Introduction To

PRESS TOOLS
 INTRODUCTION :
The word tooling refers to the hardware necessary to
produce a particular product. The most common classification
of tooling are as follows :

1. Sheet metal press working tools.

2. Molds and tools for plastic molding and die casting.
3. Forging tools for hot and cold forging.
4. Jigs and fixtures for guiding the tool and holding the work piece.
5. Gauges and measuring instruments.
6. Cutting tools such as drills, reamers, milling cutters broaches, taps, etc.
 PRESS TOOLS

Press tools are special tools custom built to produce a component

mainly out of sheet metal. Press tool is of stampings include cutting
operations like (shearing, blanking, piercing, etc.) and forming operations
(bending, drawing, etc.)

Sheet metal items such as automobile parts (roofs, fenders, caps, etc.),
components of air crafts parts of business machines, household appliances, sheet
metal parts of electronic equipments Precision parts required for horlogical
industry etc, are manufacture by press tools.
PRESS TOOLS & OPERATIONS
Blanking:
Blanking is a process of
producing flat stampings.

The entire periphery is cut

and cut out piece is called the blank.
Piercing:
It is the operation of making hole in the
stamping. Here also the entire periphery is
cut and cut piece is waste.
Cut-off:
Cut off operation separates the
work material along a straight line
or angular or irregular in a single
cut. No scrap is produced in cutting
off operation.
Parting off:
Parting off is an operation which involves cutoff
operation to produce blank from the strip as
shown in the figure. During parting, some scrape
is produced. There fore, parting is the next best
method for cutting blanks.
Perforating:

If more number of holes are

pierced, it is called perforating.
Side cam tool :
Side cam transforms vertical motion
from the press ram into horizontal or
angular motion in the tool.
Dinking:
To cut paper, leather, cloth, rubber
and other soft materials a dinking tool
is used. The cutting edges penetrate
the material and cuts. The die will be
usually a plane material like wood or
hard rubber.
Trimming:
It is the operation of cutting the
edges of the drawn components which
are wavy and irregular. The term
trimming is also used when the
material of a strip or the portion of a
blanked component or a portion of a
pierced hole is partially removed.
Shaving:
It is an operation of removing a
small amount of material a around the
edges of a previously blanked
stampings or pierced hole to get a
good finish on the cut edges and
accurate dimensions with min. radius
at the edge of the component.
Broaching:
It is similar to shaving operation. In
this a tool having a
series of teeth profile removes metal
from the edges of the
blanked component in a progressive
way.
Lancing:
It is a combination of cutting and
bending operation along a line in the
work material.
Bending:

It is the shaping of material around a

straight axis which extends completely
across the material. The result is a plane
surface at an angle to the original plane of
the flat blanked component.
Forming:
It is similar to bending except that
the line of bend is along a curved axis
instead of a straight one.
Drawing:
In drawing a flat blank is
transformed into a cup or shell.
Shell or cup produced may
be cylindrical or rectangular with
straight or tapered sides.
Curling:
It is an operation of rolling
the edges of a sheet metal into a curl
or roll. It improves the appearance of
the piece part. It is also increase
strength.
Bulging:

It is an internal forming
operation used to expand portions
of a drawn shell or tube.
The more common media
are rubber, urethane, oil, or water
Swaging:

The operation of swaging some

times called necking is exactly the
opposite of bulging.
Extrusion:

This is a special process to manufacture

collapsible tubes, shells etc. The blank which is
loaded in the die, is forged upward or downward
under high pressure between punch and die.
Coining:
It is the process of
pressing cold material in a tool
so that it flows into the
engraved profiles on the die
face.
Assembly tool:
Assembly tool assemble two or more
parts together by press fittings ,riveting or
other means.
Flaring, lugging or collar drawing:
The process of forming an outward flange
on parts is called flaring operation.
Planishing:
Planishing tool is used to straighten, blanked
components. Very fine serration points penetrate
all around the surface of the component.
Progressive tool :

progressive tool are those in

which progressive tools perform work
at a number of stations simultaneously.
A final component is taken off at final
station, with each stroke of press.
Compound tool :

In compound tool all or

maximum features of the component
can be produced in one stroke of the
ram. Basically compound tools are
inverted tool. Used to maintain high
accuracy between the features and
to get burr on same side.
Combination tool :

In combination tool two or more

operations such as forming, drawing,
extruding, embossing may be
combined on the component with
various cutting operations like blanking,
piercing, broaching and cut off.
Sub press tool:

Sub press tools blank and form

very small parts. the die components are
retained in a sub press. Sub press is a
small press which is operated in large
one.
INTRODUCTION

TO

TOOLING
 Introduction

The word tooling refers to the hardware

necessary to produce a particular product.
The most common classification of types of
tooling are as follows:

1. Sheet metal press working tools.

2. Moulds and tools for plastic molding

and die-casting.
 3. Forging tools for hot and cold forging.

4. Jigs and fixtures for guiding the tool
and holding the work piece.

5. Gauges and measuring instruments.

 6. Cutting tools such as drills, reamers,

milling cutters, broaches, taps,
etc.
• The toolmaker manufactures the above
items from the design supplied to him.

• On gaining experience the toolmaker

will be able to design and manufacture
simple tools.
 Press tools:
Press tools are special tools custom built to
produce a component mainly out of sheet
metal.
 Sheet metal processing using
press tools

 The principle operations of sheet stampings include

cutting operations (shearing, blanking, piercing,
etc.) and forming operations (bending, drawing,
etc.).

 Sheet metal items such as automobile parts

(roofs, fenders, caps etc.), components of aircraft,
parts of business machines, household appliances,
sheet metal parts of electronic equipments,
precision parts required for homological industry
etc., are manufactured by press tools.
 What Is a Stamping Die?
• A stamping die is a special, one-of-a-kind
precision tool that cuts and forms sheet metal
into a desired shape or profile.
• The die's cutting and forming sections
typically are made from special types of
hardenable steel called tool steel.
• Dies also can contain cutting and forming
sections made from carbide or various other
hard, wear-resistant materials.
• Stamping is a cold-forming operation,
which means that no heat is introduced
into the die or the sheet material
intentionally.
• However, because heat is generated
from friction during the cutting and
forming process, stamped parts often
exit the dies very hot.
• Dies range in size from those used to
make microelectronics, which can fit in
the palm of your hand, to those that are
20 ft. square and 10 ft. thick that are
used to make entire automobile body
sides.
• Piece part produced in stamping die
The part a stamping operation produces
is called a piece part .
• Certain dies can make more than one
piece part per cycle and can cycle as
fast as 1,500 cycles (strokes) per
minute.
• Force from a press enables the die to
perform.
 TYPES OF PRESS TOOLS /
OPERATIONS.

• 01. BLANKING

• 02. PIERCING

• 03. CUTTING OFF

• 04. PARTING OFF

• 05. PERFORATING
• 06. PROGRESSIVE TOOL

• 07. COMPOUND TOOL

• 08. TRIMMING

• 09. NOTCHING

• 10. SHAVING

• 11. LANCING
• 12. DINKING

• 13. SIDE CAM TOOL

• 14. BROACHING

• 15. PLANISHING

• 16. EMBOSSING
• 17. COINING

• 18. EXTRUSION

• 19. BENDING

• 20. FORMING

• 21. DRAWING
 22. FLARING / LUGGING

 23. CURLING

 24. COMBINATION TOOL

 25. SUB PRESS TOOL

 26. ASSEMBLY TOOL

 26. BULGING

 27. SWAGING
 BLANKING
 Blanking is a process producing flat stampings.
 The entire periphery is cut and the cut-out piece is
called blank or stamping.
 The tool used is called as blanking tool.
 A dual-purpose cutting operation usually
performed on a larger scale, blanking is used in
operations in which the slug is saved for further
press working.
 It also is used to cut finished piece parts free from
the sheet metal.
 The profiled sheet metal slug removed from the
sheet by this process is called the blank, or
starting piece of sheet metal that will be cut or
formed later .
BLANKING

BLANK / COMPONENT
BLANKING
 PIERCING
• Piercing is a process of making hole
in the stamping.
• Here also the entire periphery is
cutout and the cutout piece (slug) is
a waste.
• The tool used is called piercing tool.

• Often called perforating, piercing is a

metal cutting operation that produces a
round, square, or special-shaped hole in
flat sheet metal or a formed part.
 PIERCING
• The main difference between piercing
and blanking is that in blanking, the slug
is used, and in piercing the slug is
discarded as scrap.
• The cutting punch that produces the
hole is called the pierce punch, and the
hole the punch enters is called the
matrix
PIERCING

PIERCED

SLUG
PIERCING
 CUTTING OFF
• A cut off operation separates the
work material along a straight line in
a single cut line.
• No scrap is produced in cutting off
operation.
• The process of cutting off is similar
to shearing in a shearing Machine.
CUTTING OFF

CUTTING OFF
CUTTING OFF
 PARTING OFF

•
The parting off operation separates the
work material along a straight line in a
double line cut.
• The piece removed by the punch is
scrap.
PARTING OFF
PARTING OFF
PARTING OFF
 PERFORATING

• If more number of holes are pierced, it is

called perforating.
• The process is of series of holes in a given
blank or work piece.
PERFORATING

PERFORATING
 PROGRESSIVE TOOL
• Progressive tools perform two or more
operations at different stages every time the
press ram descends.
• The stock strip is advanced through a series
of stations that performs one or more distinct
press working operations on the work piece.
• The strip must move from the first station
through each succeeding station to produce a
complete work piece.
PROGRESSIVE TOOL

PROGRESSIVE
PROGRESSIVE TOOL
 COMPOUND TOOL
• Two or more cutting operations are
performed in the same single station
and completed during the same single
press cycle.
• Typically piercing and blanking.
• The action of the piercing punch– die
functions must be directionally opposed
to the action of the blanking punch – die
functions.
COMPOUND TOOL

TWO OPERATI0NS
COMPOUND TOOL
 TRIMMING

• Trimming is an operation of removing the

excess metal which remains after a deep
drawing operation which imparts a certain
shape to the side of the strip or a
component.
The outer perimeter of the formed part or flat
sheet metal is cut away to give the piece part
the desired profile.
• The excess material usually is discarded as
scrap
 TRIMMING

TRIMMING

TRIMMED
TRIMMING
 NOTCHING
• This operation removes a small amount of
material from the edges of the strip or a
blank.
• Notching serves to shape the outer
contours of the work piece in a progressive
tool or to remove excess metal before a
drawing or forming operation in a
progressive tool.
• Notching Usually associated with
progressive dies, notching is a process in
which a cutting operation is performed
progressively on the outside of a sheet
metal strip to create a given strip profile.
NOTCHING
NOTCHING
 SHAVING

• Shaving operation is a finishing operation.

• A very small amount of material is removed
around the edge of the blank or pierced hole
• . Its objective is to obtain a straight smooth
side wall.
• The excess metal is removed as a chip
similar to the action of a metal cutting tool.
SHAVING

SHAVING OF A HOLES.
 LANCING

• This is a continuous bending and

cutting operation along a line in the
work material.
No metal is cut free during the lancing
operation.
LANCING

LANCING
 DINKING
• To cut paper, leather, cloth, rubber and
other soft materials a dinking tool is used.
• The cutting edges penetrate the material
and cut it. (Like knives.)
• The dinking punch digs into the base
plate.
• The base plate is made of wood, fiber or
hard rubber.
• The dinking tool can be used to cut inner
and outer shapes of components.
DINKING
 SIDE CAM TOOL
• Side earns transform vertical motion from the
press ram into horizontal or angular motion in
the tool.
• With a side cam tool, theSIDE CAM TOOL
• Vertical motion of the press ram is
converted into horizontal or angular
motion of the punch.
• For Example, it can be observed from the
sketch that holes required to be
punched on the vertical side periphery of
component is done by a side cam tool.
SIDE CAM TOOL

SIDE HOLE
 BROACHING

Broaching may be considered as a series of

shearing operation performed one after
the other by the same tool.
A broach is provided with a number of teeth
each of which cuts a chip as the broach
traverses the surface to be finished.
 BROACHING

• Broaching is preferred1.
• When the blanks are too thick for
shaving2.
• When considerable metal must be
removed.
BROACHING

BROACHING
 PLANISHING

• Planishing tool is used to straighten

blanked components.
• Very fine serration points penetrate allover
the surface of the component in order to
release stress and straighten the
component.
PLANISHING

PLANISHING
 EMBOSSING
• The embossing tool is used to press
letters and numbers in to a sheet metal
or no pressed piece part.
• Usually the punch will have the raised
form and the die will have the
corresponding cavity.
EMBOSSING

EMBOSSING
 COINING

• Coining is the process of pressing cold

material in a tool so that it flows into the
engraved profiles on the die face.
• Coining differs from embossing such that
in coining the metal flows where as in
embossing, the metal does not change in
thickness to a great extent.
COINING

COINING
 EXTRUSION

• This is a special process to manufacture

collapsible tubes, shells etc.
• The blank is loaded in the die and forged
upward or downward under high pressure
between the punch and die.
EXTRUSION
 BENDING

• Bending is shaping the material around a

straight axis which extends completely
across the material.
• Metal flow is uniform along the bend axis.
BENDING

BENDING
 FORMING

• Forming is similar to bending except that

the line of bend is along a curved axis
instead of a straight one.
• Metal flow is not uniform.
• It will be localized depending upon the
shape of the work piece
FORMING
 DRAWING

• In drawing, a flat blank is transformed into

a cup or shell.
• The parent metal is subjected to severe
plastic deformation.
DRAWING
 FLARING / LUGGING

• The process of forming an outward

flange on parts is called flaring
operation.
FLARING / LUGGING

FLARING
 CURLING
• Curling is an operation of rolling the
edges of a sheet metal into a curl or
roll.
• The purpose is to strengthen and
provide a protective edge.
• It also improves the appearance of
the part.
CURLING

CURLING
 COMBINATION TOOL
• In combination tools two or more
operations such as forming, drawing,
extruding, embossing etc may be
combined with each other or with
various cutting operations such as
blanking, piercing, broaching and cut
off.
COMBINATION TOOL
 SUB PRESS TOOL
• Sub press tools blank and form very
small parts.
• The die components are retained in a
sub press.
• The sub press is a small press
operated in a larger one.
SUB PRESS TOOL
 Assembly tool
• Assembly tool is used to assemble
two or more parts together by press
fittings, riveting or other means.

• Components are assembled in very

short time and the relationship
between parts can be maintained
closely.
Assembly tool
 BULGING
• Bulging is an internal forming operation
used to expand portions of a drawn
shell or tube.
• The forming force is applied from inside
the work piece and is transmitted
through a medium that will flow but will
not get compressed.
• The more common media are rubber,
urethane, oil or water.
BULGING
 SWAGING
• Swaging or necking is opposite to
bulging.
When a work piece is swaged a
portion is reduced in size and this
causes the part to become longer
than it was before swaging.
SWAGING
 PRESS TOOLS
THEORY OF SHEARING
• Shearing is the method of cutting sheets or strips without forming chips.
• The material is stressed in a section which lies parallel to the forces
applied.
• The forces are applied by means of shearing blades or punch and die.

Critical stages in shearing

Plastic deformation.
Penetration.
Fracture.
1. Plastic deformation:

The pressure applied by the punch on

the stock material tends to deform it into
the die opening when the elastic limit is
exceeded by further loading, a portion of
the material will be forced into the die
opening in the form of an embossed on the
lower face of the material and will result in a
corresponding depression on its upper face.
This stage imparts a radius on the lower
edge of the punched out material.
This is called the stage of “plastic
deformation”.
2. Penetration stage:
As the load is further
increased, the punch will penetrate
the material to a certain depth and
force an equally thick portion of metal
into the die. This stage imparts a
bright polished finish on both the
strip and the blank or slug. This is
“penetration stage”.
3. Fracture stage:
In this stage, fracture will
starts from both upper and lower
cutting edges. As the punch
travels further, these fractures will
extend towards each other and
eventually meet, causing complete
separation. This stage imparts a
dull fractured edge. This is the
“fracture stage”.
SHEARING THEORY.

• Shearing is the method of cutting sheets or strips without

forming chips.
• The material is stressed in a section which lies parallel to the
forces applied.
• The forces are applied by means of shearing blades or punch
and die.
 The forces necessary to bring rupture of the material depends
primarily upon the shearing strength (tmax) and the stressed
section or the stressed area and secondly upon the shape,
condition and position of the shear blades.
Critical stages in shearing
(STEPS IN SHEARING MATEL)

Stage 1 : Plastic deformation.

•Stage 2: Penetration.

•Stage 3: Fracture
SHEARING THEORY.
Critical stages in
shearing
• Stage 1 :
Plastic deformation.
• The force
applied by the punch
on the stock-material
tends to deform it into
the die opening.

•When the elastic limit is exceeded by further application of

force the material is forced into the die opening in the form
of an embossed pad on the lower face of the material.
SHEARING THEORY.
•A corresponding
depression is formed
on the upper face.

• This stage
imparts a radius on
the upper edge of the
opening in the strip
and on the lower
edge of the punched
out material. (which
may be blank or slug)
 SHEARING THEORY
Stage 2: Penetration.

