and solve problems independently

6. They should have strong mathematical skills, and be capable of doing

work that requires concentration and physical effort.

ADVANCEMENT

a) There are several ways for skilled workers to advance. Some move
into supervisory and administrative positions in their firms or they may
start their own workshop.

b) Others may take up computer courses and become computer-

controlled machine tool programmers. With a college degree, a Tool &
Die maker can go into engineering or Tool design.

PRESENT GLOBAL STATUS OF TOOL AND DIE MAKERS

• About 75% of Tool & Die makers are in manufacturing industries, such as
the fabricated metal products, Machinery and Aerospace products and
Spare parts industries.

• Rest is self employed in the related field.

 BASIC WORKSHOP MACHINES

Radial drilling Universal milling

machine Center lathe Shaping machine machine

Horizontal boring Vertical boring

Slotting machine Planning machine machine machine

Universal gear Hydraulic hacksaw

hobbing machine machine
Grinding and Polishing Machines

Universal tool & Bench grinders / Abrasive belt

cutter grinder Pedestal grinder Polishers/Buffers grinders

Roll grinding Cylindrical /

Surface grinder machine centerless grinder
 PRESS MACHINES

Metal forming press is one of the most commonly used manufacturing machines.
Every day, millions of parts are produced by metal forming ranging from battery caps to
automotive body panels. Therefore, even a small improvement may add to significant
corporative gain.

Currently, the metal forming presses can be divided into two categories:
a) MECHANICAL PRESSES
b) HYDRAULIC PRESSES

The former is fast (high speed presses may reach up to several thousand shots
per minute) and energy efficient (the large flywheel eases the impulsive force), but lacks
flexibility.

On the other hand, the hydraulic presses are flexible (their motions can be
programmed) and accurate, but are expensive to build and to operate. Recently, there
are mechanical presses driven by servomotors.

They could perform as flexible as hydraulic presses with high speed.

Nevertheless, they are even more expensive to build and to operate.
FLY PRESS

Fly presses are simple hand devices used for light work. These are extensively
used in small scale industries and need very less space and any unskilled worker can
operate with minimum supervision. Fly presses are available in different range of
capacity.

Generally, Blanking, Piercing, Notching, V – Bending and L – Bending are

performed using single stage press tools.

Bending press is a typical machine applies direct pressure to the material and
forcing it to change shape.
 PRESS BRAKE

A brake press is a special type of press machine that bends sheet metal into
required shape.

Example:
• Backplate of a computer case
• Brackets
• Frame pieces
• Electronic enclosures

Some press brakes have CNC controls and can form parts with accuracy to a
fraction of a millimeter. Machine presses are used extensively around the world for
shaping all kinds of metals to a desired shape.

SAFETY ASPECTS

Injuries in a press may be permanent, because of the large forces used.

Bimanual controls (controls the use of which requires both hands to be on the
buttons to operate) are a very good way to prevent accidents, as are light sensors that
keep the machine from working if the operator is in range of the die.

TOOLS FOR POWER PRESSES

Planishing press has a set of plates with a relief, or depth-based design, in them.
The metal is placed between the plates and the plates are pressed up against each
other deforming the metal in the desired fashion.

This may be Coining or Embossing or Forming

 Punch press is used for forming holes

Capping Presses form caps from rolls of aluminium foil at up to 660 per minute.

Progressive press tool is a manufacturing method that can involve punching,

coining, bending and several ways of modifying the metal, combined with an automatic
feeding system.

The feeding system pushes or pulls a coil of metal through all of the stations of a
progressive stamping die.

Each station performs one or more operations until a finished part is made per
the requirements on the print. The final operation is a cut-off operation, which separates
the finished part from the parent stock.

The parent stock material that is punched away in previous operations is

considered as scrap metal or skeleton.

Power press with a fixed barrier guard

SHEET ROLLING MACHINE SHEARING MACHINE
PRESS BRAKE CNC BENDING MACHINES

CNC PUNCHING MACHINES

 Presses & Hammers (for Sheet Metal and Forging applications)

Hand Fly Press and 'C' Frame Power Pillar Type Power
Arbour Press Press Press Deep Drawing Press

Metal Gathering
Screw Press / Mechanical Forging Friction Drop Machine / Heating
Forging Press Hammers Hammers Upsetter

Metal & Sheet Metal Working Machines

Foot Operated
Mechanical &
Hand Lever Shearing Motorized Guillotine Billet Shearing Universal Sheet
Machines Shears Machine Nibbling
 Hand Operated and
Circle Cutting Motorized Swaging
Machines Spinning Lathes Machines Sheet Folding

Pinch Pyramid Plate

Bending Machine,
Hand Operated &
Motorized Bending
Mechanical Press Rollers & Taper RO / ROPP Cap
Brakes Rollers Seaming Machines Sealing Machine

Section Straightening
Machine

Roll Forming Profile Bending

Machine vice Cut to Length Line Machines Machine

Tapping - Threading Form & Thread Pantograph Milling &

Machines Rolling Machines Riveting Machine Engraving Machines
 MECHANICAL BLANKING & FORMING PRESSES

General view of a blanking and forming press

ADVANTAGES
• More parts are produced
• Improved part dimensional accuracy
• Greater material strength

With its blanking and forming presses in this series offers manufacturing systems
that permit cost-effective blanking, drawing, coining, piercing, and calibrating for the
production of ready-to-install precision parts in a single operating sequence.

A number of fields - proven modules can be assembled to form application -

specific, customized manufacturing systems. Press models in these series are
mechanical presses with modified knuckle-joint drive.

They are available in nominal press forces of 200T up to 1500T and bed
dimensions of 1,500 to 4,000 mm with fixed or adjustable stroke.

ADVANTAGES

• High stroking rates even for complex parts

• Multiple forming operations in a single press pass
• Extreme rigidity of the entire system
• Reduced impact speeds to protect dies
• Optimized slide motion
• Precision, ready - to - install components requiring no subsequent
machining
 Die space with progressive die

MECHANICAL PRESS LINES

Mechanical press line with feeder automation

ADVANTAGES

1. Automated mechanical press lines ensure efficient manufacturing of medium-size

and large panels in production of high volumes.

2. Depending on the number of required forming operations, the lines consist of

four, five, or six automated mechanical single presses

3. Advanced mechanical presses offer a long slide stroke and thus permit the
manufacture of complex part shapes.

4. Fully automated systems solutions for high - volume manufacturing

5. Fast and reliable component transport with advanced technology

6. Parts of the highest quality thanks to perfected press and bed cushion
technology

7. The most advanced automation technology increases production rates

8. High levels of uptime for the lines & Process reliability

Mechanical press line with automation

 SHEARING AND ITS ACTIONS

DEFINITION

The result of the force imposed on the stock material by the action of the
blanking or piercing punch and die is called “Shearing Action”.

These are also related to the effective working and durability of the tool.

The 3 stages of Shearing action are:

1. PLASTIC DEFORMATION

2. PENETRATION

3. FRACTURE

1. PLASTIC DEFORMATION

When the elastic limit of the stock material is exceeded “Plastic deformation”
takes place.

A radius is formed on the top edge of the hole and bottom edge of the slug or
blank. The radius is often referred to as “Roll over”.

Load
STOCK EDGE RADIUS
MATERIAL PUNCH

DIE
2. PENETRATION

Punch is forced to penetrate into the stock material and a piece part is displaced
into the die opening by a corresponding amount.

Load
BURNISHED PORTION
STOCK ON STOCK MATERIAL
MATERIAL PUNCH

DIE

BURNISHED PORTION ON
SLUG OR BLANK

This is the actual cutting portion of the cutting cycle. Compression of the slug
material against walls of the die opening burnishes a portion of the edge of the blank.
BRIGHT BAND

At the same time the plastic flow pulls the material around the punch, causing a
corresponding “Bright band or Burnished area” in the work material.

The sum of the edge radius depth and the burnished depth is referred to as
Penetration.

3. FRACTURE

It is clearly shown in the illustration that further continuation of punch pressure

causes fracture to start at the cutting edges of punch and the die. Under proper cutting
conditions, the cut edge meets exactly at the breaking lines.

Load BURNISHED PORTION

STOCK ON STOCK MATERIAL
MATERIAL
UNDER COMPRESSION
PUNCH

DIE

BURNISHED PORTION ON
SLUG OR BLANK UNDER TENSION

The edge radius appears more when using soft materials. Highly burnished land
is the result of the material being forced against the walls of the punch and die and
rubbing during the final stages of plastic deformation.

The remaining cut portion is the Fractured area or Break.

4. BURR

Burr is the projection which appears during fracture.

This burr is not preferable, since the breaking lines of both the cutting lines will
not meet each other, resulting in the reduction of the tool life.
SEPERATED PIECE PART
BURR
BREAK

BURNISHED LAND
OR CUT BAND

EDGE RADIUS
PENETRATION

Space for notes

 CUTTING CLEARANCE & ITS EFFECTS

DEFINITION

Cutting clearance is the intentional gap provided between the punch and die for
the purpose of separating a piece part from the stock material.

It is expressed in Percentage [%]

NATURE OF CUTTING CLEARANCE

The cutting clearance depends on the type of

1. STOCK MATERIAL

2. SHEAR STRENGTH OF THE MATERIAL

3. SHEET THICKNESS

A visual check of these characteristics tells whether the punch and die have the
proper amount of clearance between them.

PLEASE NOTE:

The burr side of a Blank or Slug is always towards the Punch.

The burr side of the Pierced opening is always towards the Die opening

This illustration shows the uniform distribution of Cutting clearance

between Punch and Die at each side
OPTIMUM OR NORMAL CUTTING CLEARANCE

If the cutting clearance given is sufficient

• Burnished area or cut band will be approximately 1/3 (one third) of the
sheet thickness

P IE C E P A R T
T E N S IO N A L B U R R
B R EA K

P U N C H O U T L IN E B U R N IS H E D L A N D
O R CU T BAND
O PT IM U M C U T T IN G PU NCH ED G E R A D IU S
CLE AR ANC E P E N ET R A T IO N
O P T IM U M C U T T IN G C L EA R A N C E
S T O C K M A T E R IA L B U R N IS H E D P O R T IO N
O N S T O C K M A T ER IA L
D IE O U T L IN E U N D ER C O M P R E S S IO N

D IE

B U R N IS H ED PO R T IO N O N U N D ER T E N S IO N
SL UG O R BLANK
(1/3 rd O F S H E ET T H IC K N E S S )

EXCESSIVE CUTTING CLEARANCE

If the cutting clearance given is Excessive

• Cut band or the burnished area will be less than 1/3 (one third) of the
material thickness
• Tensile burr (loose burr) will be more

P IE C E P A R T
TE N S IO N A L B U R R
B REA K

B U R N IS H E D LA N D
P U N C H O U TLIN E
OR CUT BAND
E X C E S S IV E C U T T IN G PUNCH E D G E R A D IU S
P E N E T R A T IO N
CLEAR A N CE
E X C E S S IV E C U T T IN G C L E A R A N C E
S T O C K M A T E R IA L B U R N IS H E D P O R TIO N
O N S TO C K M A TER IA L
D IE O U T L IN E U N D E R C O M P R E S S IO N

D IE

B U R N IS H E D P O R T IO N O N
U N D E R T E N S IO N
S LU G O R B LAN K
( L E S S T H A N 1 / 3 rd O F T H E S H E E T T H IC K N E S S )

INSUFFICIENT CUTTING CLEARANCE

If the cutting clearance given is Insufficient

 • More than one cut band
• Breaking lines will not meet each other
PIE C E PA R T
T E N S IO N A L B U R R
BREAK
B U R N IS HE D L A N D
O R C U T B AN D
PU N C H O U T L IN E
BR E A K
IN S U F FIS C IE N T C U TT IN G PU N C H E D G E R AD IU S
C L E AR A N C E P E N E T R A T IO N
IN S U FF IS C IE N T C U T T IN G C L E AR AN C E
S T O C K M AT E R IAL B U R N IS H E D PO R T IO N O N S T O C K M A T E R IA L

U N D E R C O M PR E S S IO N
D IE O U T L IN E

D IE

B U R N IS H E D PO R TIO N O N U N D E R T E N S IO N
SLU G O R BLAN K
(M O R E T H A N 1/3 rd O F T H E S H E E T T H IC K N E S S )

MIS-ALIGNMENT OF PUNCH AND DIE

This is the actual shift between the punch and die which affects the proper
cutting of the stock material.

Due to this there will be an irregular cut band appearing on the periphery of the
component.

CHARACTERISTICS OF CUTTING

Cutting characteristics indicate whether, the Punch and Die are in perfect
alignment.