• As the load is further

increased, the punch will
penetrate the
material to a certain
depth.
• An equally thick
portion of the metal is
forced into the dies.
•This imparts a bright polished finish (cut band) on both the
strip and the blank or the slug.
•On optimum cutting conditions the cut band will be 1/3rd the
sheet thickness.
 SHEARING THEORY
Stage 3:
Fracture
• In this stage,
fracture starts from
both upper and lower
cutting edges.

•As the punch travels further, these fractures will extend

towards each other and meet to cause complete separation.
• This stage imparts a dull fractured edge.
STRESSES IN SHEARING
PUNCH PENETRATION INTO AND FRACTURE
OF METAL
CUT EDGE CHARACTERISTICS

BURR
 PRESS TOOLS
CUTTING FORCE
CUTTING FORCE:
“Cutting force is the force applied on the stock material in order to cut out
the blank or slug”. This determines the capacity of the press to be used for
particular tool. The area to be cut is found by multiplying the length of cut by
stock thickness.
Formula for calculating the cutting force:
Cutting force = L x S x T max
L = Length of periphery to be cut in ‘mm’.
S = Sheet thickness in ‘mm’
T max = Shear strength in N/mm2
Shear and tensile strengths for most materials are not the same.

Generally for calculation purposes Shear strength is considered

as 80% of tensile strength.
 The fig. Represents the typical load curve of cutting force
of blanking or piercing punch.
Formula to calculate the press force :
Press force = Cutting force + stripping force
(striping force = 10% - 20% of cutting force)
The following table gives the shear strength (T max = 0.2 for tensile strength σ
max ) of several materials.

MATERIAL T max in N/mm2

Steel with 0.1% carbon 240 -300
Steel with 0.2% carbon content(deep draw steel) 320 - 400
Steel with 0.3% carbon 360 - 420
Steel with 0.4% carbon 450 - 560
Steel with 0.6% carbon 550 - 700
Steel with 0.9% carbon 700 - 900
Silicon steel 450 - 550
Stainless steel 350 - 450
MATERIAL T max in N/mm2
Copper 200 – 400
Brass 350 – 400
Bronze 360 – 450
German silver(2 - 20% Ni, 45 - 75% Cu) 300 – 320
Tin 30 – 40
Zinc 100 – 120
Lead 20 – 30
Alluminium 99% pure 20 – 120
Alluminium manganese alloy 150 – 320
Alluminium silicon alloy 120 – 250
Paper & card board 20 – 50
Hard board 70 – 90
Laminated paper or rosin impregnated paper 100 – 140
Laminated fabrics 90 – 120
Mica 50 – 20
Plywood 20 – 40
Leather 7
Soft rubber 7
Hard rubber 20 – 60
Celluloid 40 – 60
Example:
Calculate the press force required to produce the following component.
Sheet thickness 2mm. Material is brass.

Cutting force = L x S x T max

= 126 x 2 x 400
= 100800 N
= 100.8 KN

Press force = Cutting force +Stripping force

= 100800 + 20% 100800
= 120960 N
= 120.960 KN.
METHODS OF REDUCING THE CUTTING FORCE :

It sometimes becomes necessary to reduce the cutting force

to prevent press over loading .

1. Stepped punches to be used.

2. To grind the face of the punch or die to a small shear angle.

•In some cases it will be necessary to reduce cutting force to prevent over
loading press
• A method to reduce press force is to grind the face of the punch or die
at a small shear angle with reference to the horizontal plane.
• This reduces the area of contact during shear at anyone time.
• Providing shear angle also reduces shock to the press and smoothens out
the cutting operation.
• To prevent distortion on the stock material for blanking operation the
shear angle will be on the die member for piercing operation
the shear angle will be on the punch member.
• Another method to reduce cutting force is to step punch lengths.
• Punches or groups of punches are made progressively shorter.
by about one sheet thickness.
ASSIGNMENTS
1.0 Fill in blanks.
1.1 For calculating cutting force the ……….. Strength of the material is
considered.
1.2 Press overloading can be over come by reducing…….
1.3 Stepping punch length is done to ………. press force.
1.4 Shear angle of blanking operation is given on the……………
1.4 Shear angle for piercing is given on the ………………
2.0 Calculate the press force required to produce the following component.

MATERIAL: SILICON STEEL

THICKNESS: 1mm
T max: 500N/mm2
MATERIAL: MILD STEEL MATERIAL: CRCA MATERIAL: BRASS

THICKNESS: 3mm THICKNESS: 0.7 mm THICKNESS: 1.2 mm

T max: 360N/mm2 T max: 360N/mm2 T max: 400N/mm2

 CUTTING CLEARANCE

•Cutting clearance is
the gap between a
side of the punch
and the
corresponding side
of the die opening
when the punch is
entered into the die
opening.

•Cutting clearance should always be expressed as the amount of

clearance per side.
• Proper cutting clearance is necessary for the longer life of the
tool.
CUTTING CLEARANCE
•Quality of the piece part
also depends on proper
cutting clearance.
•A visual examination of the
punched component will
indicate the amount of
clearance and whether the
punch and die have

Optimum cutting clearance.

Excessive clearance or

In sufficient clearance or

Misalignment
 OPTIMUM CUTTING CLEARANCE

• When optimum cutting clearance condition exists a small edge

radius is formed.
• The edge radius is the result of the plastic deformation (first
stage of shearing).
 OPTIMUM CUTTING CLEARANCE

• A highly burnished cut band results from the second stage

(penetration).
• The width of the cut band is approximately one third the
thickness of the stock material.
• The balance of the cut is the break resulting from fracture
(third stage).
 EXCESSIVE CUTTING CLEARANCE

• The gap between the punch and the die is comparatively more
in this case.
• The stock material reacts to the initial pressure on a manner
approaching that of forming rather than cutting.
 EXCESSIVE CUTTING CLEARANCE

• Therefore the edge radius becomes larger.

• It does not blend smoothly with the cut band.
• The cut band becomes smaller.
• The break shows greater irregularities.
• Heavy burrs are noticeable all along the cut contour.
• The burr results from the dragging of the material
 INSUFFCIENT CUTTING CLEARANCE

• When cutting clearance is slightly less, the width of the cut

band will be more.
• If cutting clearance is too less two or more cut bands will be
formed.
 INSUFFCIENT CUTTING CLEARANCE

• Because of the steeper angle between the punch and the die
cut edges the resistance of the stock material to fracture is
increased.
• The resulting pressure will cause the initial fracture to originate
at clearance rather than at the cut edges.
• Burr may be caused by compressive forces.
 MIS AIGNMENT OF PUNCH AND DIE

• The cutting characteristics also indicate whether the punch and

die openings are in accurate alignment.
• Because of misalignment, clearance on one side increases and
the other side decreases.
• The component will show the corresponding difference on cut
band.
 BURR SIDE

• The burr side is adjacent to the break. Burr should be

practically nonexistent
If the cutting clearance between the punch and die is optimum.
If the cutting edges are sharp.
• The burr side of a blank or slug is always towards the punch
(die starts shearing).
• The burr side of a punched opening is always towards the die
opening (punch starts shearing).
• The characteristics of the blank or slug and the punched
opening are inversely identical.
 RELATIONSHIP OF PIECE PART SIZE
TO PUNCH AND DIE SIZE

• When pierced or blanked piece parts are measured,

the measurement is made at the cut band.
 BLANKING

• The actual cutting of the blank or slug is done by the cutting

edge of the die opening.
• Therefore the die opening determines the size of the blank or
slug.

BLANKING PUNCH SIZE = BLANK SIZE - TOTAL CLEARANCE.

BLANKING DIE SIZE = BLANK SIZE

 PIERCING

• The actual cutting of the opening in the stock material is done by

punch.
• Therefore the size of a punched opening is determined by the
punch.

PIERCING PUNCH SIZE = PIERCED HOLE SIZE

PIERCING DIE SIZE = PIERCED HOLE SIZE + TOTAL CLEAR

 CUTTING CLEARANCE

Clearance calculation.
The ideal clearance can be calculated by the following formula

Clearance = C x s x √ T max
10

Where C is a constant
= 0.005 for very accurate component
= 0.01 for normal components
s = sheet thickness in mm
T max = shear strength of the stock material in N/mm2.
WORKED OUT EXAMPLE -2
WORKED OUT EXAMPLE -2
WORKED OUT EXAMPLE -2
WORKED OUT EXAMPLE -2
WORKED OUT EXAMPLE -3
WORKED OUT EXAMPLE -3
 WORKED OUT EXAMPLE -3

• BLANKING DIE DIMENSION IS SAME AS COMPONENT

DIMENSION.
• PIERCING PUNCH DIMENSION IS SAME AS THE PIERCED
OPENING DIMENSION.
WORKED OUT EXAMPLE -4
WORKED OUT EXAMPLE -4
 WORKED OUT EXAMPLE -4

• BLANKING DIE DIMENSION IS SAME AS COMPONENT

DIMENSION.

• PIERCING PUNCH DIMENSION IS SAME AS THE PIERCED

OPENING SIZE.
 Land
The inner walls of the die opening are not usually
made straight through.
• If they are straight, the blanks or slugs tend to get
jammed inside the die opening.
• This may lead to the breakage of punch or die.
• To avoid this, the die walls are kept straight only
to a certain dimension from the cutting edge.
• The straight wall is called as land.
LAND = 3mm for sheet thickness up to 3mm and
for thicker material equal to the sheet thickness.
LAND AND ANGULAR CLEARANCE
LAND
ANGULAR CLEARANCE
 ANGULAR CLEARANCE

• The die walls below the land are relieved at an angle for the
purpose of enabling blanks or slugs to clear the die.
• Soft material requires greater angular clearance than hard
materials.
• The normal value of angular clearance is 1.5° per side.
• Dies for materials like silicon steel and stainless steel are
provided with angular clearance from the cutting edge. (No land
is provided).
• These materials are abrasive in nature and tend to bell-mouth
the die opening rapidly if land is provided.
 DIE WITH EJECTOR WITHOUT ANGULAR
CLEARANCE

• Tools employing ejectors to clear the blanks will have straight

walls without any angular clearance.
 CUTTING FORCE
•Cutting force is the force which has to act on the stock material
in order to cut out the blank or slug.
• This determines the capacity of the press to be used for the
particular tool.

Calculation of cutting force:

 RELATIONSHIP BETWEEN SHEARING ACTION
AND CUTTING FORCE

• The three critical stages of shearing action are related to cutting

force.
• Resistance begins when the punch contacts the stock material.
• The load builds up rapidly during the plastic deformation stage.
• It continues to increase while penetration takes place.
• The accumulated load is suddenly released when fracture
occurs.
The curve levels off near the bottom.
• The last portion of the load curve represents frictional
resistance developed,
As the punch travels through the stock material
As the blank or slug passing through the die.
• If proper cutting clearance condition exists between the punch
and the die fracture will occur when cutting force
equals the shear strength of the material.
RELATIONSHIP BETWEEN SHEARING ACTION
AND CUTTING FORCE
 METHODS OF REDUCING PRESS FORCE

• In some cases it will be necessary to reduce cutting force to

prevent over loading press

• A method to reduce press force is to grind the face of the punch

or die at a small shear angle with reference to the horizontal
plane.

• This reduces the area of contact during shear at anyone time.

• Providing shear angle also reduces shock to the press and

smoothens out the cutting operation.
 METHODS OF REDUCING PRESS FORCE

• The shear angle should provide a change in punch length from

1 to 1.5 times the sheet thickness.

• Double shear angle is preferred over single shear angle

because it does not create lateral forces.

• Double shear angled punches should be concave to prevent

stretching the material before it is cut.
 METHODS OF REDUCING PRESS FORCE

• To prevent distortion on the stock material for blanking operation

the shear angle will be on the die member for piercing operation
the shear angle will be on the punch member.

• Another method to reduce cutting force is to step punch lengths.

• Punches or groups of punches are made progressively shorter.

by about one sheet thickness.
WORKED OUT EXAMPLE -1
WORKED OUT EXAMPLE -2
WORKED OUT EXAMPLE -3
WORKED OUT EXAMPLE -4
 ASSIGNMENTS -1
CALCULATE THE PRESS FORCE RQUIIRED TO PRODUCE
THE FOLLOWING COMPONENTS
 ASSIGNMENTS -2
CALCULATE THE PRESS FORCE RQUIIRED TO PRODUCE
THE FOLLOWING COMPONENTS
 ASSIGNMENTS -3
CALCULATE THE PRESS FORCE RQUIIRED TO PRODUCE
THE FOLLOWING COMPONENTS
 ASSIGNMENTS - 4
CALCULATE THE PRESS FORCE RQUIIRED TO PRODUCE
THE FOLLOWING COMPONENTS
 PRESS TOOLS
CUTTING CLEARANCE
Cutting clearance:
Cutting clearance is the gap
between the side of the punch and the
corresponding side of the die opening on
one side of the edge, when the punch is
entered into the die opening. It is
expressed in the amount of clearance
per side.
IMPORTANCE OF CUTTING CLEARANCE
Proper cutting clearance is necessary to:

1. Aid the life of the die.

2. Increase the quality of the piece part.
3. Improve the characteristics of piece part.
4. Reduces undue stress and wear on the cutting edges
of the tool.
OPTIMUM CUTTING CLEARANCE:

Fig shows the blank or slug made under optimum cutting conditions.

The edge radius (die roll) is the result of initial plastic deformation, which
occurred during the first stage of plastic shear action.

•Highly burnished cut band results from the second stage (penetration) of shear
action.
•The width of the cut band is approximately 1/3rd of the thickness of stock material.
•The balance of the cut is the break, which results from the third stage
(fracture) of the shearing action.
 EXCESSIVE CUTTING CLAERANCE:

In this the large gap between the punch and die cutting edges allows the
stock material to react to the initial pressure on a manner approaching that of
forming rather than cutting. Therefore the edge radius becomes larger and the
cut band becomes smaller.
INSUFFICIENT CUTTING CLEARANCE:

When the cutting clearance is slightly less the condition can be identified by
greater width of the cut band. Because of steeper angle between the punch and
die cut edges the resistance of the stock material to fracture is increased. In case
of excessive clearance the burr results from dragging of the material. While
insufficient clearance compressive forces cause the burr.
 BURR SIDE:

The burr side is the adjacent to the break. The burr side is also called
because of a noticeable burr developed in this side. Burr should be practically
very little if the cutting clearance between the punch and die is correct and if the
cutting edges are sharp.

The burr side of the blank or slug is always towards the punch (die starts
shearing) the burr side of the punched opening is always towards the die opening.
DETERMINATION OF PUNCH AND DIE SIZE:
For Piercing:
Pierced hole size =Piercing punch size
Die = Hole size + 2 clearance.

For Blanking:
Blanking punch = Blanking size – 2 clearance.
Blanking size = Die size

For finding the cutting clearance following formula to be used.

Clearance = c X s X

 for above 3 mm clearance =

(1.5x s) x (s-0.015) x
Where

s = sheet thickness in mm
c = constant= 0.005
T max = shear strength = 80% Ultimate tensile strength in N/mm2

If we take c as 0.005 we get a Clarence which yields a better and

cleanest work piece but required a higher cutting force and considerably more
energy. If we take c as 0.01 cutting force energy as its minimum but finish will be
bad. The usual practice however is to take c as 0.01
Applying Clearance

Given diagram illustrates how to

apply clearance to obtain correct size of
hole and blank.

When the metal is punched out

from the functional part and the metal
around the opening is scrap, the die is
made to desired part size and the
clearance is subtracted from (applied to)
the punch size as shown in figure A.

when the slug is discarded and the

punched opening is functional, the required
clearance is applied (added to) the die
opening as shown in figure B.
PROBLEMS:
1. Calculating the clearance for punching a 2mm sheet. Tmax
to be assumed to be 300 N/mm2.

Clearance = c X s X

= 0.01 X 2 X

= 0.02 X

= 0.12 mm/side

Therefore clearance on one side = 0.12 mm

2. Determine the punch and die dimension for the component Given below. Sheet
thickness 0.5mm, stainless steel sheet, T max is 400 N/mm2. C = 0.01

Clearance = c X s X
= 0.01 X 0.5 X
= 0.03 mm/side
Blanking punch:
 Blanking die dimension is the same as that of component dimension.
 Piercing punch size is the size of the pierced hole.

Piercing Die:
Determine the punch and die dimension for the component Given below. Sheet
thickness 2mm MS,T max is 400N/mm2 C=0.01.
Clearance = c X s X
= 0.01 X 2.0 X
= 0.13 mm/side
 Blanking die dimension is the same as that of component dimensions.
 Piercing punch size is same as component size.

Piercing Die size = component size + clearance

= 10.00 + 0.26
= 10.26mm
ASSIGNMENTS
1.0 What will be the characteristics of the component.
1.1 When the cutting clearance is optimum.
1.2 When the cutting clearance is excessive.
1.3 When cutting clearance is in sufficient.

2.0 Fill in the blanks :

2.1 The burr side of a blank is towards the ……….. side.
2.2 The burr side of a slug is towards the ………… side.
2.3 The burr side of a punched opening is towards the ………side.
2.4 Blanking punch size is ……………
2.5 Blanking die size is ……………
2.6 Piercing punch size is ……………
2.7 Piercing die size is ……………
 3.0 Determine the punch and die size to produce the following components.
1. Material : Copper
Thickness : 2mm 2. Material : Brass
Thickness : 1mm
Tmax : 350 N/mm²
Tmax : 350 N/mm²

3. Material : Aluminium
Thickness : 0.3mm 4. Material : M S
Tmax : 350 N/mm² Thickness : 1.5mm
Tmax : 400 N/mm²
 Land
The inner walls of the die opening are not usually
made straight through.
• If they are straight, the blanks or slugs tend to get
jammed inside the die opening.
• This may lead to the breakage of punch or die.
• To avoid this, the die walls are kept straight only
to a certain dimension from the cutting edge.
• The straight wall is called as land.
LAND = 3mm for sheet thickness up to 3mm and
for thicker material equal to the sheet thickness.
LAND AND ANGULAR CLEARANCE
LAND
ANGULAR CLEARANCE
 ANGULAR CLEARANCE

• The die walls below the land are relieved at an angle for the
purpose of enabling blanks or slugs to clear the die.
• Soft material requires greater angular clearance than hard
materials.
• The normal value of angular clearance is 1.5° per side.
• Dies for materials like silicon steel and stainless steel are
provided with angular clearance from the cutting edge. (No land
is provided).
• These materials are abrasive in nature and tend to bell-mouth
the die opening rapidly if land is provided.
 DIE WITH EJECTOR WITHOUT ANGULAR
CLEARANCE

• Tools employing ejectors to clear the blanks will have straight

walls without any angular clearance.
Land And Angular
CLEARANCE
LAND:

The inner walls of a die opening

are not usually made straight
through as the blanks or slugs tend
to get jammed inside, which may
result undue stress build up.This may
lead to the breakage of the punch and
die.
To avoid such situation the die
walls are kept straight only to a
certain amount from the cutting edge.
The straight wall is called
“ LAND”.
 An amount of 3mm land for stock thickness up to 3mm.
 For thicker materials equal to their sheet thickness.
ANGULAR CLEARANCE
OR ANGULAR RELIEF:

Generally,soft materials require

greater angular clearance than hard
materials. Soft thicker materials above
3mm require more angular clearance.
An angular Clearance of 1.5°per
side will meet the usual requirements.
 In special cases, the angular clearance extends from top to bottom of the
die wall completely eliminating the land.
 Dies employing an ejector to clear the blanks will have straight walls without
any angular clearance, as the blanks
do not get accumulated in the die.
ASSIGNMENTS
1. Show diagrammatically what is land.
2. Land = ……………. mm for sheet thickness up to 3mm,
for thicker materials land = …………………………
3. Show diagrammatically angular clearance.
4. What is the normal value of angular clearance.
5. Draw the sectional front view of a die used to blank silicon steel, stainless
steel etc.
 CUTTING FORCE
•Cutting force is the force which has to act on the stock material
in order to cut out the blank or slug.
• This determines the capacity of the press to be used for the
particular tool.

Calculation of cutting force:

 RELATIONSHIP BETWEEN SHEARING ACTION
AND CUTTING FORCE

• The three critical stages of shearing action are related to cutting

force.
• Resistance begins when the punch contacts the stock material.
• The load builds up rapidly during the plastic deformation stage.
• It continues to increase while penetration takes place.
• The accumulated load is suddenly released when fracture
occurs.
The curve levels off near the bottom.
• The last portion of the load curve represents frictional
resistance developed,
As the punch travels through the stock material
As the blank or slug passing through the die.
• If proper cutting clearance condition exists between the punch
and the die fracture will occur when cutting force
equals the shear strength of the material.
RELATIONSHIP BETWEEN SHEARING ACTION
AND CUTTING FORCE
 METHODS OF REDUCING PRESS FORCE

• In some cases it will be necessary to reduce cutting force to

prevent over loading press

• A method to reduce press force is to grind the face of the punch

or die at a small shear angle with reference to the horizontal
plane.

• This reduces the area of contact during shear at anyone time.

• Providing shear angle also reduces shock to the press and

smoothens out the cutting operation.
 METHODS OF REDUCING PRESS FORCE

• The shear angle should provide a change in punch length from

1 to 1.5 times the sheet thickness.

• Double shear angle is preferred over single shear angle

because it does not create lateral forces.

• Double shear angled punches should be concave to prevent

stretching the material before it is cut.
 METHODS OF REDUCING PRESS FORCE

• To prevent distortion on the stock material for blanking operation

the shear angle will be on the die member for piercing operation
the shear angle will be on the punch member.

• Another method to reduce cutting force is to step punch lengths.

• Punches or groups of punches are made progressively shorter.

by about one sheet thickness.
WORKED OUT EXAMPLE -1
WORKED OUT EXAMPLE -2
WORKED OUT EXAMPLE -3
WORKED OUT EXAMPLE -4
 ASSIGNMENTS -1
CALCULATE THE PRESS FORCE RQUIIRED TO PRODUCE
THE FOLLOWING COMPONENTS
 ASSIGNMENTS -2
CALCULATE THE PRESS FORCE RQUIIRED TO PRODUCE
THE FOLLOWING COMPONENTS
 ASSIGNMENTS -3
CALCULATE THE PRESS FORCE RQUIIRED TO PRODUCE
THE FOLLOWING COMPONENTS
 ASSIGNMENTS - 4
CALCULATE THE PRESS FORCE RQUIIRED TO PRODUCE
THE FOLLOWING COMPONENTS
 Press Tools
Different sheet forming tools.
 GUIDE PLATE TOOL
Guide plate tool
Simplest among press tool.
Preferred :
• When component shape is
simple.
• Accuracy is less.
• Fewer components are
required.

Guide plate tool is categorized in to two types

1. Open guide plate tool

2. Stripper guide plate tool
 GUIDE PLATE TOOL
Elements of a Guide Plate Tool

• Top plate.
• Bottom plate.
• Die.
• Punch.
• Punch Holder.
• Thrust plate ( Back plate ).
• Stripper or guide plate.
 GUIDE PLATE TOOL
Elements of a Guide Plate Tool

SHANK

TOP PLATE
THRUST PLATE
PUNCH HOLDER
PUNCH
BOX STRIPPER
DIE PLATE

BOTTOM PLATE
 GUIDE PLATE TOOL
Punch and Die

• These are the basic

elements of Blanking tool.
• Made out of good quality
alloy steel.
• Hardened and tempered
to 58-62HRC.
 GUIDE PLATE TOOL
Stripper

• The plate which does not allow

the strip to go along with the
punch.
• Stock strip is guided and fed in
line with the profile, thus
maintaining scrap equally.
• It aligns punch with the die in
case the stripper also functions
as a guide plate.
• Made out of Mild steel , Medium
carbon steel.
• Hardened up to 45-50HRC.
 GUIDE PLATE TOOL
Thrust plate

• observes the upward

thrust of the punch.
• Prevents from digging into
the punch holder.
• Hardened up to 45-
48HRC.
 GUIDE PLATE TOOL
Top plate

Punch assembly is mounted

on this plate.
Tool shank is also screwed
into this plate.
Made out of mild steel or cast
iron.
Should be thick enough to
prevent bending.
 GUIDE PLATE TOOL
Punch holder

• Punch is fixed with a light

press fit in punch holder.
• Punch holder ensures the
position of the punch. In
case of profiled punches
fitted on the face of the
punch holder, dowels are
fixed to prevent rotation.
 GUIDE PLATE TOOL
Shank

• Locates and clamps the

tool to the press ram.
• Diameter of shank depends
upon the Dia of bore in the
press ram.
• Shanks are standardized to
suit different presses.
 GUIDE PLATE TOOL
Screws and Dowels

• Screws are used to hold the

die parts.
• Dowels are used to align
the die parts.
 GUIDE PLATE TOOL
Bottom plate

• Gives cushioning effect to

the die.
• Opening in the Base plate
allows the blank or slug to
fall clear of the tool.
• Made out of mild steel or
cast iron.
GUIDE

PLATE

TOOL
 GUIDE PLATE TOOL:

• Guide plate tool is preferred when

• 1) Shape of component is simple.

• 2) The accuracy of the component is less.

• 3) Only fewer components are required.

GUIDE PLATE TOOL
 GUIDE PLATE TOOL
The guide plate tool consists of :

Shank.
Top plate
Thrust plate (back plate).
Punch holder.
Punch.
Screws. Guide plate.
Stopper.
Dowel pin.
Die plate.
Bottom plate
IMPORTANCE

OF

GUIDE PLATE

TOOL

ELEMENTS.
 TOP PLATE:
• This plate is also
known as top
bolster or die head.
• Punch unit is rigidly
and accurately held
on this plate.
• Top plate should be
thick enough to take
the load of punch
backpressure.
• It is made out of
mild steel or cast
iron.
 BOTTOM PLATE:
• This plate is also
known as bottom
bolster or base plate
or die shoe.
• Die unit is rigidly and
accurately mounted
on this plate.
• Bottom plate should
be thick enough to
take the load of the
punching pressure or
load.
• It is made out of
mild steel or cast
 PUNCH HOLDER:
• This plate is also
called as punch plate.
• All the punches are
accurately held in this
plate.
• This plate should be
thick enough to
accommodate punch
shoulder and keep the
punches perpendicular.
• It is made out of mild
steel.
• Punch plate is made out
of single piece and a
need base it is also
made out of more than
single piece.
 PUNCH:
• This is most important
element of the tool.
• It is cutting element of the
tool.
• Punch gives the hole size
and the shape on the
component.
• This is made out of high
carbon high chromium steel
Material.
• Punches are hardened and
tempered to 58-60 HRC.
• The length of the punch in
normal condition is kept up to
60mm.
• Opposite end of the cutting
face is shouldered or tapered
 DIE PLATE:
• This is most important
element of the tool.
• This is mounted on
bottom plate.
• Die punch plate is the
cutting element of the tool
which gives the blank size
and shape.
• This is made out of high
carbon high chromium
steel material.
• It is hardened and
tempered to 60-62 HRC.
• Die plate thickness is
decided on the basis of
stock material being cut.
 BACK PLATE:
• This plate is also known
as thrust plate.
• This plate is mounted on
top of the punch holder.
• It is made out of medium
carbon steel.
• It is hardened and
tempered to 45 to 48
HRC.
• Punch heads have direct
contact with this plate,
which will prevent the
punch penetration into
top plate during punching
operation.
 SHANK:
• Shank is the important tool
element.
• This is fixed on the top plate.
• Shank is fixed in the press
ram.
• This should be strong enough
to take the total weight of the
punch unit and stripping force.
• There are different types of
shank standards.
• Selection of the shank is
based on the need base.
• It is made out of mild steel.
• The location of the shank point
is very important and different
load acting as top plate is to
 GUIDE PLATE:
• This plate is also called as
stripper plate. (Box stripper)
• In guide plate tool this element is
known as guide plate.
• This plate helps in stripping
operation.
• It not only strips the strip from the
punch but the main function of
this plate is to guide the punch
accurately with maintains the
alignment between punch and
die.
• Hence the plate is made with the
same care as die. It is mounted
on die plate.
• It is made out of mild steel.
• In some cases this guide plate is
also made out of tool steel.
• A channel is milled in the plate,
which will guide the stock strip.
• Channel width = Strip width + 0.5

• Channel depth = Sheet thickness

+
collar height
+
0.5
 STOPPER:
• The stopper is
cylindrical pin.
• The pin is mounted
in the die block.
• The function of the
stopper is to arrest
the movement of
the strip when it is
fed forward to one
pitch length.
 DOWEL PIN:
• This is a cylindrical pin
hardened and ground on
center less grinder.
• This dowel is made to m6
tolerance.
• Dowel pins keep the
alignment between the plates
and prevent it from lateral
movement.
 SCREWS:
• This is fastening element.
• Screws are used to hold
the plates together.
• The sizes of the screws
are selected on the basis
of tool size.
•
 Plate thickness

3 Cutting force
Die plate. =

• Top plate. = 1.25 to 1.5

t
• Bottom plate. = 1.5 to 1.75 t
• Punch holder . = 0.75 to 0.8 t
• Stripper (Guide) plate . = 0.75 to 1.0
t
• Thrust plate (back plate). = 6 to 12 mm
– Where t is thickness of die plate.
 PRESS TOOLS
STOCK MATERIALS
 STOCK MATERIAL
• The material out of which stampings are made is known as
STOCK MATERIALS.
• Stampings can be made from metallic or non metallic materials.
• Metallic materials include ferrous and non ferrous metals.

• Ferrous metals :
Hot rolled steels
Cold rolled steels
Stainless steels
Spring steels etc.
• Non ferrous metal :
Copper
Brass
Bronze
Aluminum
Tin
Zinc etc.
Non metallic materials :
Plastic
Rubber
Wood
Cloth
Paper etc.

STOCK STRIP.
• Stock strips are fed into the tool.
• They are advanced through the required advance distance at each
press stroke for a series of repetitive operations.
FERROUS METALS

UNIT STOCK
• Stock materials which are fed individually into the tool for processing are
called unit stock.

PIECE PART
• A piece part is a product of a tool.
• It may be a complete product in itself one component of a product.
Hot rolled steel sheets

• They are used for manufacturing where scaling and discolouration are
not objectionable.
• The surfaces are painted after operation (if required).

Pickled and oiled sheets

• Immersing hot rolled sheets in acid solutions results in smooth clean

scale free surface.
• Oiling protects the surface against rusting.
• Pickled and oiled sheets are used in the manufacture of parts for
household appliances, automobile parts. toys etc.
• The sheets can take long lasting painting due to the absence of scales.
Medium carbon steels.

• These are hot rolled carbon steels having 0.4 to 0.5% carbon.
• They are hard, tough and resistant to abrasion.

COLD ROLLED SHEETS

• They have a smooth deoxidized finish.

• This provides excellent base for paint lacquer or enamel coating.
• The thickness of the sheet is uniform.
• They are available in six grades of hardness.
 HARD.

• Hard sheets and strips cannot bend in either direction of the grain
without cracks or fracture.
• Such sheets are used for producing flat blanks that require resistance to
bending and wear.
 THREE QUARTER HARD.

• Three quarter hard strips can be bend to an angle 60" from flat only
across the grain.
 HALF HARD.

• Half hard steel strips can be bent to 90° across the grain.
 QUARTER HARD.

• This can be bent over flat (180°) across the grain and to a sharp right
angle along the grain.
 SOFT.
• Soft grades of steel can be bent over flat (180°) both across and along
the grain direction.
 DEAD SOFT.

• This grade of steel is used for severe forming and drawing operations.
DEEP DRAWING STEEL SHEETS.
• They are cold rolled low carbon steels.
• They are thoroughly annealed, deoxidized and oiled.
• Deep drawing steel sheets are used for difficult drawing, spinning and forming
operations.

SILICON STEEL.
• Silicon steel is used for electrical laminations.

STAINLESS STEEL.
• They are used where corrosion resistance is a requirement
NON FERROUS METALS.
• Copper and its alloys are widely used as a stock material.
• They are good conductors of heat, electricity and also are highly non –
corrosive.
Copper alloys include:
Beryllium copper
Red brass
Low brass
Cartridge brass
Yellow brass
Muntz metal
Phosphorus bronze.

OTHER NON FERROUS METALS USED ARE:

Aluminium and Aluminium alloys.
Magnesium and Magnesium alloys.
RARE METALS.
• Rare metals like zirconium, tantalum, vanadium, tungsten and
molybdenum and their alloys are used in press working.

PRECIOUS METALS.
• Precious alloy like that of gold, silver, platinum etc are used for
manufacturing laboratory equipment and for electrical industry.
CLAD METALS.

• It consists of a core of one metal and a covering layer of dissimilar

metal
PREPARATION OF STOCK.
• In steel mills the metal is formed into large sheets by rolling.
• The sheets are cut into strips in a shearing machine.
• Slitting machines are also used to cut the sheets.
 GUIDE

PLATE

PROGRESSIVE

TOOL.
 A simple design of blanking tool or piercing tool
is made when the piece part has no internal
details.
 When piece part is to be produced with internal
details, then altogether a different tool is to be
produced by combination of piercing and
followed by blanking operation in one tool.
 The piercing operation is performed in the first
stage.
 Stock strip is advanced equal to pitch and
stopped against final stop.
 In this stage i.e. 2nd stage blanking operation is
performed.
 Hence a piece part is produced with internal
details of piercing operation.
 When more internal details are to be
produced in the piece part, same procedure
is to be followed.
 In the first stage piercing operation is done.
 The strip is advanced equal to pitch
stopping against the finger.
 In this stage piloting operation is performed.
 In the II stage piloting operation is carried out
and with piloting some more internal detail
can be performed.
 Hence internal details performed in the II
stage is with relation to the pilot hole.
 Similarly strip can be advanced equal to
pitch stopping against auxiliary stop.
 Once again in this stage piloting can be done
and internal detail operation is performed.
 In this manner number of internal detailed
operations can be performed in different
stages.
 Finally the strip is stopped against the final
stop and blanking operation is carried out.
 In this progressive die piece part is
produced with internal details.
 In guide plate progressive tool, piece part is
produced following the above procedure.
 During the design of guide plate progressive
tool, the limitations of this tool are to be
understood and then the design is to be made.
 The limitation is also same like guide plate
tool.
 Piercing punches, pilots and blanking punch is
purely guided by the guide plate.
 The accuracy is mainly depending on the
accuracy of guide plate.
 Guide of tool elements like punches and pilots
and alignment is governed by guide plate tool.
 Hence the following factors are to be kept in
mind while deciding guide plate progressive tool.
 -When the component profile is simple.
 -When the accuracy of piece part is average
(not very accurate)
 -When production is less
 -When number of stages are less
 With the above limitations keeping in view, the
decision is taken to make the guide plate
progressive tool.
STRIP LAYOUT
BLANKING TOOL
for
 STRIP LAYOUT FOR BLANKING TOOLS.