It also enables him to detect and correct misalignment conditions, when they
occur during assembling the die.
PIECE PART
TENSIONAL BURR
BREAK

PUNCH OUTLINE

INSUFFISCIENT CUTTING PUNCH BURNISHED LAND

EDGE RADIUS
CLEARANCE OR CUT BAND
EXCESSIVE CUTTING CLEARANCE
STOCK MATERIAL
BURNISHED PORTION
ON STOCK MATERIAL
DIE OUT LINE UNDER COMPRESSION

DIE

IRREGULAR BURNISHED PORTION ON UNDER TENSION

SLUG OR BLANK

Hence, proper alignment should be made between punch and die for maximum
tool life.
There are 3 methods commonly used by the tool makers to achieve this.

1. BY USING PRUSSIAN BLUE

When the cutting clearance punch and die is very less i.e., ranging from 0.01 to
0.03 mm per side this method is most appropriate.

P r u s s ia n B lu e

2. BY USING SHIM

Shims are thin foils of soft metal like copper, brass etc, which are inserted in
between punch and die to maintain the cutting clearance.

3. FEELER GAUGE

Different thickness and length of checking gauges are available depending on

the application. These are used for checking the gap between Punch and Die, after
setting them in the die set.
0.5

0.
4

0.3
2
0.

0.1

3. BY USING SOURCE OF LIGHT

This is one more method of aligning the punch and die, where cutting clearance
is ranging from 0.03 to 0.08 mm per side.

NOTE: Clearance is expressed in terms of PERCENTAGE (%) per side

or
Clearance is expressed in terms of MILLIMETER (mm) per side
DETERMINING CUTTING CLEARANCE

There are 3 important methods in practice

1. By referring the standard Cutting clearance chart
2. By using the Formula
3. By using the Thumb rule

1. By referring the STANDARD CUTTING CLEARANCE CHART

C/2 = Clearance per side in mm
Sheet thickness Hard rolled Stainless
Brass Soft steel Aluminum
steel steel
0.25 0.010 0.015 0.020 0.010 0.020
0.50 0.025 0.030 0.035 0.020 0.050
0.75 0.040 0.045 0.050 0.040 0.070
1.00 0.050 0.060 0.070 0.050 0.100
1.25 0.060 0.075 0.090 0.060 0.120
1.50 0.075 0.090 0.100 0.070 0.150
1.75 0.090 0.100 0.120 0.090 0.170
2.00 0.100 0.120 0.140 0.100 0.200
2.25 0.110 0.140 0.160 0.110 0.220
2.50 0.130 0.150 0.180 0.120 0.250
2.80 0.140 0.170 0.200 0.140 0.280
3.00 0.150 0.180 0.210 0.150 0.300
3.30 0.170 0.200 0.230 0.160 0.330
3.50 0.180 0.210 0.250 0.170 0.350
3.80 0.190 0.230 0.270 0.180 0.380
4.00 0.200 0.240 0.280 0.190 0.400
4.30 0.220 0.260 0.300 0.210 0.430
4.50 0.230 0.270 0.320 0.220 0.450
4.80 0.240 0.290 0.340 0.230 0.480
5.00 0.250 0.300 0.360 0.240 0.500

Space for notes

2. By using the FORMULA

C/2 = 0.01 X t X √ fs

Where, C/2 = Cutting clearance per side

t = Sheet thickness in mm
fs = Shear strength of the stock material in kg /mm2

SHEAR STRENGTH CHART

Shear strength (fs) in kg/mm2
Material
Soft Hard
Steel with 0.1 % C 24 32
“ 0.2 % C 30 40
“ 0.3 % C 36 48
“ 0.4 % C 45 56
“ 0.6 % C 55 72
“ 0.8 % C 70 90
“ 1.0 % C 80 105
Stainless steel 50 56
Silicon steel 45 55
Steel deep drawing quality 30-35 -
Aluminum A 1 99 & 99.5 7-9 13-16
Aluminum alloy A1 – Cu – Mg 22 38
Bronze rolled 32-40 40-60
Brass 63 & 72 22-30 35-40
Copper 18-22 25-30
Tin 3 4
3. By using the THUMB RULE
Clearance can also be calculated in Percentage [%] of Sheet thickness:
C/2 (CLEARANCE PER SIDE)
Sl. No. Material Percentage of Clearance
1 Brass 5%
2 Soft steel 6%
3 Hard steel 7%
4 Stainless steel 5%
5 Aluminum 8 – 10%

NOTE:
1. Pierced hole is getting the dimension of the PIERCING PUNCH.
Hence, the clearance should be added to the die opening.

2. Blanked component is getting the dimension of the BLANKING OPENING or DIE.

Hence, the clearance should be subtracted on the Blanking punch.

Example: Material: Steel with 0.3% Carbon

Shear strength (fs) = 45 kg/mm2
Sheet thickness (t) = 1.75 mm

Component: Dimension of the Piercing punch = Ø15.00 mm

Dimension of the Die opening =15+ (2 X C/2)

(From the table C/2 = 0.10 mm) = 15 + (2 X 0.1)
= 15 + 0.2
= 15.20 mm
Dimension of the Die opening = Ø15.20 mm

Dimension of the Blanking punch = 35 – (C/2 X 2)

(From the table C/2 = 0.10 mm) = 35 – (0.1 X 2)
= 35 – 0.2
= 34.80 mm

Dimension of the Blanking punch = 34.80 mm x 34.80 mm

Dimension of the Blanking die = 35.00 mm x 35.00 mm
 SHEAR FORCE & ITS APPLICATIONS

Shear force is the force required to separate a piece part from the stock material
with plain punches.

It is expressed in terms of Tonne.

This force is also required to determine the thickness of various plates necessary
in the construction of the tool and for selecting the appropriate press.

SHEAR STRENGTH
It is the strength required for producing fracture in the plane of cross section,
when acted on by the SHEAR FORCE.
Shear strength is expressed in Kg/mm2

TENSILE STRENGTH
The tensile or ultimate strength is the strength, corresponding to the maximum
load reached before rupturing the specimen.
It is also expressed in Kg/mm2

FORMULA USED TO DETERMINE THE SHEAR FORCE

K x L x S or (fs) x t
F = ------------------------------ = …….. Tonne
1000
Where,
F = Shear Force
K = Constant value 1.3
(Because sheet thickness will not be uniform)
L = Total length of cut in mm.
S or (fs) = Shear strength in Kg/mm2.
T = Thickness of the stock material in mm.
1000 = To convert kg to Ton
PRESS SELECTION VALUE
It is the value which is very much helpful in choosing an appropriate press for
successful production and efficient working of tool.

PRESS SELECTION VALUE

(Fp) = F + 20% of F, Where, F = Shear Force
METHODS OF REDUCING THE SHEAR FORCE
Sometimes availability of press capacity may be slightly less than the required
tonnage. To overcome from this problem there are two effective methods in practice.
1. By providing shear angle on the cutting punches
2. By varying the height of the cutting punches (Staggering the punches)

1. SHEAR ANGLE
It is the angle provided on the cutting face of either punch or die to reduce the
shearing force as shown in the illustration.
Advantage of Shear angle: By providing this angle the punch or die will gradually
come in contact with the layers of the stock material and cutting or shearing action will
be performed layer by layer.
This method is limited to secondary importance components as the cut edge will
not be good, compared to normal shearing operation.
SHEAR ANGLE PROVIDED ON PUNCH SHEAR ANGLE PROVIDED ON DIE

1t
1t

1t

1t
1t

1t

Normal (flat) Dished

Cut edge is
Cut edge is component component
at an angle
at an angle
Component is
not flat

2. STAGGERING
This is one more method of overcoming from the problem of shearing. After
assembling the punches with top unit, grind all the cutting punches to one level.
Select a set of punches in such a way that the load required to cut will be equal
to the other set of cutting punches. Reduce the height of one of the sets at least by one
stock thickness.
 Punches fixed
in punch holder

Staggering
By this method one set of punches will start shearing the material and other set
will come in contact with the stock material only after the completion of the operation
performed by the previous set of punches.

Hence, whenever this method is adopted in the tool, there will be two IMPACT
CUTTING SOUND, which can be heard very clearly. This method of varying the punch
height is called as “Staggering”.

Space for Notes

 CUTTING OPERATION

IDENTIFICATION OF OPERATIONS

BLANKING: Cutting the outer contour of a piece part. After completing all the
remaining operation, it is called as “COMPONENT”.

PIERCING: Hole originated within the piece part. Any geometrical profile of hole
can be pierced.

NOTCHING: Partial cutting is done at the side of the stock strip. Usually,
notching operations are done to simplify the blanking profiles.

SIDE NOTCHING
CUT-OFF: Single line cutting without Scrap Bridge. Produced components are of
secondary importance. Usually, used to produce commercial components
with maximum economy on tool cost

PART-OFF: Double line cutting producing scrap normally equal to the value of one
scrap bridge.

TRIMMING: Secondary operation carried to redefine the contour of the

component.
Usually Drawn cups and Die cast components are trimmed to
remove the excess material appeared during the production.

SHAVING: Secondary operation performed on pre blanked components to

resize the dimensions and achieve higher accuracy.
 This operation produces smooth surface on the periphery of the
component through its thickness

SIDE PIERCING: Usually, this is a secondary operation performed on drawn cups.

Cups of required shape and size are drawn followed by cam
piercing.

DINKING: Components from fiber material like Nylon, Plastics, Rubber, Fiber glass,
Printed circuit boards (PCB) etc, are produced with this operation.
Blanking punch is the only member which is employed for cutting the
contour.
Piercing is done as usual with punch and dies. The cutting face of the
piercing punch is made as concave profile.
 NON – CUTTING OPERATION

IDENTIFICATION OF OPERATIONS

BENDING: Bending is performed on pre-cut sheets or blanks to obtain a required

angle. It is done in straight axis. General bending profiles are L –
Bending, U – Bending, V – Bending and Z-Bending.

Usually, Bending has to overcome both “Tensile stresses” as well as

“Compressive stresses”. When Bending is done, the residual stresses
make it re-bend or spring back towards its original position, so we have to
over bend the sheet metal keeping in mind the residual stresses.

FORMING: Any profile with curves can be formed with proper study of material
behavior. Materials must posses’ good ductility and deep draw quality.
Forming takes place in a curved axis.

CURLING: More than 3/4th forming in a continuous curvature is referred to as

Curling.
This operation is divided into
a) Pre curling.
b) Final curling
Material must be soft enough to accept the severity of the forming.
Hence, deep draw and extra deep draw quality materials are
preferred.
Usually, this is employed for the production of hinges for links, to
the components which need fulcrum points etc.
FLANGING: Sometimes it is also referred to as “Extruding”. Many methods are
used in this operation.

1. Flanging without pre pierced hole

2. Flanging with pre pierced hole
3. Flanging with pre pierced hole located by the punch pilot

The height of the flange depends on the diameter of the pre-pierced

hole.

DRAWING: Cylindrical or Rectangular or Square cups are produced with this

operation.

Material undergoes severe strain and flow into the die from all the
directions. Hence, it must have maximum tensile strength and
yielding capability.

COINING: The material will experience maximum strain, because of

squeezing. The die halves are pressed against the material, which
is sandwiched and forced to accept the inner profile of the die.

Coining requires higher tonnage than any other press operation.

STAMPING: Punch profiles are directly transferred on to the work piece.
Depressed profiles to a certain depth are possible with this
operation.

EMBOSSING: Sheet metal surfaces can be depressed to a depth till it tears. Hence,
before the material selection “CUPPING TEST” has to be conducted.
In this operation thinning does not take place.
 MATERIALS AND THEIR PROCESS

Different materials are very essential to construct the tool and production of
components.

Materials are divided into two main groups.

1) Steel material for the construction of the tool
2) Sheet material for the production of component

1) STEEL MATERIAL FOR THE CONSTRUCTION OF THE TOOL

The construction of tool involves various types of steel material. It depends on

the function of the part in the tool.

Usually, HCHCr, OHNS, St-42, Mild steel (MS) and 17Mn1Cr95 materials are
used.

TOOL MATERIAL AND ITS IS: CODIFICATION

Sl. No. Material IS: Codification
High Carbon High Chromium steel
1. HCHCr:
T215 Cr12 W90
Oil Hardened Non – Shrinkable steel
2. OHNS
T110 Cr1 W2
3. St–42 Steel with 0.42% Carbon
4. MS Mild steel
Low carbon steel or Case hardening steel
5. LCS
17Mn1Cr95:
The below chart may be referred for appropriate temperature required to heat treat different materials commonly
used in tool making.