Choice of strip layout method.

• Blanking tools produce blanks out of the strip or unit stock.
• None of the edges of the strip or unit stock forms an edge of the blank.
• Blanking is the most efficient and popular way of producing intricate
and closely tolerated blanks.
• The profile and accuracy built into the tool will be reproduced on
the blank.
• In the strip layout, blanks can be positioned in different ways in the strip.
 STRIP LAYOUT

A strip layout represents the sequence of the logical, workable operations,

which is to say a sequence of ideas.
If this sequence of operations has error, the error will be surely emerge in a
try out press.

Factors to be considered while designing the layout are.

1. Shape of the blank.
2. Production requirement.
3. Grain direction.
4. Burr side.
5. Stock material.
Shape of the blank:
•The contour of the blank, decides the position of the strip.
•Some of the blanks are laid at an angle.

Production Requirement:
•If production requirement is less, then material conservation is necessary.
•This must not increase the tool cost.
•Gang die may be suitable for the mass production.

Grain Direction:
•The grains are found in the sheets when they are rolled.
•Bending the strip along the grain direction results in crack and fracture.

Burr Side:
•It is a decisive factor in laying the strip.
•In blanking, burr is found on the punch side.
•In piercing ,burr is found on the die side.

Stock Material:
•Every means is to be seen to conserve the stock material.
•A double pass layout would justify the cost of stock material conserved.
ECONOMY FACTOR:
The designer should try out every possible means to attain a min 60%
usage of any strip, without sacrificing the accuracy of the piece part.

Economy Factor =
Area of the blank x No of rows x 100
Width of the strip x Pitch
new
TERMS USED IN STRIP LAYOUT

Pitch
Distance between two consecutive operations on a strip.

Scrap bridge
This is the portion of the material remaining after blanking operation
between one edge of the strip and the cutout portion. The portion of material
remaining between the two adjacent openings after blanking is also called as the
scrap bridge.

Front Scrap
This is the scrap bridge on that edge of the strip which is towards the
operator.

Back Scrap
This is the scrap bridge on that edge of the strip which is away from the
operator
EXAMPLE:

Calculate the economy factor to punch the mild steel washer in single row
feeding. Outside diameter is 30mm, Inside diameter is 18mm and Thickness is
2mm
Scrap bridge width is = 1.2 s.
Scrap bridge width = 1.2 x 2
=2.4 mm
Pitch = 30 + 2.4 = 32 mm
Strip width = 30 + 4.8 = 34.8 mm
Number of rows = one
Area of blank = Л D²
4
= Л 30²
4
= 706.65 mm²
Area of blank x No. of rows x 100
pitch x strip width
Calculate the economy factor to punch the same washer in
double row feeding
Single row one pass layout
• This is the most popular way of laying out the strip.
• The blanks are arranged in a single row.
• The strip is passed through the tool only once to punch out the blanks
from it.
• There are two possible ways of laying out this strip.

• Narrow run.

• Wide run.
WIDE RUN
• Wide run is more desirable due to the following reasons.
• Shorter advance distance of the strip feeding promotes easy
• More" blanks could be produced from a given length of strip compared
to narrow run.
• Fewer number of strips are to be handled to produce a given
number of blanks.
• Narrow run is used when the grain direction of the piece part
has importance.
BLANKS HAVING AT LEAST TWO STRAIGHT PARALLEL
EDGES.
• In such cases the strip width should be equal to the distance between the
parallel sides.
• The blanks are produced by a cut off or parting operation.
• If the blank has got two sets of parallel sides, a cut off operation is sufficient
to produce the blanks.
• But if the blank has got only one set of parallel sides, these sides become
the sides of the stock strip and the other non-parallel sides are produced by
a parting operation.
STRIP LAYOUT FOR CUT OFF AND PARTING
• Cut off punch cuts with only one edge.
• No scrap is produced.
• A parting punch cuts with two opposite edges thereby producing a scrap.

NOTCHING
• Notching is a cutting operation for cutting off small portions from the edge
of a strip or a pre blanked component.
STRIP LAYOUT FOR CUT OFF
• Cut off punch cuts with only one edge.
• No scrap is produced.
• A parting punch cuts with two opposite edges thereby producing a
scrap.
• Trimming is an operation of cutting off material to alter the shape of the
strip or blank.
• In notching only a small area of the blank is cut off.
• In trimming a larger area of material is removed.
• Blank can be produced by combining notching, trimming and piercing
operations with cut off or parting operations.
 BLANKS HAVING IRREGULAR CONTOUR

• The following factors must be considered before determining

the best method of positioning a blank in the strip.

1. Contour.
2. Minimum material wastage.
3. Less tool cost.
4. No scrap strip to handle which renders the production faster.
5. Accuracy in strip width.
6. Accuracy of the blank.
7. Flatness.
 CONTOUR.

• If the blank has two parallel sides, it can be produced by cut off operation.
• The advantages of cut off or parting operation are:
• Minimum material wastage.
• Less tool cost.
• No scrap strip to handle.
• Speeds up production.
 ACCURACY IN STRIP WIDTH.

• Sheared strips cannot be held to an accuracy closer than ± 0,2mm.

• If the blank must be held to close limits on its width sides cutting off or
parting cannot be employed.
• When the blank dimensions are to be controlled to close limits it
should be produced with a blanking tool, regardless of the parallel
sides it may contain.

FLATNESS.

• If the blank has to be flat, a blanking tool is preferred.

• A blanking tool produce considerably flatter components than other tools.
 SINGLE ROW TWO PASS METHOD

• This strip layout demands the strip to be fed twice through the tool.
• This is to achieve greater economy in stock material utilization.
• A two pass tool requires two stops.
• The stop used for the first pass should be removed or made to retract
spring loaded stoppers) from the working surface so as not to interfere
with the second pass.
• The front and back scrap as well as the scrap bridge should be wider
than those for he single pass (about 50 to 100%).
• Two pass layouts are justified only when the wastage is considerable and
the stock material is costly.
 DOUBLE ROW LAYOUT.

• Higher economy can be attained by positioning the blanks in double rows.

 GANG DIES

• A gang die consists of two or more similar sets of tool members so as to

produce 2 or more number of components during a single stroke of the
press ram.
• A gang die eliminates the cumbersome process of double pass.
• The higher tool cost will be off set by higher rate of production.
• Gang dies are not recommended for very complex work.
 ANGULAR LAYOUT

Some of the piece parts will be require to be laid out to an angular

position to make the layout more economical.
ASSIGNMENTS
PUNCHES
 PUNCH
Punch is the cutting element of the tool. Punch gives the
hole size and shape of the component. This is made out
of high carbon high chromium steel,(D, M grade in AISI)
and hardened and tempered to 58-60 HRc

Punches can be classified into

three categories.
PUNCH • Cutting punches
• Non cutting punches
• Hybrid punches
CUTTING PUNCHES : Cutting edges

These punches perform operations like

blanking, piercing, notching , trimming etc.
NON - CUTTING PUNCHES :

These punches perform operations like

bending , forming, drawing, extruding etc.
 Cutting edges

HYBRID PUNCHES :
Forming surface
These punches perform both cutting and non
cutting operations, like shear and form,
pinch-trim etc.
PUNCH GROUPS :
There are two groups of punches :

1. Segregated punches.
Self mounted punches, which are
positioned and retained by means of
self contained screws and dowels.

2. Integrated punches.
Punches depend on other component
such as punch plate, to locate and
position them.
TYPES OF PUNCHES :

Plain punches :
• Rectangular in cross section.
• These are self mounting straight punches.

Advantages
• Material saving.
• Machine time saving.
• Easy mounting.
Pedestal punches :

• They are also called as broad based punches.

• Load distribution qualities are excellent.
• Used for heavy duty work.
Off set pedestal punches

• These pedestal punches have their base off set.

• The reason for off setting the base are space
consideration for other components in the assembly.
• Machining and grinding accessibility.
• The distribution of cutting forces is non uniform in
these punches.
Keyed punch.

• A key is provided for non circular punches to

prevent their rotation.
Punches mounted In punch holders.

Headless punches.
• This is a plain punch except that it does not require dowels.
• The positioning of the punch is done by the opening
provided in the punch holder.
• The punch is fastened to the top plate by means of screws.
Beveled head punch.
• When the punch is made with an angular seating it is called bevel
head punch.
• The bevel angle is usually between 30° to 45°.
• The beveled portion may be either machined or peened.
Step head punches (Shouldered punches)
• These types of punches are fitted in the punch plate without
screws and dowels.
Floating punches
• They are made loose in the punch holder and are guided in the
stripper plate.
Perforators

• A punch of diameter 2.5mm or below is called a perforator.

Bevel head perforators

• On these type of perforators a beveled seating is
machined or peened.
 HEADLESS PERPORATORS
WITH WHISTLE KNOTCH

Headless perforators.

• These punches do not have shoulders.

• A whistle notch is milled on the shank of the perforator.
• A screw from the side will fasten the perforator in position.
 Step head perforator shank less.

• These are similar to step head perforators

STEP HEAD
except that the shank diameter is more by 0.025
PERPORATORS mm than the point diameter.

STEP HEAD
Step head perforator. PERPORATORS SHANKLESS

• These are the commonly used perforators.

• They have a stepped head shank and a point diameter.
Pyramid perforators.

• This type of perforator is used when there is considerable

disparity between the point diameter and the shank.
Quelled perforators.

• Slender punches are to be protected from buckling.

• Quills are provided to prevent buckling.
Slug ejector perforator

• To prevent slug pulling, air pressure or spring pins are sued.

• These are known as slug ejector perforators.
Buckling of punches
 Buckling of Punches

Whenever Press tool is worked upon within the press, The punches
mounted in that tool, are subjected to compression stresses. But if due
consideration of stresses are overlooked during designing of the tool, the thin
punch within the tool may fail by buckling.
Hence by maximum force, which a punch can withstand without buckling can be
calculated by using the following formula.

Fb = [² × E × I ] Lp²
Fb= Maximum Force beyond which buckling occurs.
E = Modulus of Elasticity ( For steel Modulus of Elasticity varies from 200 to
220 GN /m²)
I= Moment of Inertia in mm4
Lp= Length of punch in mm

The ultimate condition is when,

Buckling Force = Cutting Force required for the operation

= Shear force on the punch.
Example 1:
Is it possible to punch 1mm brass sheet with a 5mm square punch?

Tmax = 320N/mm²
Shear Force = 20 × 1 × 320
Length of Punch = 60mm
= 6400N ( 1000)
= 6.4KN
Shear Force required
Buckling Force, Fb = [² × E × I ] Lp²
to pierce the hole = L×S×Tmax
E = 210GN/mm²
L = Cut length in mm
I = a4 12
S = Sheet thickness in mm
= 54 12
Tmax = Shear force in N/mm²
= 52.08 mm4
Lp = 60mm
L = 5 × 4 = 20mm
S = 1mm
Buckling Force
Tmax= 320N/mm²
= [²×210×52.08×10 –12 ] 0.06²
= 2.99835 × 10-5 GN
= 29.9835 KN
As the punch can withstand a force of 29.35KN and the force coming on the
punch is only 6.4KN, it is possible to use the punch.
Example 2:
To find the smallest diameter of the punch to pierce 2mm Mild Steel sheet.

Length of the punch = 60mm

E = 210GN/m² I = 1.389547 × 10-12 m4
Assume Fb = 800N
I = [d4 ] 64
Fb = [² × E × I ] Lp²
1.389547 × 10-12 = [d4 ] 64
800 × 10-9 = [² × 210 × I] 0.06²
800 × 10-9 × 0.06² = ² × 210 × I d4 = 1.389547 × 10-12 × 64

I = [800 × 10-9 × 0.06²] [² × 210] d4 = 2.8307619 × 10-11

= [2.88 × 10-9 ] [2070.516]
I = 1.389547 × 10-12 m4 d = 2.3066mm
2.31mm
Die Blocks
Factors influence the design of a die block

 Piece part size

 Stock thickness
 Intricacy of the piece part contour
 Type of tool
 Machinery available for manufacturing the tool
 SOLID DIES

Made up of non shrinking tool steels

Hardened & tempered to 58-62hrc

Considerations
Critical nature of the Dimensions involved
Extreme Pressures & Wear conditions while Shearing
Sheet thickness
Press force
Strength & Life of the Die:
 Sufficient wall thickness at the weakest points
 Sufficient Die thickness according to the Severity of the specific
operations.
 DIES THICKNESS

STOCK MATERIAL FOR DIE BLOCK LENGTH

THICKNESS IN m m upto125m m 125-200m m 200-400m m
upto 1 16 20 24
1 to 2 20 24 28
2 to 3 24 28 32
3 to 4 28 32 36
4 to 6 32 36 50
6 & above 36 40 60
 DIE BUSHES
 These are inserted in Mild Steel retainer plate.
 DIE BUSHES
Advantages:
 Easily replaceable.
 Reduces cost of the die manufacturing.
Applications:
In large piercing dies.
 SPLIT or SECTIONAL DIE BLOCKS
•These are the dies having more than One Section.
Deciding Factors of SOLID or SPLIT DIES
SOLID DIE SPLIT DIE
SIZE OF THE DIE BLOCK

Small Bigger

Reduces cost, Machining Time, Hardening Failures

SIZE OF THE DIE OPENING

Sufficient to perform internal working Too small for Internal working

Eases the machining process.

COMPLEXITY OF THE DIE OPENING

Simple contours Intricate cotours, Sharp Corners in the component

Eases machining

Avoids Cracks at hardening.

PERISHABILITY

No possibility of Breakage High Possibility of Breakage

Simplify the manufacture of relatively perishable portions of
the die block
PROFILE GROUND DIE OPENING

When internal grinding is possible When internal grinding is impossible

 Locating & Clamping of Die Sections
Considerations
Tilting Due to Downward Thrust.
Lateral Displacement due to Lateral Thrust created by the
Punching Action.
Methods:
 For Thin Stock materials, Dowels and Screws.
 As the Stock material thickness increases, Need of
Nesting arises.
 NESTING
METHODS OF NESTING
 Nesting in Die set pockets.
 Nesting in Retainer Plate, which is of Mild steel.
Nesting in the above methods incorporating Liners.
NESTING IN DIE SET with LINERS
 NEST BLOCKS
 Advantages:
 They do not weaken the die set.
 Can be easily hardened for heavy work.
 Can be easily ground, when Die needs to reground. As the
Whole assembly of Die Sections are ground together.

 Disadvantage
 Costly compared to pocket milled Die set type nesting, as the
separate nest block has to be machined & clamped to the die set.
NESTING in Retainer Plate
Locating & Keying of Circular Sections
DIE INSERT
 CARBIDE DIES
 Die Material: Tungsten Carbide.
 Applications:
Blanking, Piercing, Trimming, Forming, Drawing, and
Swaging operation.
Where production rates are high.
Parts having Close tolerances.
 CARBIDE DIES
 DESIGN PRINCIPLE:
 DRAW RADII or APPROACH ANGLES.
 PUNCH & DIE CLEARANCE.
 RELIEF

ALL Remains the same as that of the Steel Dies.

 Supporting of Carbide Dies inserts:
Inserts must be supported externally by pressing or shrinking them into
a Hardened steel case.
STOPPERS
 STOPPERS

After each and every stroke of the press, the strip has to be fed
forward for one pitch length. This can be accomplished by means of
stopper.
The function of the stopper is to arrest the movement of the strip
when it is fed forward to one pitch length.
It is essential that two basic definitions be associated with

The fundamental principles of stops,

• Stop position.
• Registry position.
STOP POSITION
This is the location of the actual stopper position surface against which the stock
strip is halted.
Registry position.
• This is the exact location in which the stock strip must be established in
order to obtain dimensionally correct component.
• The work is located by the stop and is registered by the pilots.
• The registry position may or may not be the same as the stop position.
• When a stop functions as an approximation gauge the stop position does
not coincide with the registry position.
• If the stop acts as a true gauge the stop position and the registry position
are same.
• If a stock strip is piloted the stop need act only as an approximation
gauge.
• The strip is overfed against the gauge and is registered by the pilots.
• If the stock strip is not piloted the stop has to function as a true gauge.
• Primary stops act as true gauges, registering the stock strip.
• Secondary stops normally serve as approximation gauges.
• Therefore overfeeding is allowed when installing them.
Solid stops
• A hardened steel block is mounted at the required location.
Plain pin stop

• It is a plain cylindrical pin mounted in the die block.

• A clearance hole for the pin stop in the bottom plate is provided for the
following reasons.
• To permit adjustment of the height of the pin stop without removing the
die lock from the assembly.
• While re sharpening the die the stop pin can be removed.
• The pin can be driven down in the event of miss feed.
• This reduces the chance of damage to the tool.
Headed pin stop.

• When the stop is to be very nearer (very small scrap bridge) to the
die opening a headed pin stop is used.
• A plain pin stop cannot be used in such cases because the opening
made for locating the stop will weaken the die.
• The mounting hole of the headed pin stop will be away from the die
opening.
Spring loaded pin stop.

• It is a spring pin located at the required stopping position.

• These stoppers do not require clearance in the opposing tool member.
• The pin is pressed down by the opposing tool member during operation.
Finger stops

• In progressive tools designed for manual feeding, finger stops locate the strip for
each station except for the final station.
• This stop is actuated manually.
• It is mounted in the stripper plate.
• Provision is made for moving the stopper through a predetermined distance.
• It is pushed inwards to enable the stock material to halt against it.
• After the press stroke the stopper is released.
• When a new stock strip is fed the stopper has to be actuated again.
Trigger stops.

Side acting Trigger stops.

• For faster manual feeding, trigger

stops are preferred.
• There are two types of trigger stops.
• Side acting.
• Front acting.
Front acting trigger stopper.

• The working mechanism for side acting and front acting trigger stops are same.
• The front acting trigger stop is mounted in the front end of the tool and the side
acting trigger stop is mounted in the side of the tool.
• The lever shaped trigger stop fits freely in the slot milled in the guide plate.
• One side of the wall of the slot is machined with a taper angle.
• It gives the necessary movement to the trigger.
• An inclined set spring at the other end of the trigger holds the trigger in
position.
• When the strip is pressed against the tip face of a trigger the trigger moves
back wards and stops against the non tapered wall of the slot.
• This allows the strip to advance.
• This advancement is equal to one margin width.
• When the tool is tripped, a knocker bar fixed to the top assembly of the tool
comes down and knocks tile free end of the trigger.
• This action lifts to clears the strip thickness and then jumps back to its old
position to fall on the strip (blanked portion).
• The strip can be fed forward.
STRIPPERS
 STRIPPERS
The main function of the stripper is to strip the stock material off the punches after
each stroke. In addition the stripper may act as a guide for the punches, as well
as hold the strip flat and tight, while the strip is being worked on.
STRIPPER CATEGORIES AND TYPES

Strippers can be classified into 2 groups,

• Fixed strippers.
• Traveling strippers.

Fixed strippers are simple and easier to make than the traveling
strippers. Fewer components are required in the construction of fixed strippers
when compared to the equivalent traveling strippers, Therefore the fixed
strippers are economically desirable as far as the die construction cost is
concerned, Mechanically a fixed stripper are solid (positive) in performance. This
is an advantage where strong stripping force is necessary.
But,
In some situations a fixed stripper may be impracticable. i.e.
• When it is necessary to clamp the strip in addition to it’s stripping function.
• When it is necessary to keep the punches engaged in the stripper during
the entire press cycle.
• A traveling stripper permits the operator to observe the work while the tool
is operating.
BOX STRIPPER
A typical box pin stripper is shown in figure.

The overall dimensions E and D are made the same as the die block. Strippers
are generally left soft. How ever when required the back gauge should be
hardened.
The tunnel dimensions are as fallows

The tunnel width X can be determined as X = W + F

W = Stock strip width at maximum tolerance.
F = Desired horizontal feeding clearance.
for the average progressive die, assuming there are no other specific
requirement, Clearance F may be 0.3 per 100mm tunnel length.
Tunnel height H=S+G , G is the required vertical feeding clearance, G may be=
0.5s for flat work cutting dies with short tunnel length. Or it may be several times
larger than the ‘S’.
Lead angle L must be provided at the tunnel entrance. The angle facilitates
starting the stock strip in to the tunnel and is very necessary for practical
operation. As a principle hard materials will have more clearance than soft
materials. If the clearance is too large it will lead to stripping distortion.
 A fixed stripper is a steel plate with a clearance slot to allow the part
material to pass under it. This plate is mounted to the die plate in a fixed position,
Clearance holes are cut through the stripper plate letting the punches extend
through without interference. At withdrawal the part material is prevented from
lifting as punches are retracted. The part material is stripped off of the end of the
punch or punches.
Fixed strippers have several drawbacks. These strippers do not hold the
stock strip flat and lack the ability to absorb impact and snap through shock. The
result is poor part flatness and premature punch failure.
Fixed strippers are not generally recommended for high volume or high
precision applications.
HOOK STRIPPER

Hook pins are made from cold drawn steel rod. The
function is as shown in figure.
PRESSURE PAD STRIPPERS

Pressure pad strippers hold the material during cutting and strips it from the punch
in the upward stroke. They may be actuated by the springs, rubber cushions or
hydraulically.
 Travelling strippers offer superior performance.
The main advantage is that as the die closes the stripper holds the stock strip or
part flat and in place while the perforating and stripping operation take place.
The stripper prevents the part material from Lifting or hanging upon the punches.
Because the stripper lifts away from the part material after each stroke, visual
monitoring of the die performance is made easy.
Stripping force varies based on part material type and thickness as well
as punch and die clearance. This force can range from nearly zero to as much
as 25°/0of the force required to perforate the initial hole. Most applications do
not exceed 10°/0of the perforating force.
SPRING STRIPPERS

Spring stripper is a pressure pad stripper. They are used when it is

necessary or desirable to hold the stock material flat (or very nearly flat),
or to provide better visibility and access when the tool is mounted on the
press. Inverted dies have stationary punches & therefore require
traveling pressure pad strippers. Pressure pad strippers are also used for
push back applications.
CLAMPING SPRING STRIPPERS

They are true pressure pads. They bears against the stock material, applying
pressure to it. The material is clamped between stripper and die. Clearance
must be large enough to ensure clamping.
NON CLAMPING SPRING STRIPPER

These kinds of strippers are used when the material is not to be clamped.
There will be clearance between the stock strip and the strip for obtaining good
flatness, clearance within 0.05 to 0.4mm is recommended. The pilot registers the
stock strip. In most cases, spring stripper are an effective device for producing
good flat piece parts.
PILOTING THROUGH SPRING STRIPPERS

It is often necessary to employ pilots in conjunction with spring strippers.

If the stripper is a clamping stripper, it cannot be used to strip the pilot completely.
This is because the pilot should register the stock strip before the strip contacts
the material.
To strip the material from the pilot, the guide rails are used. If the pilots however
are too far away from the hooking action of the guide rail legs, the stock material
may pull up, bowing the strip.
 Even if the stock material doesn’t pull out of the rail confinement, there
will be bowing action. It can cause excessive pilot wear, seriously deteriorate
the quality of the pierced opening and adversely affect the ultimate flatness of
the pierce part. When the pilot position is too far away a non clamping stripper
are applied, so that the stripper strips the stock strip also from the pilot.
COMPENSATING WASHER

When cutting punches are sharpened they become shorter. In many

applications, the springs are compressed a little more and are not always
desirable. A practical method to eliminate this is to install the cylindrical washer
as shown in the figure. Each time the punches are sharpened the washer is
reduced for the amount
SPRING AROUND THE STRIPPER BOLTS
Such a construction is shown figure. This construction has desirable
features and undesirable features

Desirable features are

 The bolt retains the stripper at center
of spring pressure
 The bolt acts to confine the spring in
location so that the double spring
pocket can be eliminated
Undesirable features are
 The assembly needs considerable
vertical space often than available
STRIPPER BOLT SUSPENSION :
Bolt hole is drilled larger than shoulder diameter (clearance hole is
provided ).When the die fully closed and the stripper bolt is at its maximum
travel position must be sufficient to assure adequate punch grinding life.
Normally, a space should exist between the end of the stripper bolt and
the stripper.
To ensure stripping a spring stripper should over travel a distance equal
to sheet thickness, when the stripper is at its extended position. The over travel
is between 0.1 for every light work to 1.5 for heavy work. In any case each time
the punch is sharpened, the over travel increases. This should be corrected
from time to time by inserting the compensator under striper bolt head as shone
in figure.
 STRIPPER BOLT SUSPENSION :

STRIPPER BOLT STRIPPER BOLT

SLEEVE

SPRING
SPRING
GUIDING STRIPPERS :
Two typical stripper guide pins
arrangements are shown in figure.
The drawings are self explanatory.
STRIPPING FORCE :
Stripping force for most operations range from 10 to 20% of the cutting
force. If the die has more than one punch the stripping force for that die is the
sum of stripping force required for each punch.

STRIPPING FORCE FOR THE BLANKING AND PIERCING :

The following factors affects stripping force,
1. Stock material : Material, which have high friction, value and material, which
tend to cling, are more difficult to strip.
2. Surface condition of side walls : A punch, which has smooth finish on its
side, wall strip more easily than punch, which is not as smooth.

3. Distance between punches: More effort is required to strip punches that are
close together.
4. Area of the stock material to be stripped : Figure shows two piece parts one
larger than other. The thickness and the type of stock material. The pierced
opening is the same size in both parts . The cutting is the same for both the
parts . But the larger piece part requires the greater stripping effort.
The larger area of the stock material surrounding the punch is stronger
and causes the material to cling more tightly to the punches.
GAUGES
 GAUGES
Gauges must be considered in the design of press tool because theses
component position the strip longitudinally in its travel through the die. In
second operation dies, gauges locate the previously blanked or formed part
for further processing operations.
Design consideration includes :
• Material choice: finished tool steel is used for gauges in first class die. Cold
rolled steel should be used only when low production n requirements exists.
• Adequate thickness: the back gauge and the front spacer must be thick
enough to avoid binding of the strip between stripper plate and die block.
• Good doweling practice: since the gauges locate the strip they should always
be doweled in position.
• Accuracy of location surfaces: The gauging surfaces which actually bear
against the strip or part should be ground, and so marked on the die drawing.
BACK GAUGE AND FRONT GAUGE
In passing through at two station piece and blank die the strip is positioned
against back gauge by the operator. Strips support helps to align the bottom of
the strip with the top surface of the die block to prevent binding. Back gauge is
the actual guiding member and the function of the front gauge is only to provide
an approximately gauging. The required dimensional relations are mentioned
from the back gauge to the die opening.
BULGE CLEARENCE

Thick and soft material tend

to bulge side wise as soon as
blanking operation is performed.
This makes it quite difficult to
feed as well as to gauge the strip
further unless a bulge clearance
is provided in such stations.
Bulge clearance is provided
usually in the back gauge only.
SIZE OF BACK GAUGE AND FRONT GAUGE

The gauge should be thick enough to avoid binding of the strip

between the stripper and the die block. The recommended thickness of
3mm for sheet up to 1.5mm and strip thickness+1.5mm for heavier(more
than 1.5mm) strip is found to be satisfactory if automatic stops are
employed in the tool. The space between back gauge and the front spacer
is made to strip width+0.5mm if roll feeding is used and strip
thickness+1mm for hand feed.
EXTENDED BACK GAUGE
For easier gauging usually the gauge is extended beyond the die on the
feeding side. An amount equal to 2and ½ times the strip width for hand feeding
and equal to the strip width for roll feeding is sufficient.

STRIP SUPPORT
While hand feeding the strip to reduce fatigue to the operator a strip
support should be provided. The strip support should be made wider and
brought closer to the die block to provide better support and guidance. Roll
feed doesn’t require strip support.
PUSHERS
These are provided to keep the strip firm against the back gauge during its
travel through the tool. Spring loaded pushers are often employed to achieve
this.
NESTING GAUGES
Nest gauges are used in secondary operation tool or whenever limit stock
is fed in to the tool.
There are three conditions to be met to achieve the best result.

ACCURACY : The fit between the gauge part and the gauge should be
perfect. For gauging purpose it is not necessary of the nest to fit entire
contour of the piece part. All that is required to provide sufficient number of
locating points. The number of locating points required for certain nest
depends upon the size and the shape of the piece part. A minimum of three
part for circular and angular shape and 4 points for other shapes are
required.
EASY AND QUICK LOADING AND UNLOADING
Nest gauges facilitate fast and easy loading and unloading of the
components. The main factor which decide this are good visibility and
accessibility to the nest. Adequate lead angle should be provided around the
nesting profile for easy loading.
Unloading more difficult than loading. For low production tools simple pick of
slots machined in the nest would be sufficient to allow the operator to manually
pick the piece out of the nest. Ejection of piece parts out of the nest by means of
lever operated ejectors is another solution. If the piece part is thin it can be
ejected from the nest by means of compressed air jets.

FOOL PROOFING
Any possibility of the piece part being loaded in the incorrect manner by the
operator should be prevented by the nest. Fool proof pins could easily
accomplish.
TYPES OF NEST GAUGES
PIN TYPE NEST GAAUGES :
The simplest form of nest
gauges comprises of plains or
headed cylindrical pins
arranged in such way as to
provide enough number o f
locating points for the piece
part. These hardened and
ground pins are press fritted in
to the die block. The
arrangement of the pins should
be such that a total clearance of
at least 0.03mm results
between them. The upper end
of the pins must be doweled for
easy loading and unloading.
The opposing member should
have relief holes drilled in to it to
receive these pins.
 In inverted tools the nest pins are fitted in to the traveling stripper and the
relief holes are to be drilled in the die block. If these holes happened to appear
in the near vicinity of the die opening the die will be weekend in such case the
nest pins should be of the spring loaded type and made to disappear below the
face of the stripper, upon contact with the die block. It is obvious that
disappearing nest pins are less accurate and should be used only if inevitable
PLATE TYPE NEST GAUGE
these type nest is a plate in
to which an opening is
machined to receive the piece
part. As mentioned already the
opening need not fit the entire
contour of the piece part. Plate
type nest could of sectional
constructions for easiness in
machining and hardening. Plate
type nest gauges should be
perfectly screwed and dowelled
in position.
As a general rule, all
gauging elements should be
made out of tool steels and
hardened to 48-52 HRC.
NESTING IN DIE SET:
Simplest nesting method is
to fit the section in to the pocket
that is milled directly in the die set.
The die section should be fit
tightly into the pocket but the
assembly pressure should be so
great as to distort the die set. It
should be noted that nesting does
not eliminate the need for the use
of screw.
 good morning

STRIPPERS
 STRIPPERS
The main function of the stripper is to strip the stock material off the
punches after each stroke. In addition the stripper may act as a guide
for the punches, as well as hold the strip flat and tight, while the strip is
being worked on.
 STRIPPER CATEGORIES AND TYPES

Stripper can be classified into 2 groups,

Fixed stripper,
Traveling stripper.
Fixed stripper are easier to make than the traveling strippers.
Fewer components are required in the construction of fixed strippers when
compared to the equivalent traveling stripper. Therefore the fixed strippers
are economically desirable as far as the die construction cost is
concerned, Mechanically, fixed stripper are solid in performance. This is
an advantage where the stripping force is necessary.
But,
In some situations a fixed stripper may be impracticable. i.e.
• When it is necessary to clamp the strip in addition to it’s stripping
function.
• When it is necessary to keep the punches engaged in the stripper
during the entire press cycle.
• A traveling stripper permits the operator to observe the work while
the tool is operating.
 Box Stripper
A typical box pin stripper is shown
The tunnel dimensions are as fallows
The tunnel width X can be determined as
X=W+F
W = Stock strip width at maximum tolerance.
F = Desired horizontal feeding distance.
for the average progressive die, W
assuming there are no other specific
requirement, Clearance F may be 0.3 per

G
100mm tunnel length.

H
Tunnel height H=S+G , G is the
required vertical feeding clearance, G may

s
be= 0.5s for flat work cutting dies with short
tunnel length. Or it may be several times X
larger than the ‘S’
HOOK STRIPPER hook pin

Hook pins are made from cold drawn steel.

The function is as shown in figure.