Annealing Hardening Tempering

HRc Quench
Sl. No. Type of steel temp temp temp
o o o Media
C C C

1 High Carbon Steel (2.15%) 750 - 780 750 - 780 120 - 350 62 – 40 Water

HCHCr (2.15%)
2 820 - 850 920 - 970 200 - 350 62 - 56 Oil or Air
T215Cr12W90

3 HSS(W) (0.6%) 820 1250 -1300 550 62 - 60 Oil

4 HSS (Mo) 820 1100 - 1175 550 62 - 60 Air

5 HDS (0.4%) 850 - 875 950 – 1000 550 - 590 52 – 42 Air

OHNS (1.1%) T110 Cr1

6 750 820 – 840 150 - 300 62 - 56 Oil
W2
 A brief description is given below about the material and the tool element.
1. Die and Punch
for cutting operation -------------- HCHCr (T215 Cr12 W90)
2. Die and Punch
for Non-Cutting operation -------- OHNS (T110 W2 Cr1)
3. Punch Back plate ------------------- OHNS or 17MN1CR95
4. Die Back plate ---------------------- OHNS or 17MN1CR95
5. Punch plate ------------------------- Mild steel (MS)
6. Stripper plate ---------------------- Mild steel (MS)
7. Stripper insert --------------------- OHNS
8. Guide plate ------------------------ Mild steel (MS)
9. Strip support plate---------------- Mild steel (MS)
10. Top plate --------------------------- Mild steel (MS) or Cast iron
11. Bottom plate ---------------------- Mild steel (MS) or Cast iron
12. Shank ------------------------------- Mild steel (MS)
13. Guide Bush and Pillar ------------ OHNS
14. Tie bar ----------------------------- Mild steel (MS)

1. HIGH CARBON HIGH CHROMIUM STEEL (HCHCr)

These are specifically used for cold working press tools and oil hardened up to
60-62 HRc.

The chemical composition:

a) 2.15% Carbon,
b) 0.9% Tungsten
c) 12% Chromium
d) Small percentage of Silicon and Manganese.

These materials are best suited for cutting dies and punches, as they retain the
cutting edges for a longer period.

2. OIL HARDENED NON-SHRINKING STEEL (OHNS)

These steels consists
a) 1%-2% Carbon
b) 4%-12% Chromium

Oil hardened upto 60-62 HRc. But for non-cutting operations 56-58 HRc is quite
sufficient.
3. MILD STEEL (MS) and St-42
These are used for most of the parts in press tool, mould box, jigs and fixtures.

Mild steel contains

a) 0.3% Carbon
b) 0.1% - 0.8% Manganese.

Example: Steel En2. This steel can also be case carburized and hardened upto
54-56 HRc.
 Free cutting Steel like “En” contains less than 0.15% carbon and cannot be
hardened.

4. CAST IRON (C.I)

Cast iron contains 2.25 - 2.75% carbon and can absorb vibrations well and
suitable for bases, machine beds and bodies of fixtures. These have self lubricating
properties, hence also suitable for machine slides and guide ways.

5. 17Mn1Cr95
These are case hardening steels have good toughness and cost saving. Used
where there is no movement of parts and needs good support for the other tool
elements.

As the percentage of carbon in the material is not sufficient for hardening process
the case must be enriched with carbon by carburizing process.

A case depth of 0.5 to 0.7mm is achieved by a prolonged period of 4 to 5 hours.

2) SHEET MATERIAL FOR THE PRODUCTION OF COMPONENT

Many types of sheet materials are used for the production of components.

Namely,

Non – Conventional materials

a) Plastic coated paper
b) Thin plastics
c) Poly-fibres
d) Corrugated sheets
e) Printed circuit boards (PCB)
f) Tablet strips

Conventional materials
1. Steel – CRCA (Cold Rolled Close annealed)
D – Quality (Draw quality)
DD – Quality (Deep Draw Quality)
EDD – Quality (Extra Deep Draw Quality)
2. Brass – 1/4th hard, Half hard, 3/4th hard and Full hard
3. Copper - 1/4th hard, Half hard, 3/4th hard and Full hard
4. Phosphor bronze -1/4th hard, Half hard, 3/4th hard and Full hard
5. Aluminum – 1/4th hard, Half hard, 3/4th hard and Full hard
2A) FINISHING OPERATION OF COMPONENTS

a) VIBRATORY FINISHING GUIDE

In vibratory finishing, energy in the form of vibratory forces is transformed by the

machine's drive system into a mass of loose media and then into the parts.

The entire load is in motion at same time so that the media act against the parts
throughout the complete mass.

Producing good surface finishes using barrel finishing depends on the right
selection and use of tumblers, abrasives, lubricating agents, carrying agents and
polishing agents.

Barrel finishing, also known as “Barrel tumbling”, is a surface improving

operation in which a mixture of parts, media and compounds are placed in a six- or
eight-sided barrel and rotated at a predetermined speed for the purpose of rounding
corners, de-burring, grinding, de-scaling, de-flashing, improving surface finish,
burnishing, polishing and radiusing parts in bulk.

It works by tumbling parts in a rotating barrel, thus creating friction by tumbling

parts against each other and against other materials, such as media and compounds.

Tumbling Highlights

• Parts can be finished less expensively than by hand.

• Many parts can be processed at one time.
• Requires very little handling.
• Parts are tougher and stronger after tumbling
• Tumbling provides a certain amount of stress relief
• Forgings and castings can be blended
• Machine parts and stampings can be deburred and burnished to a high finish
• On long runs, the systems can run overnight
• Careful and proper machining of your parts will save tumbling time
 MATERIAL WEIGHT CALCULATION

DEFINITION

1. WEIGHT

It is the sum of the volume and the specific gravity of the material. Weight is
expressed in Kgs. Value of Specific gravity for each material varies depending on the
density of molecules in it.

CALCULATION:
Volume X Specific Gravity
Weight =--------------------------------------- =-------- Kg
1000000

V X Sp. Gr.
W =-------------------=------------- Kg
1000000

Where, W = Weight of the material in Kg

V = Total volume of the material in mm3
Sp. Gr. = Specific gravity in Kg/mm2

Volume of the Flat material =L X B X t

Where, L = Length of the material in mm

B = Width of the material in mm
T = Thickness of the material in mm

∏ X D2
Volume of the Round material = ------------- X t
4
Where, ∏ = 3.1416
D = Diameter of the material in mm
t = Thickness of the material in mm

SPECIFIC GRAVITY CHART

 Material Specific gravity gm/Cm3

Steel 7.85

Cast steel 7.85

Grey cast iron 7.2

High speed Steel 9.0

Hard metal H1 14.75

Invar (36% Ni) 8.7

Brass (Ms 60) 8.5

Al bronze 8.4

Al cast bronze 7.6

Tin bronze 8.6

Lead bronze (Pb Bz 25) 9.5

Al cast bronze 2.8

 BASIC CONSTRUCTION OF THE TOOL

1. Die and Punch for cutting operation -------------- HCHCr

2. Die and Punch for Non-Cutting operation -------- OHNS

3. Punch Back plate ------------------------- OHNS or 17Mn1Cr95
 A A

PUNCH BACK PLATE

Material = OHNS

4. Die Back plate ---------------------- OHNS or 17Mn1Cr95

A A

DIE BACK PLATE

Material = OHNS

5. Punch plate -------------------------Mild steel (MS)

6. Stripper plate ---------------------- Mild steel (MS)

SECTION-AA

7. Stripper insert --------------------- OHNS

SECTION-AA

A
A

8. Guide plate ------------------------ Mild steel (MS)

9. Strip support plate---------------- Mild steel (MS)

SECTION-AA

10. Top plate --------------------------- Mild steel (MS) or Cast iron

SECTION-AA

TOP PLATE
A Material = St-42

11. Bottom plate ---------------------- Mild steel (MS) or Cast iron

 SECTION-AA

A
A BOTTOM PLATE
Material = St-42

12. Shank ------------------------------- Mild steel (MS)

13. Guide Bush and Pillar ------------ OHNS

14. Tie bar ----------------------------- Mild steel (MS)

 SECTION-AA

15. Die set and its types

1. Diagonal pillar dies set

2. Rear pillar or Back pillar die set
3. Center pillar die set
4. Four pillar die set
H7/j5
H7/h6 Thread for fixing the Shank

Top

SHUT HEIGHT OF THE TOOL

plate

Guide bush

Guide pillar

H7/p6

Bottom plate

SECTIONAL VIEW OF A STANDARD DIE SET

PROGRESSIVE STAMPING DIE

Progressive die with strip and punching

A progressive stamping die is one of the types of press tools, designed and
built to convert a flat strip of metal into parts that conform to component specifications.

FUNCTION OF PROGESSIVE TOOL

The die is mounted on a suitable press. As the ram moves up, the punch unit
opens and closes when the press moves down.

The stock material is fed through the die while the die is open to a precise
amount with each stroke of the press.

When the punch unit is brought down, the tool performs its work on the sheet
metal. Due to this action one or more completed piece parts will fall down through the
opening in the bottom plate.

These dies can modify the stock metal into different shapes like Bending,
Embossing, Drawing, Forming, Horning, Extruding, Coining, and Punching. Different
hole profiles is possible to cut in the stock metal.

Since additional work is done in each stage of the die, it is important that the strip
be advanced very precisely, so that it aligns within accurately as it moves from station to
station.
ROLE OF PILOTS

DEFINITION
Pilots are non-cutting male members, mounted usually in the punch holder for re-
registering the pre-pierced hole for consecutive stations especially in progressive tools.

These are made with good tool steel material that is OHNS (T110 W2 Cr1) and
hardened up to 56-58 HRc. These pilots are also available readily (material used is
HSS) in the market with standard diameter and length.

Function of a Pilot:

The function of a pilot is to position the stock strip accurately and bring it into
proper register for successive stations.

Bullet shaped or conical "pilots" enter previously pierced round holes in the strip
to assure this alignment, since the feeding mechanism usually cannot provide the
necessary precision in feeding.

VARIOUS OTHER TYPES OF PILOT NOSE PROFILES

BULLET NOSE PILOT

TYPES OF PILOTS
FLAT ACCORN PILOT

RECTANGULAR PILOT

CUT-OFF PILOT

CONICAL STUB NOSE PILOT

PILOT NOSE CORNER

RADIUS
ROLE OF STOPPERS

DEFINITION
Stoppers are stopping agents, fixed or engaged on the die to arrest the feeding
movement of the stock strip. This is the location of the actual stopping point or stage
against which the stock is halted.

TYPES OF STOPPER
Sl. No. Name of the stopper Sketch
Butting surface

1 Solid stopper or Solid stop block Solid

Stop
block

Pin stopper
2 a) Plain pin
b) Headed pin

3 Side or stage stopper

4 Trigger stopper

Heeled punches

Specially, the illustrated punch is a notching punch. However, principles relating

to the heel function will be much the same for other punches as well.

Here, the heel is made in a manner commonly used in progressive dies. The
nature of the notching operation is such that, cutting force at the front of the punch is
unopposed and thus tends to displace the punch away from the front cutting edge.

Partial notching will tend to displace the punch in a direction parallel to the
feeding. The purpose of a heel is to support the punch by resisting displacement. This
type of heel is an integral boss extending beyond the working face of the punch.
 HEEL

Partial cutting punch with Heel

Secondary strip width

Primary strip width

SCRAP

The heeled portion is made a sliding fit in the die opening on three sides.
Therefore, the heel affords lateral thrust resistance along any displacement included
within the three directions.
Pitch punch

Pitch punches are cutting punches used in the progressive tools for accurate
feeding of the strip. These are made of good Tool steel material i.e. (T215W90Cr12)
HCHCr and hardened up to 60-62 HRc and ground to the exact size equal to PITCH.
These punches are suitable for sheet thickness less than 2 mm. Pitch punches are
placed in the very first stage of the operation.
These are also called as “Partial cutting punches” for the reason that they cut
only a portion of the side of the stock strip which is exactly equal to ONE PITCH.

Since pitch punches cut only a portion of the side of the stock material. Due to
this cutting action is imbalanced which deflects the punch resulting in punch breakage.
Hence, heels are provided behind the cutting edge to support the pitch punch.
 .0°
f 0.5xSheet

45
thickness

b
M5 0r M6 a
x 20mm deep 2xscrap+2mm
5to6mm
R2(TYP)

HEEL

Pitch punch with HEEL

Secondary strip width

Primary strip width

SCRAP
 VALUES FOR SIDE SCRAP AND SCRAP BRIDGE
Sheet thickness in Component horizontal width in Millimeters
mm Upto 10 10 – 50 50 -100 100 -150 150 - 250
0.5 1.5 2.0 3.0 3.5 4.0
1.0 1.0 1.75 2.0 2.5 3.0
1.5 1.5 2.0 2.5 3.0 3.5
2.0 2.0 2.5 3.0 3.5 4.0
2.5 2.0 3.0 3.5 4.0 4.5
3.0 2.0 3.5 4.0 4.5 5.0
4.0 2.5 4.0 4.5 5.0 5.5
5.0 3.0 4.5 5.0 5.5 6.0
6.0 3.5 5.0 5.5 6.0 6.5
7.0 4.0 5.5 6.0 6.5 7.0
8.0 5.0 6.0 6.5 7.0 8.0
9.0 6.0 7.0 7.5 8.0 9.0
10.0 7.0 8.0 8.5 9.0 10.0
Stripper

Inside Out side

step headed step headed
stop pin stop pin
Die plate

Outside step headed stop pin

 NON – CUTTING OPERATION IN DETAIL

INTRODUCTION

Present day calls for lots of innovative products which essentially require good
knowledge of tooling.