PRESSURE PAD STRIPPERS

Pressure pad strippers hold the material during cutting and strips it from the
punch in the upward stroke. They may be actuated by the spring, rubber or
hydraulically.
SPRING STRIPPERS

Spring stripper

Spring stripper is a pressure pad stripper. They are used when it is

necessary or desirable to hold the stock material flat (or very nearly flat), or
to provide better visibility and access when the tool is mounted on the
press. Inverted dies have stationary punches & therefore require traveling
pressure pad strippers. Pressure pad strippers are also used for push back
applications.
CLAMPING SPRING STRIPPERS

They are true pressure pads. They bears against the stock material, applying
pressure to it. The material is clamped between stripper and die. Clearance must
be large enough to ensure clamping.

spring

Clamping stripper

Die
NON CLAMPING SPRING STRIPPER

These kinds of strippers are used when the material is not to be clamped. There will
be clearance between the stock strip and the strip for obtaining good flatness, clearance
within 0.05 to 0.4mm is recommended. The pilot registers the stock strip. In most cases,
spring stripper are an effective device for producing good flat piece parts.

spring

Clamping stripper
Gauge

Die
PILOTING THROUGH SPRING STRIPPERS

It is often necessary to employ pilots in conjunction with spring stripper. If

the stripper is the spring loaded, it cannot be used to strip the pilot completely, this
is because the pilot should register the stock strip before the strip contact the
material. To strip the material from the pilot, the guide rails are used. If the pilots
however are too far away from the hooking action of the guide rail legs, the stock
material may pull up, bowing the strip even if the stock material doesn’t pull out of
the rail confinement, there will be bowing action. It can causes the excessive pilot
wear, seriously deteriorate the quality of the pierced opening and adversely affect
the ultimate flatness of the piece part. When the pilot position too far away,
then non clamping strippers are applied, so that the stripper strips the stock strip
also from the pilot.
COMPENSATING WASHER
When cutting punches are sharpened they become shorter. In many
applications, the springs are compressed a little more and are not always
desirable. A practical method to eliminate this is to install the cylindrical washer
as shown in the figure. Each time the punches are sharpened the washer is
reduced for the amount
 SPRING AROUND THE STRIPPER BOLTS
Such a construction is shown figure. This construction has
desirable features and undesirable features
Desirable features are
 The bolt retains the stripper at
center of spring pressure
 The bolt acts to confine the spring
in location so that the double
spring pocket can be eliminated
Undesirable features are
 The assembly needs considerable
vertical space often than available
STRIPPER BOLT SUSPENSION :
Bolt hole B is drilled larger than shoulder diameter A. (clearance hole is provided
).When the die fully closed and the stripper bolt is at its maximum travel position
E must be sufficient to assure adequate punch grinding life (E is about 6mm).
Normally,a space G Should exist between the end of the stripper bolt and
the stripper (G = 0.5mm).
To ensure stripping a spring stripper should over travel a distance S, when
the stripper is at its extended position. The over travel is between 0.1 for every
light work to 1.5 for heavy work. In any case each time the punch is sharpened,
the over travel increases. This should be corrected from time to time by inserting
the compensator under striper bolt head as shone in figure.
STRIPPER BOLT SUSPENSION
:
STRIPPER BOLT STRIPPER
BOLT

SLEEV
E
SPRI
SPRIN
NG
G
GUIDE STRIPPERS :
Two typical stripper guide pins arrangements are shown in figure.
The drawings are self explanatory.
STRIPPING FORCE :
Stripping force for most operations range from 10 to 20% of the cutting force.
If the die has more than one punch the stripping force for that die is the sum of
stripping force required for each punch.

STRIPPING FORCE FOR THE BLANKING AND

PIERCING :
The following factors affects stripping force,
1. Stock material : Material, which have high friction, value
and material, which tend to cling, are more difficult to
strip.
2. Surface condition of side walls : A punch, which has
smooth finish on its side, wall strip more easily than
punch, which is not as smooth.
4. Area of the stock material to be stripped : Figure shows
two piece parts one larger than other. The thickness and
the type of stock material. The pierced opening is the
same size in both parts . The cutting is the same for both
the parts . But the larger piece part requires the greater
stripping effort.
The larger area of the stock material surrounding
the punch is stronger and causes the material to cling
more tightly to the punches.
PILOTS
 PILOTS

Pilots play a vital role in the operation on multiple-station dies, and

many press lines troubles can be traced to their faulty design. In applying
pilots the following factors should always be considered:
1. They must be strong enough so repeated shock will not cause fracture.
2. Slender pilots must be sufficiently guided and supported to prevent
bending, which can cause faulty strip positioning.
3. Provision should be made for quick and easy removal of he pilots for
punch sharpening .
Purpose of pilots.

• The pilot positions the stock strip in relation with the die opening.
• This is termed as registering.
• The strip is normally overfed more than the pitch length.
• When the press is tripped the pilot comes down and engages the pre pierced hol
• The strip is dragged back into the registry position.
• When mechanical feeding is employed the strip is underfed.
• The pilot pulls the strip into registry position.
PILOT SIZE:
The accuracy with which the work can be registered depends upon the proper
location and the diameter of pilot.
The following will indicate the pilot diameter ;
Average work Ø of pilot= ( Ø of hole to be piloted-0.05 to0.1mm )
Close work Ø of pilot = ( Ø of hole to be piloted-0.03to 0.05mm)
Accurate work Ø of pilot =( Ø of hole to be piloted – 0.01to 0.2mm)
However the thick stock materials & the stock materials like
aluminum and copper need often bigger tolerances between the pilot and the
pierced hole.
PILOT LENGTH
Registering the strip must be complete before the cutting punches come
and engage the strip. Therefore the pilot must be longer than the punches. If the
pilots are too short they cannot perform there function
This creates serious consequences ranging from spoiled work to
damaged pilots. Care must be taken while setting the stroke of the press so that
pilots clear the stock strip without obstructing the future feeding of the strip. In any
case the piloting length should be extended beyond the punch face equal to the
sheet thickness.
PILOT OPENING IN THE DIE
The opening of the pilot in the die should not be too large. If so, the stock strip
may tend to draw into the opening. In case of the thin material pilot may not
displace the material into registry position but may instead draw the material on
one side therefore it is advisable to have the opening Ø as pilot dia + double
clearance. weaker pilots are guided in the stripper.
PILOT OPENING IN DIE SHOE:
Through hole is provided in the die shoe for the pilot so that slugs
produced during miss feed are cleared. It also helps in clearing the accumulated
burrs dislodged from the pierced hole.
PILOT NOSE PROFILE
The main function of the pilot nose profile are to allow smooth riding of
the pilot into the stock strip. The most commonly used nose profiles are
described below:

Bullet nose.
The most common pilot nose profile is bullet nose. The bullet shape is
formed by radius R which is equal to piloting diameter. For piloting in holes less
than 6mm the length of radius R can be increased to reduce the lateral force
during piloting. Bullet nose is strong simple to make and smooth in action.
The other three commonly used pilot nose profiles are:
1. 45º conical stub nose
2. 30º conical stub nose
3. 15º angular long nose
45º CONICAL STUB NOSE PILOT
The profile is used when a shorter nose
profile is desired. 45º cone increased the
relative lateral forces hence not
recommended for delicate pilots used for
piloting thin soft material.

30º CONICAL STUB NOSE PROFILE :

This is same as the above pilot
except the nose angle is30º this is a
compromise between the 45º stub nose
pilot and the conventional bullet nose

15º ANGULAR NOSE:

This small angle provides good
mechanical advantages they are used for
small pilots and for thin materials.
TYPES OF PILOTS:
RETRACTABLE PILOTS:
In many occasions especially
during hand feeding miss feeding occurs
due to over shooting of the stock strip over
the stoppers. This creates the problem
when a tool is having pilots in it. Pilots may
break or buckle obstructing smooth
function of the tool.
Generally retractable pilots are
spring loaded in such away that they will be
lifted upwards when they come in contact
with the un pierced area during press
descends. Care should be taken while
selecting spring so that springs allow more
telescopic movement of the pilot.
REMOVABLE TYPE PILOTS:
Pilots break very often due to
miss feeding of the stock strip. Much
consideration must be given for
changing quickly the broken pilots
,preventing greater time loss during
production. Removable type of pilots
can over come this difficulty. These
pilot inserted through top bolster into
the punch holder and fastened with a
back up screw as shown in fig :
PILOT IN PUNCHES:

Pilot mounted in punches is called

punch pilots. Piloting size should extend
beyond the punch face a distance of at least
stock thickness, but minimum dimensions of
1.5 mm. When pilots are mounted in
blanking punches there is a tendency of
pulling the blanks by the punch. When the
blanking punch retracts spring-loaded pins
are provided to prevent this pulling of
blanks.
METHODS OF PILOTING :
Direct piloting :
It consist of piloting in holes pierced in
that area of the strip which will become the
blank. All pilots decided so for have been
direct pilot which are retained in the
blanking punch.

Indirect piloting:
Indirect piloting consist of piercing hole
in the scrap area of the strip and locating in
these holes at subsequent operations direct
piloting is the preferred method but certain
blank condition require indirect piloting, as
will be explained.
PART CONDITION :
There are seven condition that required in
indirect piloting.
•Close tolerance on hole. Pilots can enlarge holes in
pulling a heavy strip to position.

•Holes too small. Frail pilots can break or deflect in

operation.

•Holes too close to edge of the blank. Distortion can

occur in blank because of enlargement of holes
•Holes in weak area. Piloting in projecting tabs is
impractical because they may deflect before the
strip is pulled to position

•Holes placed too closely. Piloting in closely

placed hole does not provide an accurate relation
between two holes and edge of the blank

•Blank without holes. Piloting is done in the scrap

area where ever the blank does not contain holes.

•Projection in hole. When ever the hole in the

blank contain weak projection which could be bent
down by the pilot, indirect piloting should be
selected.
SIDE CUTTERS
 SIDE CUTTERS
Side cutter is an accurate method of stopping arrangement used mainly
for thinner strips where it is difficult to accommodate the other type of
stoppers.

A side cutter is a trimming punch which trims the side of the stock
material, providing a shoulder. This shoulder is stopped against a hardened
insert provided in the spacer in small tools the spacer may be fully hardened
to avoid the insert. the width of the side cutter is equal to the pitch.
The allowance for side cutting depends upon the type and thickness of
the stock material. Table gives the allowance for side cutting for different
materials.
NO MATERIAL SHEET THICK NESS CLEARENCE
01 Steel 0.2-0.4 2.5
Brass 0.2-0.6 1.5
Bronze 1.0-1.5 2.5
1.5 1.5 x s
02 Copper 0.2-0.5 3
Zinc 0.5-0.1 2
Aluminum 1.0-1.5 2.5
03 Leather, paper 0.4 5
Fibers 0.4-1.0 4
Card boards 1 3xs
 The size of the side cutter will be
more than the pitch by 0.05-0.1 for the
purpose of registry the strip with the pilot.
But in case of tools without pilot, the side
cutter is made equal to the pitch. The stop
position and registry position will be the
same.
Due to the unbalanced cutting force
cutting force acting on the side cutter, the
side cutter are provided with heels. the
undercut provided on thee side cutter
eliminates the difficulties of feeding due to
thorn formation. Thorns are small
projection which occurs at the side of the
strips due to the punch wear out. In side
cutting there is a tendency of the slugs
being coming up with the punch, causing
difficulties in further punching. Slug
pushers are used to avoid this. A
standard side cutter shape is shown in
the fig.
THE ADVANTAGES OF SIDE CUTTER :

1. It is a safer method than stop pin

2. Avoids the danger of the deformation of margins of thinner strips by
the stop pins, when pressed against it.
3. Preferred for small punching where it could be difficult to employ
other types of stops
4. It is economical and avoids complications in tools where number of
stages are more
5. Pilots can be avoided for punching components with moderate
accuracy.
 The side cutter is installed in the first position of the tool. this eliminates extra
stops and simplifies both construction and operation of the tool. Usually the side
cutter is located along the front edge of stock strip, because of the fact that the strip
are usually meant to gauge of the tool

Two side cutters, one on each side is used where the number of stages are
more or if pitch is less
 EJECTORS AND SHEDDERS.

Ejectors and shedders are the tool members serves the purpose of
supporting the blank while cutting action, which helps in maintaining flatness
and also eject out the component which is struck inside the die opening
after the cutting action.
These may use hydraulic or mechanical menace for actuating

• In conventional drop through type blanking tools, the punch

forces the blank in to the die.
• The blank will be retained within the die cavity till the
subsequent blanks push it past the land.
• Then it falls down through the opening in the bottom plate and
subsequently through the opening in the press bed.
EJECTORS AND SHEDDERS.

Shedders and ejectors are used when it is not possible to remove the blanks in
the conventional methods due to the following reasons:

1.0 Size of the blank does not allow it to conveniently pass through the
opening in the press bed.
2.0 Contour of the blank is such that it tends to stick and get distorted
during its travel through the die cavity.
3.0 Opening in the press bed fitted with die cushion which will interfere
with the piece part disposal.
4.0 Close tolerance specified for the flatness of the blank.
5.0 Tools of inverted nature.
EJECTORS

In the conventional position. die is the

lower member of the tool.
If the expulsion of the blank achieved by forcing it
upwards, the action is known as "ejection". The
element of the tool which ejects the blank is called
an "ejector“.
Ejectors may be actuated by compression
springs. Rubber, pneumatic devices or hydraulic
devices.
Ejectors if used with spring strippers,
always return the blank into the strip due to the
simultaneous stripping and ejecting action.
In some progressive tools. the blanking
station is provided with an ejector to return the
blank into the strip to be carried forward to the next
station for further operations known as the cut and
carry method.
EJECTORS
SHEDDERS
Another way to accomplish the expulsion of the blanks from the die cavity
is by making use of the knockout mechanism on the press. For this purpose, the
tool should be of the inverted design.
In inverted tools, die becomes the upper member of the tool,
being clamped to the press ram. The expulsion of the blanks is achieved by
forcing them downwards. This action is generally known as "shedding" and the
element of the tool which sheds the blanks is known as the "shedder".
TYPES OF SHEDDERS
POSITIVE SHEDDERS
Shedders operated by the knockout mechanism on the press are called
positive shedders.
The knockout arrangement of the press is usually of a bump type knockout
bar, mounted through slot across the press ram. The knockout bar is free to move up
and down with in the slot, as well as it could ride up and down together with the ram.
COMPRESSION SHEDDER
Shedders backed up by compression springs, hard rubber or disc springs
are called compression shedders.
It could be used to produce flatter and neatly sheared blank. They are
also used if the blanks are too large to allow the incorporation of an efficient
positive knockout system.
SHEDDING PINS.
The stock material is usually coated with a rust preventive solution. It is
obvious that any liquid or oil deposit left on the stock material will cause the
blanks to stick to the face of the shedder. Spring loaded shedding pins are
employed to overcome this problem.
Shedding pins will be more effective if applied to one side of shedder
face rather than in the centre. All ejection and knockout elements are to be case
hardened to 48-52 HRc depending on severity of operation.
KNOCK OUTS.
Positive knockouts are classified into 2 groups
1. Direct knockout
2. Indirect knockout

1. DIRECT KNOCKOUT
In this knockout system if the knockout rod is directly in contact with the
shedder, the system is known as direct knock out system.
2. INDIRECT KNOCKOUT SYSTEM
As the passage of the knockout rod is through the shank, any punch which
comes in line with or near to the centre line of the shank will obstruct the knockout
rod from coming in direct contact with the shedder. In such cases an indirect
knockout system should be employed. In addition to the shedder and the knockout
rod, it consists of a knockout plate and transfer pins as shown in the figure.
The location and number of transfer pins depend on the size and shape of
the blank.
 FASTENERS
The subject of fastener is an important one because these components
are applied so frequently and employed in such large quantity. although small
they perform important function. In design of tool and dies, Fasteners are
often the weakest link in the tool and, if they are not selected properly and
applied correctly, they can become cause failure of the entire tool.
DIE FASTNERS

In this exploded
view of typical die for producing
blank from the strip, all fasteners
have been shown removed from
the components which they
locates and hold. from this
drawing it is apparent that
fasteners ,all though small
individually, from the substantial
portion of the entire tool when
taken together.
TYPES OF FASTNERS
These are the types of fasteners most commonly used in die construction. they are
1. Socket cap screw
2. Counter sunk screw
3. Grub screw or set screw
4. Eye bolt
5. rivets
6. Cotter pins
7. Dowels
8. Removable dowels
Less frequently employed type include the following:
Hexagon nuts, washers, studs , rivets and wood screw.
SOCKET CAP SCREW:
These are generally used to fasten the
plate elements of the press tool like
punch holder assembly to the die top
and die stripper assembly to the die sleeve.

COUNTER SUNK SCREW:

These are used to fasten elements like
nest gauges, spacers, plate stoppers etc.

GRUB SCREW OR SET SCREW:

These are used to fasten parts which are
to be confined within a hole, like springs etc.

EYE BOLTS:
Eye bolts are used for lifting heavy die sets
or mould housings. it is also called as
carrier blots.
NON THREADED FASTENERS:
This group includes the elements like rivets and
cotter pins.
RIVETS:
Rivets are generally used to fasten
support plate of an extension table
in press tool. They are made of
MS, ALUMINIUM, COPPER OR BRASS
COTTER PIN:
These are used to prevent the
loose parts from coming out of holes.
DOWEL:
Dowel holds parts in perfect related alignment by
absorbing side pressure and lateral thrust. also,
they facilitate quick disassembly of components
and reassembly in there exact former
relationship.
REMOVABLE DOWELS:
One type of removable dowel is illustrated these
dowel are used in blind application
Shank and Shank Point Location
 SHANK

Shank is an element of the press tool which acts as connecting link from
tool to the press platen and also locates the centre of gravity the tool which aid
the tool cutting elements.

Five ways of mounting the shank.

By Riveting
By Press fitting
By means of threading
By making it as integral part of top plate
By making flange fastening
Self aligning type shank:

The shank permits quick loading and unloading of the press tool on a
press. The design of the shank is different from the other types. A TEE coupling
mechanism is made in two sections. The Half mounted on the tool is the male
member. The half fixed to the press ram is the female member. They are case
hardened.
Location of a Shank on a Tool

Balancing of the punches is the most important aspect during punching

operation.
Un balanced force on the tool may lead to undue wear on punch and die
as well as pillars.
The resultant forces of all cutting forces acting on many punches should
pass through the shank centre.

The position of the resultant forces of all partially cutting forces can be
found by the following methods

By Mathematical calculation.
By Polygon system(Graphical)
By Mathematical calculation.

shank point location can be found by calculating the X and Y co-

ordinates for the point. The formulae used for the calculation are.

X = (l1x1)+l(2x2)+(l3x3)……….+(ln xn)
l1+l2+l3……………….,,,,,+ln

Y = (l1y1)+l(2y2)+(l3y3)……….+(ln yn)
l1+l2+l3……………….,,,,,+ln
Example

The die layout for manufacturing the component is given herewith

reference axis. To find the center-point of shank location, proceed by taking X
and Y coordinates for each of the section as given below (in the table).
Reference edges for X and Y axis are to be taken from the sides of die
plate or from the side of the punch holder.
This is because the position of punches and die are available on these
two plates and center axis of punch and die will be same as these two plates.
The data pitch 32 is provided to fix "Y" values of each section in the die from
the reference edge.
 X axis` Y axis
Sl. No. L x X product Sl. No. L x X product
01 22 x 25 = 550 01 22 x 110 = 2222
02 10 x 30 = 300 02 10x 112 = 1120
03 12.56 x 37.9 = 476.02 03 12.56 x 117.09 = 1470.65
04 10 x 48 = 480 04 10 x 120 = 120
05 11.31 x 57 = 644.67 05 11.31 x 116 = 1131.96
06 20 x 61 = 1220 06 20 x 100 = 2000
07 26 x 48 = 1248 07 26 x 90 = 2340
08 15.71 x 30 = 471.3 08 15.71 x 86.815 = 1363.86
09 25.136 x 43 = 1080.84 09 25.136 x 48 = 1206.52
10 15.71 x 30 = 471.3 10 15.71 x 26 = 408.46
By Polygon system(Graphical)

The centre point of shank location can be determined by graphical method

which is also known as polygon system. To construct the polygon force diagram
the sequential steps given here have to be followed.

1 Draw the cutting forces to a scale in a straight line on x and y axis at right angle.
2 Draw the arrow heads at the ending points of each force as shown in Fig.9.
3 Draw two more lines at 45° angle from starting and finishing points of the total
length of the forces so as to form an isosceles triangle and call the intersecting
point as "pole centre".
4 Draw the lines from each arrow head to join the pole point and call them as pole
beams.
5 Draw the forces to scale at given distance.
6 Draw the lines parallel to the pole beams, cutting force line graphically as shown
in Fig. A
7 The line of action of the resultant goes through that point where those two pole
beams intersect.
Die Sets
 DIE SET

The following elements are considered before selecting the die set.
1. Make or manufacture,
2. Type,
3. Size,
4. Material,
5. Thickness of the die holder,
6. Type & length of the bushing,
7. Thickness of the punch holder,
8. Length of guide post,
9. Shank diameter,
10. Grade of precision.

DIE SET COMPONENTS:

Top plate.
Guide bushing.
Guide pillar.
Bottom plate.
• TOP PLATE:
The upper working member of the die set is called the top plate. The
upper surface of the top plate is bears against the under side of the press
ram. Punch components are fastened to the lower finished surface. The
top plate is generally made out of MS.
PUNCH SHANK:

The punch shank projects above the top plate and it aligns the centre the
die with the centre line of press. In operation the shank is securely clamp to
the press ram and it drives the punch portion of the die, rising and lowering
the die.

For semi steel die sets, the punch shank is cast integrally with the body
of the top plate and it is then machined. To supplement their holding power
of the shank, cap screws are often inserted upward to engage tapped in the
press ram.
SHANK
BOTTOM PLATE :

The bottom plate is the lower working member of the die sets. Usually the
bottom plate is made thicker than the top plate to compensate the weakening
effect of the slug and blank holes which must be machined through it.
Generally it is made up of MS.
GUIDE PILLAR:
Guide pillars are precision-ground pins which are press fitted into
accurately bored holes in the bottom plate. They aligns punch & die components
with the high degree of accuracy.
Guide pillars are used for precision die sets are chromium plated to
provide high degree of accuracy of resistance to wear. The addition of chromium
reduce wear up to 50%.
They are specified at least ¼ inch shorter than the shut height.
REMOVABLE GUIDE PILLAR:

Pillars may be removed for die sharpening, specially in large dies.

In first kind of removable pillar have an axial hole machined through them
are tapered at one end to engage a taper pin.
In second type of removable pillar, the taper pin is advanced for locking by
means of a socket cap screw.
In third type of removable pillar a socket head cap screw is engaged In
retaining cap to clamp the pillar to the bushing.
NON STICKING GUIDE PILLARS:

In initial engagement the jamming of top plate and bottom plate

is problem to avoid this kind of problem non sticking pillars are used.
Sticking occur until the bushing have engaged the pillars sufficiently
for complete alignment.
GUIDE BUSHINGS:
Guide bushings are engaged with the guide pillars for aligning the top
plate with the bottom plate. most bushings are made up of tool steel they are
also available in bronze.
There are two types :
1. Plain bushing are simple sleeves, pressed into the top plate.
2. Shouldered bushings are turned down at one end and they are
pressed into the top plate against the shoulder thus formed.
BALL BEARING DIE SETS:

Some die sets are provided with ball bearing .Guide pillars are pressed
into the top plate and thy engage linear ball bearings.
Lubrication is provided by cup greasing and this is sufficient for entire run.
Ball bearings should take more place than conventional guiding and they
reduce die space a small extend.
PILLAR ARRANGEMENT:
Ways of positioning the pillars in a
die set.
1. Two pillars are applied at the
back of the die sets. This is most
commonly used two pillar
arrangement.
2. Pillars are applied at the sides
force feeding strip from front to
back.
3. The pillars are arranged
diagonally.
4. Four pillars are used the
foregoing are standard pillar
arrangement as listed in die set
catalogue.
 TWO PILLAR DIE SETS:
Most tools are provided with two guide pillars applied at the back of the
die set because this type gives maximum visibility and accessibility since
it is open on three sides.

There are three most distinct type of back pillar die sets.
1. Regular : This type is employed with average proportions.
2. Long : This type is used for dies which are long and narrow.
3. Reverse : This type is used for dies which are relatively longer in
measurement from front to back than their measurement from side to
side.
THREE PILAR DIE SETS:
It provides increased stability for
unbalanced cuts. These are
incorporated only in square or
rectangular steel sets. For hand
feeding, the extra pillar is applied as
shone in fig A, at the front. when the
feed is automatic it is centered as
shown in fig B.
FOUR PILLAR DIE SET:
These die sets are selected for
retaining round disc as drawing
tools, trimming tools, and the like.
There are two back pillar style as
shown in figure A and center pillar
style as shone in fig B are available
in diameters ranging from 4 to 48
inches.
LONG NARROW DIE SETS:

This type of die set is used to

retain tools for cutting ,bending and
forming of long, narrow parts. they
are back pillars sets, and they are
available with either two or three
pillars. Two pillars are specified for
sets ranging from 12 to 72 inches in
length and three pillars for sets
ranging from 84 to 240 inches.
ROUND DIE SETS:
Three die sets are selected for retaining round dies such as drawing
tools , trimming dies, and the like .There are two back style pillar as shown
in fig A and center pillar style as shown in fig B are available in diameters
ranging from 4-48 inches.
CENTER POST DIE SET:
These die sets are used for
secondary operation work such as
coining, piercing and left & right
hand. Parts of one hand may be
conveniently loaded from one side .
When the other hand is to be run the
die set is turned around 180ºin the
press for ease in loading.
FOOL PROOFING:
Center pillar and diagonal
pillar die set are provided with
different diameter pillars,
dimension A and B Thus, the top
plate cannot be reversed on the
bottom plate.
FLOATING –ADAPTER DIES:

In blanking and piercing thin stock

and for shaving and broaching
operations very little clearance. can be
allowed between the punch and die
members. Long should be used with
these die sets because, in operation the
guide pillar must always be guided
within them.
LARGE DIE SET :
Large die sets are made of plate. They have ground surfaces and are
square or rectangular in shape. Three pillars arrangements are shown in fig.
RECOMMENDED THICKNESS:
The thickness is illustrated in this example.
E.g.
If the die set area for a particular die measures 30 by 20 inches and the
force in tons is less than 30, the values of 1 x 3/4th inches for C and 2 inches
for D would be selected. However, if the force is in tons were 60, we would use
the values opposite pressure in tons of 50-70,and the value for C would be 2½
inches and for D3 inches.
HEAVY DUTY DIE SETS:
The heavy duty die sets are particularly used for long runs. They ar
assembled with removable boss bushings to provide adequate alignment betwee
top & bottom plate.
SPECIAL DIE SETS:
These are designed for specific jobs. In this type ribs are provided at
high stressed areas or sections. Specific rules cannot be given because of
variety of conditions encountered.
 PROGRESSIVE TOOL

PROGRESSIVE TOOL

PROGRESSIVE BLANKING AND PIERCING TOOLS

A simple blanking tool is designed only when the piece part has no
internal details. An altogether different tool is to be designed if the piece part is
to be produced by the combination of blanking and piercing operations. It can
be done in the following way in the same tool. The piercing is performed in the
first station. Then the stock strip is advanced to another station where
blanking is carried out. The relative position with the previously pierced hole is
maintained during the blanking operation. The tool is known as "progressive
tool" because the processing progresses from station to station.
 PROGRESSIVE TOOL
Before designing the tool the piece part drawing should be studied
carefully. This is to plan the operations to be carried out in different stations. Then
the drawing of the stock strip is done. The drawing will be similar to the stock strip
as it will appear after it has gone through all the stations till a finished part is
removed from it. It must be fully dimensioned and should carry all in formations
necessary to start the design of the tool.

The in formations are:

1. Feed direction
2. The amount of pitch by which the strip should advance after each stroke.
3. Position of stoppers.
4. Width of the strip
5. Scrap bridge dimensions.
STRIP LAYOUT.
PROGRESSIVE TOOL
•Fifty to seventy per cent of the cost of stamping is on the material.
•The method employed in laying out the strip influences the economic success or
failure of any pressing operation.
•The strip layouts should be such that the maximum area of the strip is utilized
for the
production of stamping.
• In the tool shown the finished piece part is produced when the strip passes
through
three stations.
• The strip is stopped at the first station by the auxiliary stopper. (Finger Stopper).
• During the first stroke of the press ram two holes are pierced by the piercing
punch.
• The strip is then advanced to the next station.
• To do this the first finger stopper is withdrawn and the second finger stopper is
engaged.
• Now the pierced hole comes in line with the two pilots.
• The pilots are longer than the piercing punches.
PROGRESSIVE TOOLS
PROGRESSIVE TOOL
•The strip is then advanced to the next station. To do this the first finger stopper
is withdrawn and the second finger stopper is engaged.
• Now the pierced hole comes in line with the two pilots.
• The pilots are longer than the piercing punches.
•Their nose is conical shaped with a radius at the tip.
• During the next stroke of the press ram, the pilots enter into the previously
pierced holes and locate the strip. (Second station)
• In the first station the piercing punches again pierce two holes in the strip.
• Again the strip is advanced and brought to stop against the final stop.
• During the third stroke of the press ram the pilots enter the pre-pierced holes
and locate the strip.
• In the first station the two piercing punches produce two holes.
• In the third station the component is blanked and a piece part is obtained.
• This piece part will conform to the piece part drawing.
• Once the first blank is removed from the strip the strip is lifted to clear the fixed
stopper.
• The strip is fed till it again stops against the newly formed edge of the opening
in the strip created by the removal of the first blank.
• Only when a new strip is introduced into the tool the auxiliary stoppers are used
again.
COMPOUND TOOL
 COMPOUND TOOL

COMPOUND PIERCING AND BLANKING TOOLS

• Compound tools also produce blanks having holes.

• In a compound tool both the piercing and blanking operations are performed
simultaneously.
• The conventional positions of punch and die are inverted.
• The blanking punch is clamped to the bottom plate of the tool.
• The blanking die is clamped to the top plate.
• The piercing punches are positioned in-side the blanking die opening.
• They are mounted on punch holders.
• Their mating piercing dies are formed in the blanking punch.
• Because of the positions the mating parts assume, the blanking and piercing
operations take place in the opposite directions, but simultaneously.
• Because of this the piercing' and blanking burrs are formed on the same side
of the piece part.
 COMPOUND TOOL
• A fixed stripper cannot be clamped to the die because the die is mounted on the
top plate.
• A moveable stripper is fitted around the blanking punch.
• The stripper is actuated by self contained compression springs or by the die
cushion of the press.
• In addition to stripper some means should be provided to knockout or shed the
piece art from the blanking die as well as to strip itself from the piercing
punches.
• This is achieved by a shedder which is closely fitted in the blanking die and
around the piercing punches.
• The shedder can be actuated by a compression spring or can be connected to
the knockout mechanism of the press.
• The slug produced from the piercing operation falls down through the opening
provided in the bottom plate.
• The blanking die walls are straight without angular clearance.
• The piece parts are knocked out of the die as soon as the blanking is over.
COMPOUND TOOL
ADVANTAGES AND DISADVANTAGES OFCOMPOUND TOOLS
OVER PROGRESSIVETOOLS.

ADVANTAGES

Piece parts produced from compound tools are very accurate and identical
because all operations are carried out in a single station.
This is possible because the accuracy of the piece part does not depend on the
accuracy of the advance of the strip or the accuracy of the layout of the stations
as in the case of progressive tools.
Scrap stocks from other tools can be employed to produce piece parts in a
compound tool.
But progressive tool always need stock strip sheared to size.
In a compound tool burrs resulting from piercing and blanking
are on the same side of the piece part.
Piece parts produced on a progressive tool will have burr both sides.
Cost of manufacturing a compound tool is normally lesser
than that of a progressive tool for the same component.
This is because of the smaller size of the tool and the easier
manufacturing methods required.
 DISADVANTAGES.

If the pierced holes are too near to the outer edge of the piece part the blanking
punch of the compound tool which accommodates the piercing dies will become
very weak.
This is a major disadvantage because the punch may break either during
manufacture or during the course of the tool life.
When piece parts are having pierced holes too near to their outer edges
progressive tools are preferred.
 Shaving
Secondary press operation
 SHAVING
• Shaving is the secondary cutting operation. It is done by removing
(shaving) a small amount of material from the previously cut edge.
• The purpose of shaving is
 To improve the dimensional accuracy of the piece part.
 To improve the cut edge characteristics of the piece part.
 To improve the flatness of the piece part.
SHAVING CLEARANCE:
The cutting clearance in shaving operation may be practically non
existent. It is common practice to use close fit between punch and die with
minimum clearance possible. However in the case of larger shaving allowance
a cutting clearance of 5% of shaving allowance will be acceptable .
SHAVING ALLOWANCE:
The width of the scrap web removed by shaving operation is the shave
allowance .
Shave allowance for steel
A = C+0.04 s.
Or minimum =0.08.
A1= c/2 or min 0.04.

Shaving allowance for brass, copper, German silver etc.

A = c or min 0.08mm.
A1 = c/2 or minimum 0.04.
C = Cutting clearance used for previous cutting operation
(prior to shaving).
A = Shave allowance for single shaving operation is employed.
A1= Shave allowance for second shaving operation is employed.
SHAVING DIRECTION:

To improve the flatness of blank used to produce a better square cut edge,
it is necessary to keep up side down in the shaving. The cutting action is
opposite to that of the previous cutting and a more flat blank will be obtained.
The striking force required for shaving operation is two to three times that
of the stripping force required for the blanking, piercing.
Example: A blank o outside diameter 40mm and inside diameter 10mm is
to be shaved and outside in a single stage. Calculate the
allowance and decide the component size for blanking. Material MS
Thickness 2mm Tmax =360N/mm².
Given:
od= 40mm
id = 10mm
s = 2mm
Tmax = 360N/mm2
Shaving allowance of M.S.

In single stage A = C + 0.04s

C =0.005 x 2 x√360/10.
=0.06/side.
A =0.06 +(0.04 x2)
=0.14/side.
Size of blank for blanking = Ǿ40 + (2 x 0.14)
Size of hole for piercing = Ǿ10 – (2 x 0.14)
Out side Ǿ = Ǿ40.28.
Inside Ǿ = Ǿ9.72.
BENDING
 BENDING
Bending is a method of producing shapes by stressing
metal beyond its yield strength, but not past its ultimate tensile
strength. The forces applied during bending are in opposite
directions, just as in the cutting of sheet metal. Bending forces,
however, are spread farther apart, resulting in plastic distortion of
metal without failure.

527
PRINCIPLES OF BENDING
• Any elastic material when deformed within its elastic limit regains its
shape as soon as the force is withdrawn.
• But if deformed beyond its elastic limit it remains permanently in the
formed shape. (Fig 1)

• When a material is subjected to bending its outer layer experiences

tensile stress.