Mechanical, Electrical, Electronic and Automobile industries need products

having verities of profiles for different applications.

Non - cutting operations are those which shape the flat blank to the required
profile.

In these operations material undergoes severe strain and needs very good
knowledge about the material property, behavior, strength and its limitations.

In many tools these operations are integrated depending on the size of the
component.

TYPES OF NON - CUTTING PRESS TOOL OPERATIONS

NON – CUTTING
1. FORMING 9. COINING HYBRID
2. BENDING 10. STAMPING
1. LANCING
3. DRAWING 11. IRONING
4. CURLING 12. PLANISHING 2. LOVRING
5. FLANGING 13. SWAGING
6. DIMPLING 14. EXTRUDING
7. EMBOSSING 15. BULGING
8. HORNING

Examples of products for Non – Cutting operations

1. Pressure cooker
2. Pressure pan
3. Utensils
4. Contacts and Relays
5. Heating elements
6. Computer hardware
 7. Electrical appliances
8. Gear box cover
9. Automobile parts – Doors, Bonnet, Wheel
drums Clutch plates etc.,
10. Aviation and Space components

It is the basic behavior of material. Whenever a sheet metal deformed and an

external loading is unloaded, it will be restored to its initial state i.e., after unloading
nothing in the state of structure remains of the previous condition.

CHARACTERISTICS OF MATERIAL

This unique character of the material is most useful in sheet metal fabrication
because most products of sheet metal press work are not flat components that can be
produced by die cutting operations alone.

They generally have a third dimension obtained by a shaping operation, which

can be performed in the same die as of the cutting operation or in a separate die.

Shaping operations are generally divided into three groups.

GROUPS OF
NON – CUTTING
DIES

BENDING FORMING DRAWING

TYPES OF OPERATIONS IN NON-

CUTTING DIE GROUPS

BENDING FORMING DRAWING

1. WIPING 1. FLANGING 1. SQUARE CUP
2. AIR-BEDING 2. COINING 2. RECTANGLE CUP
3. OBTUSE ANGLE 3. SWAGING 3. TRIANGLE CUP
BENDING 4. BULGING 4. CONE CUP
4. ACUTE ANGLE 5. NECKING 5. SHALLOW CUP
BENDING 6. CURLING 6. DEEP DRAW CUP
5. L-BENDING 7. HORNING 7. FLANGED CUP
6. U- BENDING 8. EMBOSSING
7. V- BENDING 9. FLARING
8. Z-BENDING 10. STAMPING
11. EXTRUDING
12. NIBBLING
1. BENDING
Bending is shaping the material around a STRAIGHT AXIS, which
extends completely across the material. One or more bends may be involved in the
bending dies.

These dies are important class of press tools.

The sheet material flow in these tools is always uniform and its thickness
remains unchanged.

TYPES OF BENDING
a) L – Bending
b) U - Bending
c) V – Bending
d) Z – Bending

Z -B E N D IN G

L - B E N D IN G

U -B E N D IN G
V -B E N D IN G

NEUTRAL PLANE AND ITS IMPORTANCE

Inside of bend FORCE
(SQUEEZED)

n e
pla
al
utr
Ne

Outside
DIE
of bend
(STRETCHED)

Neutral plane is an imaginary plane exists between the area under tension and
the area under compression.

The neutral plane always moves towards the inner surface at a distance of one-
third (1/3) to one-half (1/2) the thickness of the material.
EFFECT OF GRAIN DIRECTION DURING BENDING

DEFINITION

The particle chain in the sheet material is called “Fiber” and these fibers are
arranged parallel to each other and called as “Grain direction”.

In bending operation the grain direction should be considered for effective

bending of the component.

CONDITION OF GRAIN DIRECTION IN BENDING

The Grain direction should always be perpendicular to the bend axis.

Bending will not be effective and bent portion will not be strong, when the axis of bend is
parallel to the grain direction.
DETERMINING THE FLAT LENGTH BY BEND ALLOWANCE METHOD

Θ x Π (IR + Kt)
B A = ---------------------
180
Where,
B. A = Bend allowance [Arc length of neutral axis] in mm
Θ = Bend angle in degrees
IR = Inside radius of bend in mm
t = Sheet metal thickness in mm
K = Constant for neutral axis location
K = 0.33 when IR is less than 2t
K = 0.50 when IR is more than 2t

DEFECTS IN BENDING

1. SPRING BACK

After bending operation if the pressure is released, elastic stresses remaining in

the bend area will cause a slight increase in the bend angle.

Material movement of this type is known as “SPRING BACK”.

 BENDING RETAINED SPRING BACK SPRING BACK
UNDER LOAD

2. THINNING

This defect occurs when there is misalignment and axial deflection between the
punch and die.

If the clearance between punch and die is less than the sheet thickness,
results in the elongation of side wall of the component.

THINNED AREA
METHODS OF PREVENTING SPRING BACK

A) Over Bending in V-bending and Air-bending dies

B) Corner setting or Coining in V–bending and U - Bending
A) OVER BENDING
In this method the blank is bent to a lesser angle than required and the blank is
spring back to the required angle.

DIFFERENT METHODS OF OVER-BENDING

CASES SKETCH

Punch
Component
88°
1. Over bending in a V-bending 90.0°
die is accomplished by under
Die
sizing the punch to 880.
90.0°

Component
2. In a single L or U-bending die Punch
clearance between punch and die 88.0° 90.0°
must be slightly less than the sheet Die
metal thickness and punch must be Pressure
under sized to 880. pad

3. In this case the punch is made to Pressure pad

900 but the bending die is under sized
Punch
to 880 and clearance provided
88

between punch and die is less than

.0

the sheet thickness. Die

°

4. In this case both punches are under Punch

sized to 880 to allow the component to
88

achieve 900
88

.
0°
.0

Movable
°

side punch
Pressure pad
B) CORNER SETTING

In this method the metal is squeezed slightly in the corner in order to relieve
elastic stresses. This method is also known as ‘Coining or Squeezing’.

The punch nose is modified for corner setting operation. When the punch is
bottomed pressure builds up rapidly.
REMEDIES SKETCH

Punch
1. Squeeze the intersection points to A
88° Detail-A
retain the bent angle permanently.
2. Bottoming is done by squeezing the Punch
bent area to retain the bend after
Die
releasing the load.
90.0°

BENDING FORCE
It is the amount of force required to bend and give a desired shape to the piece
part. It depends on the sheet thickness, die opening factor, length of bend and the
amount of bottoming or ironing used.

FORMULA TO DETERMINE BENDING FORCE

K X S U X W X t2
FB = ------------------------
L
Where,
K = Die opening factor (0.33)
L = Length of bend (rd + rp + C)
rd = Die radius
rp= Punch radius
C= Die clearance
Su= Ultimate tensile strength in kgs/mm2
t = Sheet thickness
W = Width of the component or stock material
Where, K is 0.33, when the die opening is less than [<] 5 times the thickness,
0.667 when the die opening is 5-10 times the thickness and 1.20 when the die opening
is 10-16 times the thickness.
Pressure pad force FP = 0.5 x FB
Total force required = FP x FB
2. FORMING

The operation of forming is similar to bending except that the line of bend is
along CURVED AXIS instead of a straight one. The metal flow is not uniform. Forming
dies transfers more complex forms to sheet metal components.
3. DRAWING

In draw tools, flat blank is transformed into a cup or shell. The parent material is
subject to severe plastic deformation.

4. HORNING

Horn dies are provided with an arbor or extended horn over which the parts are
placed for secondary operations such as Seaming.

Horn dies may also be used for piercing holes in the sides of shell.

5. CURLING

It is an operation of rolling the edges of the sheet metal into a curl or roll. The
purpose is to strengthen and provide a protective edge.

Example: A hinge in which both members are curled to provide a hole for
inserting the hinge pin.
 Component with Uniform curve
Pre-curling
Good quality
component

Component
Deformed
without Inferior
component
Pre-curling quality
component
 Final radius
6

1 5 1 5
2 2
3 6 3

4 4

6. BULGING

Bulging is an internal forming operation used to expand portions of a drawn shell

or tube. The bulging force is applied from inside the tubular structure which transmits
through a medium that will flow, but does not compress.
Most common Medias are rubber, urethane, bulging oil or water. This presses
and expands the walls of a cup, shell or tube with an internal expanding segmental
punch or compressed air or liquids or semi liquids, such as waxes or tallow of rubber
and other elastic materials.
 After

After

Before

Before

BULGING DIE USING LIQUID MEDIUM

Cross section
of the component
PLUNGER
RUBBER SEAL O-ring GASCKET
Before bulging
SPLIT DIE
PARTING SURFACE

CYLINDRICAL TUBE

LIQUID BULGING
MEDIA

SPLIT DIE
After bulging

In the case of using bulging oil as bulging media gaskets must be fixed in
between the two halves of the die to prevent leakage of oil.

Otherwise the pressure of the oil cannot be controlled and which may result in
the variation of the shape and size of the component.

BULGING MEDIUMS

Urethane is commonly used because it is more resistant to abrasion, tears and

cuts and is superior to oil and grease. This is clean, easy to use and either made to
order or readily available.

Grease, oil, water are used only when shape of work piece prevents the use of
urethane. The piece part is filled with liquid medium in the die cavity. Since time
consuming is more, this is used for limited production.
7. SWAGING
The operation of swaging sometimes is called ‘NECKING’, and exactly opposite
to bulging.
 When a work piece is swaged, a portion is reduced in size and this causes the
work piece to become longer than it was before swaging.

After
Before

8. EXTRUDING

This is a special process to manufacture collapsible tubes, shells etc. The

blank is also called as “Billet” which is loaded in the die is forged upwards or
downwards under a high pressure between punch and die.

The amount of clearance between punch and die determines the wall thickness
of the extruded shell.
EXTRUDED PART

After

BILLET

Before

9. FLANGING (Flaring)

The process of forming an outward protrusion (flange) in a piece part is called

“Flanging”.

It is performed particularly for creating threads, inserting guide pins for further
assembly.

Flanging is done in stage tool as well as progressive tools with pre piercing or
direct flanging with hybrid punches.
 DIRECT FLANGING
FLANGING WITHOUT PILOT PUNCH WITH PILOT

DIE DIE
RADIUS RADIUS

PRE PIERCING

FLANGING WITHOUT PRE PIERCING

(WITH HYBRID PUNCH)

FLANGING PUNCH

DIE
RADIUS PRE PIERCING
PUNCH

10. DIMPLING

A forming die which produces a conical flange (stretch flange) encircling a hole in
one or more sheets of material.

Dimpled projection
11. COINING

In coining metal flows and occupies the space between two halves of the die
suffering too much of strain in cold state.

Hence it is also called as “Cold forming”.

12. IRONING

An operation in which the wall thickness of the drawn shell or bent component
reduced intentionally and then its surface is smoothened.

T
Ironed
surface

13. EMBOSSING

It is a process which produces relatively shallow indentation or raised

deformation with theoretically no change in the material thickness.

Embossing is also used as locater for springs in certain electrical assembly so

that the spring is not displaced during working.
 A B

PUNCH PUNCH

DIE DIE

Depression

Projection
14. PLANISHING OR PLANNING

It is an operation done to flatten dished components produced by conventional

press tools.

There are two types of planning in practice.

1) First method: Between two hardened plain blocks dished components are
placed and pressed with sufficient pressure.

2) Second method: Components are placed in between two hardened blocks

having diamond projected points as shown in figure and pressed.
In this operation the drawback is indentation marks which appear on the
components. But this method is most effective in relieving the internal stresses that may
induced due to many reasons.
 PLANNING DIE

PLANNING DIE
PLANNING DIE

PLANNING DIE

Cross section of a
planished component PLANNING DIE

15. ASSEMBLY PRESS OPERATION

These press operations are done for assembling the sheet metal components
together with rivets.

Two or more number of components placed in position as per the requirement

and rivets are inserted in the pierced holes. Then all these are placed in the tool
between punch and die and pressed till rivets gets bulged and perfectly holds the parts.

This unit is called as “Sub-assembly”. The pressure on the rivets can be easily
controlled by placing setting blocks in the tool.

Rivets

Assembly press operation

 DRAW OPERATION

BASIC FUNCTION OF A DRAW TOOL

To produce a cylindrical cup a round flat blank (cut from flat strips) is placed on
the draw die, the punch pushes the blank in to the die by the application of an external
force.

During the return stroke, cup is removed by the counter bore made in the bottom
of the die.

DRAW OPERATION WITHOUT BLANK HOLDER

Air vent
Punch

Flat blank Blank locator

Die

Drawn cup

DRAW OPERATION WITH BLANK HOLDER

Air vent
Flat component Punch

Blank holder

Die

Drawn cup
AIR VENTS

During the operation the punch tries to push the blank material into the die. At
this time, the air in the draw die has no way to escape. This leads to rupture of the
component.

Hence, a small diameter through hole is drilled in the punch & die, to allow the
entrapped air to escape.

CLEANING OF AIR VENT HOLE

During continuous production of components, the air vent often gets blocked.
This is because of continuous use of lubricants.

Hence, it is advised to clean the air vent hole frequently by blowing out the
foreign substances with compressed air.

PUSH THROUGH DRAW DIE

A simple draw operation is shown in the following illustrations. A round flat blank
cut from flat strip is placed on the die face and punch pushes the blank in to the die.

On the return stroke the cup is stripped by the counter bore in the die. This
operation is known as “Shallow drawing” and die is called as “Push through die”.

DRAW OPERATION WITHOUT BLANK HOLDER

Air vent
Punch

Blank
Flat blank locator

Die

Drawn cup
DRAW OPERATION WITH BLANK HOLDER

Air vent
Flat component Punch

Blank holder

Die

Drawn cup

DRAW OPERATION WITH RIGID BLANK HOLDER

Air vent

Flat component Punch

Blank holder

Die

Drawn cup
Drawn cup
1. SHALLOW DRAWING
Operations where the depth is less than half the cup diameter the operation is
also called as “Shallow drawing”.

Drawn cup
Depth
Height

Note:
Shallow drawing: Where, depth of cup is less than half the cup diameter.

Example: Plates, Shallow pans etc.,

2. DEEP DRAWING

The drawing of deeply recessed parts from sheet material through plastic flow of
the material when the depth of the recessed equals or exceeds the minimum part width
is known as “Deep drawing”.

Deep drawing is drawing a cup whose depth is more than half the diameter of the
cup.
Drawn cup
Depth
Height

Note:
Deep drawing: Where, depth of cup is more than half the cup diameter.

Example: Pressure cooker bottom, Cups, Washing machine tubs etc.,

DETERMINING THE FLAT BLANK DIAMETER

Flat blanks are the previous shape of the material in any draw operation. These
are produced from cutting press tools, usually blanking tools and used for the
production of drawn components.

Drawn cup
A Flat blank

h1 B C E

PROCEDURE:
1. Draw an arc C-D with B as centre and BC as radius
2. Draw an arc D-E with A as centre and AD as radius, which bisects the line
BC produced at E
3. The length B-E gives the radius of the blank
DETERMINING THE FLAT BLANK DIAMETER OF A DRAWN CUP BY ALGEBRAIC
METHOD

The Drawn cup consists:

Ød2
Ød

Ød1 Cylinder

h1
h
Drawn cup

Flat bottom

Where, d1 = Inside diameter

d2 = Outside diameter
d = Mean diameter
h = Mean height
h1 = Total height
________
Flat blank diameter: D = √ d2 + 4dh

D2 – d2
Formula for calculating the cup height: “h” = --------------
4d
Some of the factors are listed below.

1. Blank diameter
2. Percent reduction in drawing and re-drawing
3. Draw force
4. Blank holding force
5. Ironing force
6. Hydraulic press of proper capacity
7. Whether Draw beads are required or not

1. BLANK DIAMETER

It is the diameter of the flat blank produced from blanking tools. This must be
determined theoretical calculations.

2. PERCENT REDUCTION IN DRAWING AND RE-DRAWING

It is also known as reduction ratio. This should also be determined for successive
reduction to produce a final component.

i) Percentage Reduction (P) = 100 (1 –d/D)

Where, d = Internal diameter of the cup

D = Outer Diameter of the Cup

t0 X t
ii) Reduction ratio (%): Ri = --------------- X 100
t0

Where, t0 = Thickness of cup wall before Ironing

t = Thickness of cup wall after Ironing
iii) Possible number of reductions for a given ratio of shell height with respect to the
diameter
No. of I draw II draw III draw IV draw
Ratio H/d
draws % % % %
Upto 0.8 1 40 - - -
0.8 - 1.5 2 40 25 - -
1.5 - 3.0 3 40 25 15 10
3.0 - 4.5 4 40 25 15 10

3. DRAW CLEARANCE

It is the intentional gap provided between draw punch and die for successful
draw operation. Depending upon the type of metal and operation generally this
allowance range from 7% - 20% of material thickness.
4. DRAW FORCE or CUPPING FORCE

This force is a function of the strain factor and other variables required to select
appropriate capacity press. Usually, Hydraulic presses are preferred for draw
operations.

Cupping force (Fc) = Aw x Sy x nc x In Ec

Where, Fc = Cupping force
Aw = Cross sectional area of the cup (Aw = Π X dt)
Sy = Yield strength of material
nc = Deformation efficiency of cupping
In Ec = Natural logarithm of strain factor Ec
Deformation efficiency (nc) is a factor varies from 0.6 – 0.7

DRAW FORCE or CUPPING FORCE (FD):

[SU + SY]
FD = ∏ X d X t X ------------ X h = ----- Kg
2
Where, d = Punch diameter
h = Height of the cup
t = Stock thickness
Blank holding pressure: Fb = 0.3 X FD
Total Draw force: FN = 1.3 X FD
 LUBRICANTS

Lubricants are used to reduce friction between surfaces and assist material flow
during the draw operation. While selecting the lubricant for a particular type of draw,
consider the following points carefully.

POINTS TO BE CONSIDERED WHILE SELECTING AN APPROPRIATE LUBRICANT

1. Depth of draw
2. Contour or profile of the component
3. Mode of transport used
4. Material flow
5. Material specification (thickness, ductility, cupping property, treatments
required before and after the draw operation
6. Type of material: ferrous or non-ferrous
7. Drawing speed (speed of the ram head)
8. Pressure exerted on the blank holder plate
9. Function or application of the component (in its final shape)
10. Approximate time of producing the component and its dispatch time
11. Packing methods and mode of transport used

LUBRICANT’S PROPERTIES

The lubricant film must cover both surfaces in the areas required throughout the
operation. A lubricant in addition to preventing metal to metal contact will also reduce
friction and generation of heat.

LUBRICATION DURING DRAW OPERATION

A good lubricant when applied on punch and die, stops direct contact of the
component with the punch and die. Any lubricant that breaks down after a short period
of use is obviously useless for drawing sheet material.

The load applied by the punch and die is transferred to the component material
without directly contacting but via through the lubricant. Because of the elongation of the
lubricant medium a shining surface occurs on all the drawn components. Due to friction
too much of heat is generated. To dissipate this hot water soluble lubricant has to be
used.
TYPES OF LUBRICANTS AND THEIR APPLICATION

1. Lubricating oil

This is suitable only for drawing small cylindrical cups and not advisable for
larger and thicker components. This evaporates easily and also creates local non-
lubricated zones.
2. Graphite powder

Even though graphite is self lubricating, not much used in practice and may be
useful for small diameter drawn components.

3. Zinc oxide

This is a very fine powder white in color widely used for all general draw
operations. Zinc oxide is available easily in the market with reasonable price compared
to other lubricants.

4. Molybdenum Sulphide powder

This is a black powder and best lubricant medium used for draw operations.
When compared with zinc oxide this is superior but very expensive. This is best suited
for sheet material of thickness 2 mm and above.

5. Lubricant solution (Mixture)

For Steel: 3% colloidal compound with 67% water

For Brass and Copper: 5% soap flakes, 28%, colloidal compound with 67%
water
For Tin: Lubrication not required since this material is self- lubricating

Most common methods of applying lubricant

1. Using a Brush
2. Swabbing
3. Using Roller-coating
4. Dipping the blank or stock in a lubricant bath
5. Spraying on the area where maximum draw force is concentrated
 DEFECTS IN DEEP DRAW OPERATION

1. Burr collection at the draw die 2. Thinning

3. Cracking 4. Score marks
5. Ejection problems 6. Puckering
7. Wrinkling 8. Earring
9. Material and its influence 10. Surface finish
11. Wrong tool setting 12. Operator’s negligence

REASONS AND REMEDIES FOR DEFECTS IN DEEP DRAWING OPERATION

1. BURR COLLECTION AT THE DRAW DIE

Fine powder like particles gets collected at the bottom of the die due continuous
use.

Causes:
1. Type of sheet material used for producing the component
2. Thickness of the sheet material used

Remedies:
1. Polish the draw die and draw punch and smoothen the flow radius and inside
surface and use good lubricant such as ‘Molybdenum sulphide’

2. THINNING
It is a frequent problem which occurs during draw operation. Due to this
thickness of the component steeply reduce and give rise to its height.

Causes:
1. Clearance is insufficient
2. Lubrication problem
3. Insufficient die radius or punch radius
4. Drawing speed is more

Remedies:
1. Appropriate clearance is to be given in each draw stage
2. Use good lubricants such as molybdenum sulphide, so that the material
flows evenly during draw operation
3. CRACKING
Splitting of wall surface of a finished component is known as “Cracking”. It
invariably occurs after thinning

Causes:
1. Draw clearance is insufficient
2. Lubrication problem
3. Insufficient die radius or punch radius
4. Drawing speed is more

Remedies:
1. Appropriate clearance is to be given in each draws
2. Use good lubricants such as ‘Molybdenum sulphide’, so that the material
flows evenly during draw operation
3. Check the draw radii of both punch and die. Maintain them properly
throughout the profile. If it is less increase them
(i) For die = 4t to 10t
(ii) For punch = 3t to 5t
4. SCORE MARKS
These are marks formed on the component or on punch and die due to fouling of
parts or particles of the sheet material.

Causes:
1. Lubricant used is not effective.
2. Fouling is caused by the building up of particles of the sheet material from
the drawn cup on both the punch and the die which leads to scoring of the
surface of the end product.
Remedies:
1. Dismantle the tool. Clean the punch and die surfaces, lubricate and reset
them.
2. Polish the draw punch and draw die.

5. EJECTION PROBLEM
The component is struck either to the draw punch or with the draw die and is not
getting ejected for consistent production.

Causes:
1. Insufficient draft on punch or die
2. Lubrication problem

Remedies:
1. Check the draft on draw punch and draw die radii
2. Rectify by providing positive draft on die
3. Provide good lubricant such as “molybdenum suplhide”
6. PUCKERING
This is a defect mostly found in shallow drawing and less frequent in deep
drawing. This is similar to wrinkling but takes place inside the die, after the metal has
begun to form inside the die aperture.

Causes:
1. Poor die design and providing too much draw clearance
2. Stresses in the material are the underlying cause of this phenomenon
3. Lack of ductility (sheet material may be hard and not accepting the
operation)

Remedies:
1. It is difficult to set right the die
2. Redesign the tool
3. Trial to be made with draw quality stock material

7. WRINKLING
It is defined as the deformation of material into ups and downs on the surface.
This defect takes place between the pressure plate (blank holding plate) and the die
face.

Causes:
1. Insufficient pressure on the pressure pad that holds the blank
 2. Increase in the stress or stress concentration in the stock material of the
component
Remedies:
1. Apply appropriate pressure on the pressure pad
2. Use of draw beads on the die

8. EARRING
These are the extra projections caused by the directional properties in the sheet
material from which the cups are drawn.

Causes:
1. Cold working tends to produce preferred orientations in sheet materials
2. When rectangular blank is drawn to a rectangular shallow bowl

Remedies:
1. Earring can be minimized by avoiding excessive deformation in the deep
drawing process
2. Shape and size of the ears can be controlled to some extent by varying
the shapes of the blank (oval or even squared instead of circular).
9. MATERIAL AND ITS INFLUENCE
The type or quality of stock material is a very important factor controlling the
technique employed to produce any given article.

Causes:
1. When tool is used for other materials to manufacture same components.
2. Inferior quality of material supplied in the subsequent batch of material
supply

Remedies:
1. A good quality of material is essential
2. Different tools to be used for each type of material.

10. SURFACE FINISH

Surface quality of the deep drawn component depends largely on the grain size
of material of the sheet material, from which it is blanked and drawn.

Causes:
1. Coarse grains do not come into contact with the die face
2. The surface often resembles as orange peel (flakes). Hence, it is also
called as “ORANGE PEEL EFFECT”

Remedies:
1. Adequate control of grain size in the sheet to be drawn, is necessary
2. Final annealing process must be standardized and carried out for every
subsequent draw operations and annealing at too high temperature or for
too long period leads to formation of coarse grains
3. In case of mild steel normalizing the drawn cup at 910ºC, instead of
annealing at 650ºC, leads to re-crystallization of material with fine grain
size

11. WRONG TOOL SETTING

Some times the tool setter does not have the knowledge of proper procedure of
loading the tool, which may lead to serious tool damage.

Cause:
1. The tool setter sets the tool wrongly without following the procedure
2. He may be over confident or ignorant or not knowing the procedure
3. He may try to use the available facility

Remedies:
1. Having obtained all the relevant information and procedure of tool setting,
the tool is to be set properly by the tool setter
2. Few of the things include proper clamping of the tool, lubrication, setting of
proper shut height, screws on pressure plate to be checked twice,
tightening of punch and die etc
12. OPERATOR’S NEGLIGENCE
In many instances the operators are inexperienced or experienced by just
assisting the senior operators and proclaiming themselves as skilled operators.

Because of this the basic problem, the industry faces high risk on valuable tools
and equipments.

Causes:
1. Conversation with another operator
2. Disobeying the instructions
3. Lack of knowledge in the draw tool operation
Result:
1. Sometimes complete destruction of the tool
2. Production will be held up for many days till the tool is rebuilt
3. Product become scrap
Remedies:
1. Operator must be cautious about the work
2. Operator has to obey the instructions
3. Safety instructions have to be strictly followed
4. The supervisor must be vigilant and has to supervise all of these functions
 HIGH END PRESS TOOLS

HYBRID OPERATION

1. LOVRING:

Louver is a partial tearing and bending operation usually made on engine covers,
cabinets, etc for the entry of air.

This unique operation is commonly done for air vents for stabilizer cases,
regulator cases, electrical panels etc., where air has to circulate and keeping the
equipment cool.

It is a passage with flat sloping profiles with one side opening to allow light and
air to enter in while keeping rain water out.

In this operation only one side is cut and the other three sides are bent, such
that, the air can enter into the equipment through the opening.

Entry for air

2. LANCING:

Lancing is a very important press operation involving 3 or 2 side shearing and

one side bending or forming.

This operation is widely used to provide relief for the matching part. It is also
used to locate one part into the other.
In many of the sheet metal application lancing is used to lock the part to the other
for proper assembly. Ex: Mosquito coil stand.

This is also a partial tearing and bending operation. Usually two or three sides
are teared with one side left with the parent material. Used for spring locking in
the assembly or riveting.

This is a combined bending and cutting operation along a line in the work
material.

The punch is designed to cut on two or three sides and bend along the fourth
side.

LANCING
 TYPES OF PRESS TOOLS

SINGLE STAGE TOOL

MULTI STAGE TOOL

TYPES OF
PRESS COMPOUND TOOL
TOOLS

COMINATION TOOL

FINE BLANKING TOOL

 COMPOUND TOOL

Already we have dealt with Single stage & Multi stage press tools in the previous
chapters.

We shall try to understand other special press tools in brief.

COMPOUND TOOL

INTRODUCTION
In progressive tools burr produced by blanking & Piercing appears on both the
surfaces of the sheet material, which is most common.

But, whenever we require a component with high degree of dimensional

accuracy, flatness, free from cumulative errors and burr of piecing & blanking on one
surface of the sheet material, then best option is to manufacture a special tool called
“COMPOUND TOOL”.

PRINCIPLE

The basic principle of this tool is both Piercing and Blanking operations will be
performed in the same working cycle or stroke of the press.
Strip layout of Compound tool
STRIP WIDTH

The cut band for both Piercing

and Blanking appears on the
PITCH
same surface only

Blanking

COMPONENT
Fracture
Piercing

COMPARISON BETWEEN COMPONENTS PRODUCED FROM

PROGRESSIVE TOOL & COMPOUND TOOL
 PROGRESSIVE COMPONENT COMPOUND COMPONENT

BLANKING BLANKING
CUT BAND PIERCING CUT BAND PIERCING
CUT BAND CUT BAND

BLANKING BLANKING
FRACTURE FRACTURE

PIERCING PIERCING
FRACTURE FRACTURE

1. Burr appears on the same surface

1. Burr appears on both the surfaces
of the sheet material.
of the sheet material.
2. Perfect flatness is achieved.
2. Perfect flatness is not achieved.
3. Elimination of cumulative error
3. Cumulative error is common
because, there is no progression.
because of progression.
4. Components are used for high
4. Produced components are used for
precision assemblies since they
semi precision assemblies.
posses high dimensional accuracy.

CONSTRUCTION
Compound tool is a complete cutting press tool.

Usually in progressive tools, all the punches are fixed to the top unit and the die
will be to the bottom unit. But in compound tools, the blanking die is fixed to the top and
the blanking punch which has piercing die will be mounted on the bottom plate. The
piercing punch is fixed to the top unit with punch holder, supported by punch back plate
and top plate.

Shedder: These are normally spring loaded and will have sliding fit with the
piercing punch and the blanking die. Shedder guides the piercing punch during the
operation and helps in ejecting the component after the operation.

A spring loaded stripper is provided in the bottom unit moves up and down
around the blanking punch, has strip guide pins instead of guide plates.
Since, the cutting pressure is concentrated in the middle of the die set centre
pillar die sets are most appropriate.
 Piercing punch

Shedder back plate

Shedder

Component

Blanking punch

CLASSIFICATION:
1. SIMULTANEOUS ACTION (CUT & CARRY SYSTEM)
2. DELAYED ACTION (KNOCK-OUT SYSTEM)

1. SIMULTANEOUS ACTION (CUT & CARRY SYSTEM)

In this method the component is separated during the piercing and blanking
operation, ejected from the die and get fixed into the blanking opening in the skeleton
strip, carried along with it. This method is called as CUT & CARRY.

FUNCTIONING

When the top unit exerts pressure on the strip the actual cutting operation takes
place simultaneously. After the operation, the top unit starts moving upwards, the blank
which has entered the blanking die will be ejected out with the help of spring loaded
shedder.
Simultaneously, the strip is also removed from the blanking punch by the spring
loaded stripper. Because of this action, the component enters into the stock material
opening and gets embedded. There by perfect flatness is once again achieved and the
cycle continues.
Compound tool with SIMULTANEOUS ACTION
(Cut & Carry system)
 ADVANTAGES & DISADVANTAGES OF SIMULTANEOUS ACTION
(CUT & CARRY SYSTEM)
Sl.
ADVANTAGE DISADVANTAGE
N0.
Top unit construction is complicated
compared to delayed action ejection
This is a mechanical system of ejecting
1 system.
the component from the die.
Shank should have a bore for
inserting a helical spring.
Component will be carried along with There are chances of component
2 the strip. Hence, flatness of the getting stuck in the die opening due
component. to insufficient spring force.

a) Thin and large components are

forcibly inserted in the skeleton strip
This method has its own limitation.
and do not stick to the shedder face.
Thick components (more than 2 mm)
3 b) Damages to the die due to this can
require only delayed ejection
be easily prevented.
system.
c) Does not require manual removal of
the component.

2. DELAYED ACTION (KNOCKOUT SYSTEM)

This delayed action in a compound tool is obtained by “Knockout system”.

This system is comprised of

1. Shedder
2. Knockout pin
3. Knockout plate
4. Knockout rod
5. Drop bar

FUNCTIONING

When the operation is completed, the component will get stuck in the blanking
die. During the return stroke, shedder is lifted, knockout pins which are provided
beneath the shedder also gets lifted up and lifting the knockout plate.
This knockout plate which is just placed on the knockout pins lifts the knockout
rod. This rod is inserted through the shank hole. Drop bar which is an accessory of the
machine also gets lifted up.

In the press, there are adjustment screws provided on either side of the ram
head which will push the drop bar. This push force is sufficient to kick the knockout rod.

Thus knockout plate will push the knockout pins, which drives the shedder down
resulting in the ejection of the component from the blanking die.
 The component will fall on the stripper of the bottom unit which is to be removed
either by blowing the air or collected manually.

Compound tool with DELAYED ACTION

(KNOCKOUT SYSTEM)
 ADVANTAGES & DISADVANTAGES OF DELAYED ACTION
Sl.N0. ADVANTAGE DISADVANTAGE

Top unit construction is complicated.

This is a mechanical system of
Shank should have a hole for inserting
1 ejecting the component,
the knock out rod.
positively from the die.
Press should have the knock out facility.

Component is not carried along with the

There are no chances of strip.
2 component getting stuck in the
die. Flatness of the component may not be
achieved.

a) Thin sheet metal components may

stick to the shedder face and does not
fall on its own weight.
Every stroke requires manual
Damages to the die due to this removal of component which hampers
3
can be easily prevented. the production.
b) This method has its own limitation.
Larger component requires only
spring loaded ejection system.
 The following are some of the general advantages & disadvantages of
Compound tools over Progressive tools or Single stage tools.

Sl.
ADVANTAGE DISADVANTAGE
No.
Die design & manufacturing is
High degree of accuracy can be
1 complicated due to many operations
achieved.
being carried out in a single station.
Being complicated, the skill involved in
Cut band and Burr of piercing &
the manufacture of the compound die
2 blanking appears on the same
is higher and tool manufacturing time is
surface
also considerably more.
Since all the operations are
Having too many operations carried out
performed in one station,
in a single station, the tools are not
components will have close
rigid and strong.
dimensional accuracy.
3
This easily eliminates any
This fact makes such tools to frequent
inaccuracy that can originate due to
breakdown and tool maintenance and
piloting in progressive dies and
repair requires higher skill.
locating in single stage tools.
These dies maintain the repeated It is difficult to design compound dies
accuracy, for thick components as the strength of
4
It is possible to produce a die section will not be that strong
component with perfect flatness. compared to a progressive die.
Compound dies are used to produce
Thin sheets are difficult to feed as it
component from very thin material
5 may buckle while feeding and results in
which are too delicate for pitching
dimensional variation.
and piloting.
 FINE BLANKING TOOL

PRINCIPLE
Fine blanking is one of the methods of producing components without Fracture
or Die break. This is done by controlling metal flow into the die.

An inverted “V” projected ring called “IMPINGER”, which has a knife edge is
pressed into the sheet metal outside the cutting line and the metal outside this line is
restrained by the application of great force called “Strip holding force”.

1) This impinge ring will not allow the material to flow into the die.

2) The clearance between the punch and die will be around 0.007mm (7
microns) irrespective of material thickness and type of material.

As a result of these two (close clearance or insufficient clearance and restriction

to metal flow) a clean, smooth cut edge is produced.
 COMPARISON BETWEEN CONVENTIONAL BLANKING
WITH FINE BLANKING

CONVENTIONAL BLANKING: As the sheet metal is not held properly, it tends to lift,
when the punch starts applying the load. Thereby defect known as “dishing” occurs in
the piece part.

LOAD
Lifting of stock

Dishing Radius
Die

FINE BLANKING: Both Blanking and Piercing operation is performed simultaneously by

the applied shear force. Rollover radius is eliminated by firm holding of the stock, with
the help of “IMPINGER”.
Piercing punch
Shedder
Die

Component

Impinger

Blanking punch
Slug ejector
 DESIGNATION OF IMPINGER PROFILE IN FINE BLANKING TOOL

A
For Stripper plate
Material
Stripper Thickness A h r
90.0°
1 1-1.7 1 0.3 0.2
2 1.8-2.2 1.4 0.4 0.2
h

3 2.3-2.7 1.7 0.5 0.2

r

4 2.8-3.2 2.1 0.6 0.2

5 3.3-3.7 2.5 0.7 0.2
0.05 to 0.1
6 3.8-4.5 2.8 0.8 0.2

Since intentionally insufficient cutting clearance is provided between the punch

and die, the width of the cut band is automatically extended to the full thickness of the
stock material.

As tensional burr appears during separation of the component, secondary

operation like de-burring using vibrators, tumblers, etc are employed to remove this burr
only.

Generally, fine blanked component does not require any secondary press
operation like shaving, trimming etc.
CONSTRUCTION OF THE TOOL
The construction of the tool almost resembles a compound tool. The only
difference is the addition of V - inverted impinge ring around the blanking area. This
impinge ring is provided usually on the floating stripper, which projects from the stripper
top surface.

Impinger ring is made from tool steel OHNS (T110 W2 Cr1), hardened and well
polished with sharp knife edge.

The tool should be rigid enough to absorb the heavy load. Hence, the die should
be thick enough and housed in a hardened OHNS material and this again housed in a
main housing made of St-42 material.

Generally, for fine blanking tools four pillar die sets with ball cage are preferred
for higher rigidity and frictionless movement.

Fine blanking tools requires sophisticated machines to manufacture and skilled

workmen to assemble and maintain.

Sectional elevation of fine blanking tool

IMPORTANT STAGES IN FINE BLANKING
Fine blanking operation involves four main stages.

1st stage: Impingement

2nd stage: Cutting operation
 3rd stage: Ejection of the component
4th stage: Positioning fresh portion of the stock strip

Initial stage: Die is in open condition.

Stock material is placed in between punch and die.

1st stage: Impingement: Tool is in closed condition. Stock material is held firmly
between the IMPINGER which is fixed on the DIE and the spring loaded STRIPPER

2nd stage: Cutting operation: Blanking and Piercing operations are accomplishing
simultaneously by the applied shear force. Rollover radius is eliminated by firm holding.

Intermediate stage 1: Operation is completed. Blank is held firmly between the

Blanking punch and Shedder. The pierced slug is held between the piercing punch and
the ejector.
Intermediate stage 2: Top and Bottom units are separated, but the component and the
slug are still within the tool. Skeleton stock is not released from the IMPINGER.

3rd stage: Ejection of the Piercing slug: Piercing slug is ejected by the ejector. Stock
material is relieved from impinging pressure.

Intermediate stage: Ejection of the component: Component is ejected out by the

Shedder and the skeleton strip is released from the inverted V- shaped IMPINGER

Intermediate stage: Stock strip movement: Component is ejected from the die. Stock
material starts moving in the feeding direction.
4th stage: Positioning fresh portion of the stock strip: Component and the Piercing
slug are removed by blowing high pressured air. Fresh portion of the stock material is
again positioned for the next cycle.

FUNCTION OF THE TOOL

Tool should be loaded on a Triple action hydraulic press. The three actions of
the press are IMPINGEMENT or STRIP HOLDING, CUTTING and EJECTION.

Bottoms ram moves upward to grip the stock with great pressure and impinge the
stock material. Further, the bottom ram continues to move a distance equal to the stock
thickness. And thus the blanking and piercing operations are accomplished.

The lower ram descends and the shedder removes the component from the die
whereas the pierced slug is removed by the ejector. Both component and pierced slug
are collected in a container by blowing high pressured air.

The stock strip is positioned for the next cycle in such a way that impinged area
does not come in the new blanking area. Since impinged area cannot be used for
producing the component, utilization of the stock material will suffer.
Sl.
ADVANTAGE DISADVANTAGE
No.
Components posses smooth edge
Due to insufficient cutting clearance, die
1 all over, perfect flatness, high
construction is complicated
accuracy and good finish.
Components do not require Shear force required is approximately 3
2 secondary operations which saves times more, compare to conventional
manufacturing time. shearing.
Tool cost approximately 50% more 1. Higher tool cost.
than the conventional tools, but the 2. Tool manufacturing and
3
cost is more than offset by the maintenance requires a highly
elimination of secondary operation. knowledgeable tool maker.
Components are used usually in Though the quality of component is
automobiles, where matching of the unmatched with the component
5 assembled product is very precise. produced form conventional tools, not
Ex: Sprockets, Gears, Free advisable for all types of components
wheels, Chains etc. due to high production cost.
 COMBINATION TOOL

PRINCIPLE
Combination tools are unique press tool which perform both cutting and non
cutting operations (usually draw operation) in one cycle of the press with better
dimensional accuracy and quality.

Generally, a Double action press with die cushion is quite essential for
Compound tool, Draw tool and these Combination tools.

CONSTRUCTION
Combination tools are almost similar to a compound tool by appearance, but
non-cutting die and punch are enclosed within the cutting area. Shedder which is a
sliding fit in the blanking die acts as draw die also.

An ejector is provided within the shedder to eject the component as soon as the
top unit moves upwards completely. Normally, knock-out system is employed to do this
ejection function. Either centre pillar or four pillar die sets are used in the tool
construction for longer life of the tool.

TOOL FUNCTIONING
When the top unit start dwelling down, the stock strip which is placed on the
floating stripper (spring loaded stripper) is held firmly before performing the operation.
Further dwelling results in the blanking of outer contour of the flat blank.

As the downward stroke continues, the cut blank starts entering into the draw die
by the action of the draw punch, which is mounted on the bottom unit.

Spring loaded shedder moves upwards and butts to the shedder back plate;
thereby bottoming of the component is achieved.

As the top unit moves upward, the shedder starts sliding down by the spring
action. The ejector which is within the shedder will knock the component out by the
action of the knock-out system.

Thus, the component will fall on the bottom unit (floating stripper), which may be
collected either by blowing the air or collected manually. And the cycle continues in the
same manner.
Sectional elevation of COMBINATION tool
 COMPONENT

COMPONENT
STRIP LAY-OUT Sheet thickness
STRIP WIDTH

FEED PITCH BLANKING & DRAWING

COMBINATION TOOL

ADVANTAGE DISADVANTAGE
1. In one cycle of the press complete 1. Tool design is complicated
component is produced 2. Requires sophisticated
2. Production time is less machines to machine the parts
3. Material handling is minimized 3. Assembly of the tool requires
4. Requires no secondary highly skilled person
operations 4. Tool cannot be loaded on
5. Production cost is low compare to ordinary press
other types of tools 5. Accident to the tool is very
6. Quality and dimensional accuracy serious
of the component is very high 6. Tool maintenance is expensive
compare to conventional tools 7. Tool manufacturing cost is high

LIMITATIONS
As this is a complicated tool the parts which involved in the direct production of
the components are delicate.
Hence, these tools are not advisable for:
a) Higher sheet thicknesses
b) Holes and profiles which are too close to each other
c) Drawn components having projections on the side walls
 STRIP LAY-OUT

There are two important methods of rolling in practice

Methods of Rolling

Hot Rolling Cold Rolling

These sheets are These sheets are
generally referred as generally referred as
“HR” “CR”

HOT ROLLING

Hot rolling is the core production process between melting and finishing
operations. It is the main transformation stage where the billets are processed into bars
wires, sheets or foils.
If the sheets are rolled in hot condition, it is called as hot rolled sheets.

COLD ROLLING

Hot billets are cooled, cleaned, surface ground and Cold rolled to specific
thickness on latest computer controlled mills, which continuously monitor the material
for uniform gauge.

TYPES OF SHEETS AVAILABLE

Sl. No. Type of Sheet Metal Available size
CRCA (Cold Rolled Close Annealed)
1 HR (Hot Rolled) 4’ X 8’
Aluminum
Brass
12’’ X 48’’,
2 Copper
14’’ X 48’’ & Coil form
Phosphor bronze

UTILIZATION OF STRIP

During the production of stampings, major consideration is very often given to the
economical use of the raw material and blank lay-out in general is planned with
minimum scrap.

UTILIZATION FACTOR

It is the percentage of the raw material (stock material) used in the component.

Represented by:
 fo
K. W = ------- x 100 =------%
f1
Where,
fo = (Surface area) Area of the material in the component
f1= (Surface area) Area of material required to produce the component
KW= Utilization factor
100 = To convert the value into percentage

Ex: Blank size = 20mm x 30mm and the value of Scrap bridge and Side scrap =
1.75mm
Pitch = 21.75mm and Strip width = 33.5mm

fo
K W = ---------- x 100
f1

fo = 20 X 30 = 600 mm2
f1 = 21.75 X 33.50 = 7728.62 mm2
KW = (600 / 728.62) X 100
KW = 82.34%

1000
No. of components per meter = ----------
Pitch
1000
No. of components per meter = --------------- = 45.97
21.75

No. of complete components = 45

METHOD OF CALCULATING NUMBER OF COMPONENTS PER SHEET WITHOUT

ANY SCRAP
Ex: Component dimension = 15mm x 45mm
Sheet dimension = 4’ x 8’ (4 Feet x 8 Feet)
[Standard size of CRCA steel sheet]

1st step: Convert Feet to Millimeters [mm]

We know that, 1feet (1’) = 12 Inches (12”)
1 Inch (1”) = 25.4mm

4 Feet = 1219mm and 8 Feet = 2438mm

(Decimal values are neglected)

2nd Step: In a sheet of 1219mm x 2438mm

2438
 Number of pieces produced of size 45mm = ----------- = 54
45

1219
Number of pieces produced of size 15mm = ------------ = 81
15

3rd Step: Number of pieces from the sheet (1219mm x 2438mm)

= 54 x 81
= 4374
[Conclusion: From a sheet of 4 Feet x 8 Feet, number of pieces produced are
4374]

Important note: Practice the above calculation for other sheet sizes with different blank
dimensions.

As per thumb rule the Scrap bridge and Side scrap is as follows:
1.5 X sheet thickness for metallic materials
2.0 X sheet thickness for non-metallic materials
BLANK LAY-OUT
The initial preparation of tool design, involves deciding the position of cutting tool,
stopping positions, direction of feed and its value, instruction of feeding the strip and
operations in the tool.

DEFINITION
It is a plan of cutting the blanks from the stock with optimum economy which is
influenced by many factors.
Sometimes when there is no provision for deciding precise and economical strip
lay-out for irregular contours, blank lay-outs are more preferred.

STRIP LAY-OUT
Strip lay-out is very important as it serves as the basis for designing and
manufacturing of press tool.

DEFINITION
It is a complete plan of producing the component in a progressive tool from the
stock material.
Nomenclature such as sequence of operation, the location of tool limit at each
station, operation taking place at each station, feeding direction etc, are clearly
indicated.
There are different methods of blanking out the desired shape. Before the tools
are designed, it must be decided which method is to be adopted.
The following important points are to be considered while designing a strip lay out.
Sl. No. Strip lay out points
1 Stock material from which blanks are cut
2 Direction of burr on the component
3 Grain direction in the stock material
4 Direction of feeding the stock strip
5 Production quantity of components required
6 Tool cost
7 Specification of press
8 Tool making possibilities and facilities
9 Scrap and Utilization factor of stock material

Blanking Side Scrap

Piercing Scrap Bridge
Strip width

End Stopper

Pitch
Side Scrap
 WORKED OUT EXAMPLE FOR DESIGNING SEQUENCE OF PRESS TOOLS FOR
THE DRAWN COMPONENT

The below drawn cup requires four different types of tools to produce. It is always
better to understand the component well, before designing the tool.

Different stages of press operations for drawn cup

1. Blanking tool: To produce Flat blank required for drawn cup

2. Draw tool: To shape flat blank into a cup

3. Piercing tool: To originate a hole in the centre of the drawn cup

4. Cantilever Piercing tool: To originate a hole at the side of the drawn cup

3-D VIEWS OF THE DRAWN COMPONENT

 1. BLANKING TOOL

Sectional elevation of the blanking tool

This is a single stage cutting operation tool which performs only one operation
like Blanking.
Centre pillar die set is used assuming huge volume of components and
concentration of shearing load in the middle.

Die set is always optional depending on the

1. Stock thickness
2. Type of sheet material
3. Clearance between punch and die
4. Type of press used
5. Quantity required
6. Speed at which the tool has to work

Fixed stripper or box stripper (Channel stripper) used as the sheet thickness is
quite thick.
For easy falling and collection of blanks spacers are provided under the die set.
 2. DRAW TOOL

Sectional elevation of the draw tool

Flat blank is shaped into a circular cup with flange. The alignment between
punch and die is made perfect to avoid draw defects like Tearing, Earing and
Elongation.

Blank locator is provided on the die for placing the flat blank in the perfect
position.

Spring loaded pressure pad is provided for two reasons.

a. During draw operation, the flat blank is firmly held between punch and
pressure pad, resulting in uniform flow of material in to the die.

b. During the return stroke of the top unit the drawn cup is also ejected or
removed from the die simultaneously. This will avoid distortion of drawn
cup shape.

Centre pillar die set is provided, as the draw pressure is centrally located.

Setting spacers: These are used for several reasons.

a. Tool setting on the press is very easy

b. To control the downward stroke of the top unit

 c. To avoid accidents to the tool, during the component production

d. Any slight change in press setting during production will not affect the
quality of the component.

3. PIERCING TOOL

Sectional elevation of centre piercing tool

Whenever a hole is required in a drawn component, it is always better to pierce,

after the draw operation.

If the hole piercing is done before the draw operation, during the draw operation
the material undergoes severe strain and resulting in stretching irregularly.

Due to this, the pierced hole loses its dimension, position and desired shape.

As the component requires a hole in the bottom, above tool is designed.

The stripper is spring loaded and will have the same profile projection as that of
the inside profile of the component for better holding and location.

A locator is fixed on the die has outside profile of the component for easy loading
of the component during production.
Solid yoked die with collar is used, as there is only one hole to be pierced. These
dies will save the tool cost at many times.
 Centre pillar die set is preferred as the piercing load is located in the centre of the
dieset.

A hardened die back plate is used to absorb the downward thrust, exerted by the
punch during the cutting operation.

Similarly, a punch back plate is also provided above the punch to avoid
penetration of piercing punch head in the top plate during the cutting operation.

Setting spacers: These are used for several reasons.

1. Tool setting on the press is very easy

2. To control the piercing punch depth in the die during the operation

3. To avoid accidents to the tool during the component production

4. Any slight change in press setting during production will not affect the
quality of the component

4. CANTILEVER or SIDE PIERCING TOOL

Front elevation of side piercing tool

This is an example for Cantilever piercing or Side piercing, which is done after
the draw operation. The reason is the piercing cannot be done before the draw
operation as the hole loses its orientation and shape during drawing.
 Example: For fixing the handles to the pressure cooker bowl and lid, this type of
operation is easy and preferred.

In this tool,
A component locator is inserted in the holder. This holder is fixed on the base
plate with screws and dowels.

A spring loaded holder is provided to hold the drawn cup during the operation.

Rear pillar (Back pillar) die set is chosen for the following reasons.
1. Easy loading and unloading of the component
2. Clear visibility of the operation
3. Operator’s friendly
 ESTIMATION AND COSTING OF PRESS TOOL

It is an art of finding the cost of the product before manufacturing. It is defined as

the probable cost of the product by assuming the cost and expenses, which are
probably incurring in different sections and processes.

Estimation requires highly skilled technical knowledge about manufacturing

method and operating time.

ADVANTAGES
a. Estimation prevents the loss to the manufacturer by giving him the nearest
price of the product, before manufacturing.

b. It aims at taking decisions to make or purchase.

c. It helps to arrive at the price setting where, there is no established data.

d. It will also help in comparing the actual production cost with the estimated
price.

PRESENT MARKET RATE OF THE MATERIAL

Sl. No. MATERIAL RATE in Rs. per KG

1 M.S 80-00

2 17 Mn 1Cr 95 90-00

3 OHNS 180-00

4 HCHCr (D2) 380-00

5 HCHCr (D3) 280-00

PRESENT HEAT TREATMENT CHARGES

Sl. No. TYPE OF TREATMENT RATE in Rs. per KG

1 Case hardening 25-00

2 Hardening and tempering 33-00

 GENERAL MACHINING CHARGES

Sl. RATE in Rs. Per HOUR from January

TYPE OF MACHINING
No. 2008

1 All general purpose machines 170-00

CNC/Jig Boring/Wire Cut/

2 680-00
Jig Grinding/EDM

3 Bench work 140-00

4 Trials 300-00

5 Design 300-00

6 Inspection 220-00

7 Tryout 300-00

8 Batch production 800-00

9 Final production 600-00

DIRECT MATERIAL COST

Sl. Total Cost per Cost in

Name of the item Matl.
No. weight Kg in Rs. Rs.

1 Die block HCHCr 5 380/- 1900-00

2 Stripper M. S 5 60/- 300-00

3 Punch holder M. S 5 60/- 300-00

4 Top plate M. S 18 60/- 1000-00

5 Bottom plate M. S 22 60/- 1200-00

6 Guide plate OHNS 2 160/- 320-00

7 Punch back plate OHNS 3 160/- 480-00

8 Pillar & Bush OHNS 6 160/- 960-00

Strip guide support

9 M. S 1 60/- 60-00
plate

10 Punch wire cut block HCHCr 5 380/- 1900-00

GRAND TOTAL 8,420-00

COST BREAK-UPS
INCURRED COST in
Sl. No. COST PARTICULARS
Rs.

Prime cost (PC)

= Direct matl. cost + Direct Labor cost(Approx.
1 15,420-00
85% of Direct matl. cost)
= 8,420 + 7,000

2 Over heads expenses = 20% of (PC) 3,084-00

3 Cost of Standard items (LUMP SUM) 2,500-00

Total Machining cost (Includes Jig boring, Heat

4 28,000-00
treatment and Wire cut)

5 Design charges = 20% of (PC) 3,084-00

6 Assembly charge =@Rs.140 X 120 hrs 16,800-00

Inspection charges
7 = No. of hrs X Rate (Rs. 220/-) 880-00
= 4 X 220/-

Try-out charges/Shift
8 = No. of hrs X Rate (Rs. 300/-) 2,400-00
= 8 X 300

9 Miscellaneous = (40% of (PC) 6,168-00

TOTAL COST 78,336-00
 SELLING PRICE
Sl. No. Description of Cost Cost in Rs.
1 Total Cost 78,336-00
2 Profit (10% of Total Cost) 7,833-60
SELLING COST 86,169-60
Rs. EIGHTY-SIX THOUSAND ONE HUNDRED SIXTY-NINE & PAISA SIXTY ONLY
 PRACTICE THE FOLLOWING ON YOUR OWN
Exercise No: 1
1. Design an economical strip lay-out.
2. Calculate the Utilization factor.
3. Calculate number of components per strip length of 1200mm.
4. Calculate number of components per sheet of size: 4 Feet x 8 Feet
5. What is the sequence of press operations involved in this component?
6. Which type of Press tool, you recommend to produce this component? Justify
your answer.
7. Calculate the Cutting clearance per side using all the 3 methods.
8. Derive the dimensions of Punch & Die for both Piercing & Blanking.
9. Determine the required Shear force.

R2 (TYP) R3
7 96
Ø6 2
°
93
°

42
93
25

15
9

°
87

Ø10

8
53 R20
60
66 Ø5
88
107
122

Component details:
1. Material: CRCA 2.0mm
2. Scrap value for scrap bridge and side scrap: 3.5mm
3. Shear strength: 38Kg/mm2
Exercise No: 2
1. Design an economical strip lay-out.
2. Calculate the Utilization factor.
3. Calculate number of components per strip length of 1200mm.
4. Calculate number of components per sheet of size: 4 Feet x 8 Feet
5. What is the sequence of press operations involved in this component?
6. Which type of Press tool, you recommend to produce this component? Justify
your answer.
7. Calculate the Cutting clearance per side using all the 3 methods.
8. Derive the dimensions of Punch & Die for both Piercing & Blanking.
9. Determine the required Shear force.

Ø4(2-Holes)
Ø21

R20
44

R4 3
Component details:
1. Material: CRCA 3.0mm
2. Scrap value for scrap bridge and side scrap: 4.5mm
3. Shear strength: 33Kg/mm2
Exercise No: 3
1. Design an economical strip lay-out.
2. Calculate the Utilization factor.
3. Calculate number of components per strip length of 1200mm.
4. Calculate number of components per sheet of size: 4 Feet x 8 Feet
5. What is the sequence of press operations involved in this component?
6. Which type of Press tool, you recommend to produce this component? Justify
your answer.
7. Calculate the Cutting clearance per side using all the 3 methods.
8. Derive the dimensions of Punch & Die for both Piercing & Blanking.
9. Determine the required Shear force.

R3(Typ) 10

Ø4(4-Holes) 10
R6
90°

50
43

10
25
20

8
5

8 2
15
33
40
Component details:
1. Material: Brass 2.0mm
2. Scrap value for scrap bridge and side scrap: 3.5mm
3. Shear strength: 22Kg/mm2
Exercise No: 4
1. Design an economical strip lay-out.
2. Calculate the Utilization factor.
3. Calculate number of components per strip length of 1200mm.
4. Calculate number of components per sheet of size: 4 Feet x 8 Feet
5. What is the sequence of press operations involved in this component?
6. Which type of Press tool, you recommend to produce this component? Justify
your answer.
7. Calculate the Cutting clearance per side using all the 3 methods.
8. Derive the dimensions of Punch & Die for both Piercing & Blanking.
9. Determine the required Shear force.

R2(Typ)
Ø6(3-Holes)
40

15

24
30

12

10

8 8 3
15
20
30
40
Component details:
1. Material: Brass 3.0mm
2. Scrap value for scrap bridge and side scrap: 4.5mm
3. Shear strength: 28Kg/mm2
Exercise No: 5
1. Design an economical strip lay-out.
2. Calculate the Utilization factor.
3. Calculate number of components per strip length of 1200mm.
4. Calculate number of components per sheet of size: 4 Feet x 8 Feet
5. What is the sequence of press operations involved in this component?
6. Which type of Press tool, you recommend to produce this component? Justify
your answer.
7. Calculate the Cutting clearance per side using all the 3 methods.
8. Derive the dimensions of Punch & Die for both Piercing & Blanking.
9. Determine the required Shear force.

12 28 R15(Typ)
R3(Typ)
15
5

12
40

Component details:
1. Material: Aluminum alloy, 1.75mm
2. Scrap value for scrap bridge and side scrap: 3.5mm
3. Shear strength: 19Kg/mm2
Exercise No: 6
1. Design an economical strip lay-out.
2. Calculate the Utilization factor.
3. Calculate number of components per strip length of 1200mm.
4. Calculate number of components per sheet of size: 4 Feet x 8 Feet
5. What is the sequence of press operations involved in this component?
6. Which type of Press tool, you recommend to produce this component? Justify
your answer.
7. Calculate the Cutting clearance per side using all the 3 methods.
8. Derive the dimensions of Punch & Die for both Piercing & Blanking.
9. Determine the required Shear force.

10
Ø2(6-Holes) R2(Typ)

31
18

21
15

6 17
27
9
39
45
Component details:
1. Material: Steel 0.5%C, 1.25mm
2. Scrap value for scrap bridge and side scrap: 2.0mm
3. Shear strength: 56Kg/mm2
Exercise No: 7
1. Design an economical strip lay-out.
2. Calculate the Utilization factor.
3. Calculate number of components per strip length of 1200mm.
4. Calculate number of components per sheet of size: 4 Feet x 8 Feet
5. What is the sequence of press operations involved in this component?
6. Which type of Press tool, you recommend to produce this component? Justify
your answer.
7. Calculate the Cutting clearance per side using all the 3 methods.
8. Derive the dimensions of Punch & Die for both Piercing & Blanking.
9. Determine the required Shear force.

Ø4(2-Holes) R4(Typ)

R20(Typ)
Ø20
5
60
55

55
33
30

27
5

5
27
30
33
Component details:
1. Material: Steel 0.3%C, 1.8mm
2. Scrap value for scrap bridge and side scrap: 2.75mm
3. Shear strength: 42Kg/mm2
Exercise No: 8
1. Design an economical strip lay-out.
2. Calculate the Utilization factor.
3. Calculate number of components per strip length of 1200mm.
4. Calculate number of components per sheet of size: 4 Feet x 8 Feet
5. What is the sequence of press operations involved in this component?
6. Which type of Press tool, you recommend to produce this component? Justify
your answer.
7. Calculate the Cutting clearance per side using all the 3 methods.
8. Derive the dimensions of Punch & Die for both Piercing & Blanking.
9. Determine the required Shear force.

56
46
R5(Typ) 26 Ø2(4-Holes)

Ø5(3-Holes)
36
R3(Typ) 46
36

56
51

6 R5(Typ)
28
31

5
28
51
62
Component details:
1. Material: Phosphor bronze 1.5mm
2. Scrap value for scrap bridge and side scrap: 2.75mm
3. Shear strength: 52Kg/mm2
Exercise No: 9
1. Design an economical strip lay-out.
2. Calculate the Utilization factor.
3. Calculate number of components per strip length of 1200mm.
4. Calculate number of components per sheet of size: 4 Feet x 8 Feet
5. What is the sequence of press operations involved in this component?
6. Which type of Press tool, you recommend to produce this component? Justify
your answer.
7. Calculate the Cutting clearance per side using all the 3 methods.
8. Derive the dimensions of Punch & Die for both Piercing & Blanking.
9. Determine the required Shear force.

R5(Typ)
R5(Typ) 30
Ø3(7-Holes)

R5
R10
30

20
38
24

19
29
33
38
Component details:
1. Material: Copper 0.5mm
2. Scrap value for scrap bridge and side scrap: 1.25mm
3. Shear strength: 28Kg/mm2
Exercise No: 10
1. Design an economical strip lay-out.
2. Calculate the Utilization factor.
3. Calculate number of components per strip length of 1200mm.
4. Calculate number of components per sheet of size: 4 Feet x 8 Feet
5. What is the sequence of press operations involved in this component?
6. Which type of Press tool, you recommend to produce this component? Justify
your answer.
7. Calculate the Cutting clearance per side using all the 3 methods.
8. Derive the dimensions of Punch & Die for both Piercing & Blanking.
9. Determine the required Shear force.

4SLOTS, EQUI-SPACED
8 Ø42 Ø4(4-Holes)

Ø40 Ø4(4-Holes)
Ø25PCD
26 9
45
°

4
60
55

6
1

Ø15
6
5

8SLOTS, EQUI-SPACED
5
55
60

Component details:
1. Material: Silicon Steel 0.5mm
2. Scrap value for scrap bridge and side scrap: 1.25mm
3. Shear strength: 36Kg/mm2