528
•Their length increases.
•The inner layers experience compressive stresses.
•Their length shortens.
•The plane in the material in between the outer and inner layers
experiences no stress.
•This is called neutral plane. It experiences no change in length.
•The material fibre at this plane is called neutral fibre.
•Neutral fibre represents the original length of the material before they
were subjected to bending. (Fig 2)

529
 The principles of bending involve.

• Selection of material of length equal to neutral fibre.

• Stressing it beyond elastic limit.

Plastic deformation due to bending:

• The act of bending causes the portion of the material which is within the area
of bend to become distorted.
• Material beyond the bend area is also slightly affected, but it can be neglected.
• The distortion is called plastic deformation.
• For illustrative purposes, the crystalline structure of the metal is represented
by cubical units equal in shape and size.
• After bending the units are displaced and deformed. (Fig 3)

530
• Material towards the inner bend surface is under compression and the material
towards the outer bend surface is under tension.
• Units outside the neutral plane are stretched longitudinally.
• Their area gets reduced.
• The units inside the neutral plane are compressed longitudinally.
• Their cross sectional area is increased.
• In the compressed part of the bend the material bulges wider than its original
width.
• On the tension side the material is reduced in both width and thickness.
• Thinning of the material on the tension side is more than the bulging on the
compression side.

531
• This is because the resistance of the material to compression is more than the
resistance to tension.
• Because of this internal movement takes place on the tension side of the bend.
• This shifts the neutral plane towards the compression side of the bend. (Fig 4)

532
533
 Factors influence the bend severity.

• Increasing the stock material thickness, increases the severity.

• Increasing the bend angle increases the severity.
• Decreasing the bend radius increases the severity.

THEORY OF METAL FLOW

In an analysis of bending, it is helpful to think of the metal part to be formed as

being made up of a number of longitudinal fibers enclosed in the part's cross section.
Such a part, undergoing a bending action perpendicular to its longitudinal axis,
behaves according to the known laws of physics, in a predictable manner: As the part
is bent, its fibers experience a distortion such that those nearer its outside, convex
surface are forced to stretch. Thus, a portion of the part's cross section is put in
tension and another portion in compression. 534
BEND ELEMENTS

535
Bending nomenclature.
Bending terms are defined in the following glossary:

Bend allowance
Length of the curved strip comprising a bend, measured along the neutral
axis from one bend tangent line to another,
Bend angle
a. Usually, the "included" angle of the work piece.
b. Also, the angle through which a bend is performed that is, the
supplementary angle to that formed by the two bend tangent lines or planes.
Bend radius
The inside radius of a bent section.
Bend tangent
A tangent line where the flat, straight section of the part stops and the
radius of the bend begins.
Neutral Plane
The neutral plane is theoretical plane originated by inherent bending
stresses. The Neutral plane occurs at a distance of 0.33 to 0.5 S, from the inner
surface. 536
Neutral Axis

Somewhere in the cross section, a plane of demarcation separates the

tension and compression zones. The fibers lying in this plane are affected by the
bending in a neutral manner, neither forced to stretch nor to compress.
This plane, situated in the cross section parallel to the surface around
which the part is bending, is called the neutral axis of the part's cross section. The
neutral axis is shown schematically in previous slides. Although not precisely true
under all conditions; for purposes of analysis, it can be assumed that the neutral
axis of a cross section coincides with the center of gravity. The location of the
center of gravity for a given cross section is determined by the geometry of its
configuration.
Therefore, for practical applications, the same can be said of the cross-
section's neutral axis. The center of gravity of a symmetrical cross section falls
exactly on its centerline, while being displaced from the centerline in the case of an
unsymmetrical cross section.

537
Fiber Deformation

Knowing the location of the neutral axis of a part helps in analyzing the
results that take place when bending occurs. It is the deformation of the part's
fibers during a bending action that is significant. The outer and inner surfaces are
of particular interest, and the deformation of their fibers is greatly influenced by the
location of the neutral axis in the part's cross section. The extent to which a fiber
distorts, whether in compression or tension, can be considered to be proportional
to the fibers perpendicular distance from the neutral axis. This distance acts on the
fibers as a lever, using the neutral axis as a fulcrum. Thus, the outer surface and
inner surface fibers experience the most distortion, while the other fibers of the
cross section are subjected to only a proportionate share.
When bent around a die, a thin part, such as a sheet, experiences little
distortion of its outer fibers, perhaps not enough to reach the yield state. On the
other hand, the outer fibers of an extrusion of substantial depth, when bent around
the same die, might undergo sufficient elongation to cause rupture. The reason is
that the lever distances acting on the fibers of the sheet are small, while those
acting on fibers of the deeper sectioned extrusion are great.

538
 Since the neutral axis accompanies the center of gravity, in a geometrical
sense, the inner fibers of an unsymmetrical extrusion, such as aT-section with
flanges of unequal thickness, may have only slight compression if the part is
formed with the heavy flange inward against the die. Consequently, wrinkling of
the inner fibers does not occur The outer fibers, on the other hand, elongate
considerably. This is because the center of gravity of the section, and hence its
neutral axis, is close to the inner fibers and relatively far from the outer fibers. The
lever distances, causing distortion of the inner and outer fibers, therefore are
different. Such parts, having their neutral axis located very near the inside
concave surface, can be formed by bending alone.
If the part were bent the other way, with the heavy flange outward, the
situation would be reversed. The outer fibers might not be elongated enough to
reach yield, while the inner fibers, with their long lever distances, could be caused
to compress to such an extent that the inner flange would buckle, as well as
wrinkle.
Thus, it is apparent that the neutral axis location is a major factor in
determining metal flow and forming characteristics of a part during bending
operations, and that the reactions of the inner and outer surfaces depend on the
part's geometry as a key determinant for the center of gravity and the neutral axis.
539
Bend allowance

Bend allowance is the dimensional amount added to a part through

elongation during the bending process. It is used as a key factor in
determining the initial blank size.
The length of the neutral axis, or bend allowance, is the length of the
blank. Since the length of the neutral axis depends upon its position within the
bend area, and this position is dictated by the material type and thickness and
the radius and degree of bend,
it is impossible to use one formula for all conditions. However, for
simplicity, a reasonable approximation with sufficient accuracy for practical
usage when bending is given by the following equation:

540
Where Lo = Developed length.
a = Angle of bend
A + B = Unbend length or Length of straight
Ri = Inner radius
S = sheet thickness
? = Correction factor ( to be chosen from graph )

541
CALCULATION FOR DEVOLOPED LENGTH

542
Examples:

1.0 Calculate the length of the component required to produce the

component which is given in the figure

2.0 Calculate the length of the component required to produce the

component which is given in the figure

543
 3.0 Calculate the length of the component required to produce the
component which is given in the figure

544
CALCULATION OF MAXIMUM & MINIMUM RADIUS

The work piece straightness if 'b' is less than y (yield stress) in order to
obtain a permanent bend the stress on bending area must be higher than the
yield point stress of the material.

In order to obtain a permanent set the stress which occurs on bending

must be higher than yield point of the material. The bellow formula therefore
gives the condition for R max. Radius which produces a permanent set.

545
CALCULATION OF MAXIMUM & MINIMUM RADIUS

The R max value of radius to which a particular material could be bent b

is just equal to y according to the previous formula,

y = SE / (2 ri + S)
i.e, 2 R max . + S = ( SE / y) – S
R max = ( SE / 2y ) – ( S / 2)
In this case S/2 can be neglected comparing to the value of R max.
Therefore,

There is also a limit for bend radius on minimum side. If the bend radius
compared with the thickness of the sheet is below a certain, the stress in the
outside fiber exceeds the ultimate tensile stress therefore rupture occurs.
So, R min could be calculated by following formula.

546
Where,
C =Constant referred to the following table.
If ri is greater than the Rmax, no permanent deformation takes place.

Sl . No Material C =Constant
01 Mild steel 1.5
02 Deep drawing tool 0.5
03 Construction steel 2.0
04 Copper 0.27
05 German Silver 0.45
06 Brass 0.4
07 Aluminum hard 0.4
08 Aluminum pure 0.7
09 Aluminum half hard 1.4
10 Gun Metal 1.2
11 Stainless Steel 0.5
12 Brass 0.3
547
Calculations:

1.0 Calculate the minimum and maximum radius to which a mild steel strip
25 x 1 mm can be bent.
Given: E = 210 GN/m2
y = 210N/mm2

548
Bending force requirements.

When simple flanges are air bent, forming loads are easily determined.
Many load charts similar to the one illustrated are available listing loads for mild
steel in various thicknesses for a range of V-die openings.
The force required to bend metal depends upon the type of material and its
physical properties, thickness of the stock, length of the bend, width of the die,
whether or not a lubricant is used, and the amount of wiping, ironing, or coining.
V-dies in which the punch does not bottom (air bending), commonly used in press
brakes, require the least force. Bending tonnage (force) required varies directly
with tensile and yield strengths of various materials.

Force Calculation

Two general types of bending are used in modern press working.

One is V-die bending, which is used extensively in brake die operations as well
as in stamping die operations. The other is wiping die bending.

549
 BENDING FORCE

FOR ‘V’ Bending dies

Where,
C = constant
b = sheet width
s = sheet thickness
W = width of the Die
The value of constant ‘C’ can be takes from the graph

or

can be calculated using the formula,

[ The formula can be used up to W=20 S] 550

FOR ‘U’ Bending dies

Where, C = Constant
b = width of the bend
s = Sheet thickness
 = Ultimate tensile stress
cb = Bending clearance
R1 = Die Radius
R2 = Punch radius

551
Calculations:

1.0 Calculate the bending force for mild steel of sheet thickness 2mm.Strip
Given: width = 20 mm,
W = 30mm
C = 1.25
 = 400 N/mm2

2.0 calculate the U bending force for MS sheet of thickness 3mm.

Given: punch radius = 5mm
Die radius = 5s
C = 1.2
 = 400 N/mm2
cb = 3.15

552
Notes:
Air Bending
In air bending the punch does not seat fully in the die; the sheet metal, supported
by high points of the die, wraps around the tip of the punch to form the bend. Air bending is
a versatile operation; a large variety of parts can be made from a single set of dies.
Accuracy of the parts must be closely monitored, however, because spring back is a factor.
Angular accuracy is obtained in air bending by over bending and then permitting
the material to spring back to the desired angle. Depending on the material, mayor may not
be consistent. Low-carbon steels, for instance, may have widely varying tolerances that
affect the Spring back consistency. An advantage of air bending is that it requires
considerably less press-brake tonnage (force) to produce a given bend-four to six times less
than in bottoming bending. Thus, some shops prefer air bending even if they have to rerun
rejected parts to obtain the desired angle. With the air bending method, the formed angle
can be specified anywhere from 180 to the included angle of the female die. The sharpness
of a bend is a function of the distance between the two edges of the female die and the
distance that the punch tip travels into the die.
Once a female die opening is selected, the repeatable accuracy of bending each
successive piece part is determined by how consistently the punch tip penetrates the die.
Variations in punch travel are particularly pronounced in forming lighter gages of sheet
metal. A variation of 0.005“ (0.13 mm), for instance, while forming l6-gage (0.063"; 1.60 mm)
mild steel may result in angular deviations of up to 70 when making 90˚ bends. In other
words, air bending accuracy of a press brake is directly related to its ability to bring the
553
punch tip to the same lowest point repeatedly during each stroke.
Bottom Bending
Bottom bending and coining form bends by letting the punch penetrate the female
die as far as the dies and the formed material will permit, Generally, bottom bending results
in more consistently accurate parts than air bending. Furthermore, a radius smaller than
metal thickness can be obtained with bottom bending and coining.
To help overcome spring back, the clearance between the punch and the die is set
slightly less than the material thickness. The resulting coining action counteracts the spring
back, provided a sufficient dwell time at the bottom of the stroke is used to allow lhe material
to make a compressive shift. While bottom bending results in consistent part quality, three to
five times the press brake tonnage is required to produce a given part in comparison to air
bending. Furthermore, to avoid damage from overloading (particularly with press brakes
using mechanical drives), clearances between punches and dies must be set very carefully:
If the clearance is too loose, reject parts will be formed 'if the clearance is too tight, full
length overloading may occur. In practice, a press brake usually is set up with material
thickness clearance between the upper and lower dies.
For this reason, bottom bending should' be used only where it is really needed-in
applications requiring a high degree of accuracy and sharp corners. For example, metal
furniture, cabinets, and partitions usually require bottom bending. Because of the higher
tonnage (force) requirement, bottom bending is generally limited to bending steel that is
no heavier than 12 gage (0.109"; 2.77 mm).

554
555
SPRING BACK

• In bending operations the elastic limit of the metal in process is exceeded but
is ultimate strength is not.

• Therefore some of the original elasticity of the stock material will be present
on the material after bending operation is over.

• Because of this when the force (punch) is withdrawn the material on the
compression side of the bend, tends to expand slightly and the material on
the compression side of the bend tends to expand slightly and the material on
the tension side is tends to contract.

• The combined result is that the work piece tends to resume its original shape.

• This causes the bend to spring open a small amount.

• This reaction of the material is called spring back.

556
•The spring back varies according to the thickness, type and condition of the
stock material.
•It also varies directly in proportion to the size of the bend radius. The larger
the bend radius the greater the spring back.

557
HOW TO AVOID SPRING BACK?
4 METHODS
to
OVERCOME SPRING BACK
in

• Over Bending ‘V’ BENDING DIES

• Corner Setting
• Offset Punch Method
• Angular Punch Relief

558
1. Over bending IN ‘V’ BENDING

Over bending is the simplest way to correct spring back. It is done by

making the punch angle (angle m) smaller by the required amount.

For soft steel, Brass, aluminum or copper spring back -0 to 1

For ¼ to ½ hard material 1 to 5
For hardened material 12 to 15 or more

559
2. Corner Setting on ‘V’ Dies:

This is the most effective way of

avoiding the spring back. This is a
method of eliminating spring back than
making compensating allowances.

560
3. Offset Punch Method

The face of the punch is offset in

order to achieve coining penetration in
the bend area. Offset dimensions
should not be made unnecessarily
deep, as this can weaken the piece
part. An offset depth of 5% of ‘S’ is
normally used.

561
4. Angular Punch Relief

An angular differential is
provided between the included
angle of the punch and the included
angle of the die opening.

562
 5 METHODS
to
OVERCOME SPRING BACK
in

‘U’ BENDING DIES

• Convex pad method.

• Punch sidewall relief – Angular
• Punch sidewall relief – straight under cut.
• Over Bending
• Corner setting

563
1. Convex pad method.

•For compensating spring back, over bending can be used in u bending.

• In the convex pad method the spring back in another area is utilized.
• The web (bottom) of the work piece is formed.
•The elastic limit of the stock material is not exceeded.
•When the work piece is removed from the tool the web spring back to a flat plane.
•This causes the bend legs to pivot inward around the bend axis.
•This compensates for the spring back of the bend legs.
• For large work pieces punch side wall relief method is used.

564
2. Punch sidewall relief

•For compensating spring back, over bending can be used in u bending.

• In the convex pad method the spring back in another area is utilized.
• The web (bottom) of the work piece is formed.
• The elastic limit of the stock material is not exceeded.
• When the work piece is removed from the tool the web spring back to a flat Plane.
• This causes the bend legs to pivot inward around the bend axis.
• This compensates for the spring back of the bend legs.
•For large work pieces punch side wall relief method is used.

There are two methods

• Punch side wall relief-angular.
• Punch side wall relief -straight undercut.

565
4. Over bending

• Over bending is the simplest way to correct spring back.

• It is done by making the punch angle (angle B) smaller by the required amount.
• For soft steel, brass, aluminum or copper spring back 0 to 1º for 1/4 hard 1/2
hard materials 1 to 5°.
• For hardened material 12 to 15° or more.
• These values are only approximate values, because many variables influence the
spring back.
• Correct values can be found out only by experiment.

566
5. Corner setting

•The face of the punch is offset in order to achieve a coining penetration in the
bend area.
•If offset dimensions are unnecessarily deep, it will weaken the piece part.
•An offset depth of 5% of sheet thickness is normally used.

567
5. Corner setting

•This is the most effective way of avoiding spring back.

•This is the method of eliminating spring back than of making compensating
allowance.
•Setting is accomplished by coining (squeezing) the stock material at the bend area.
•The coining effect causes additional compressive strain within the material.
•The extra compression strains overcome the spring back tendencies.
•Since the set is made in the bend, the practice of setting in bending operation is
referred to as comer setting.

568
HOW TO STRIP THE
BENT COMPONENT?

569
U bending operation requires two opposed stripping actions.

1.Stripping the work piece out of the die opening.

• The pressure pad performs this function.

2. Stripping the work piece from the punch.

• Positive knockout offs actuated by the knockout system of the press
• The work piece is knocked off the punch.

SPRING ACTUATED PLUNGER

570
HOOK STRIPPERS

POSITIVE KNOCK OFF

571
 EFFECT OF GRAIN DIRECTION

The most favorable condition exists when the axis of the bend is
perpendicular to the grain direction.
The most reverse bends practical for the type of material can be made
in this direction.
The least favorable condition exists when the axis of the bend is
parallel to the grain direction.
The ability of the material to withstand bending strain as the angle
approach 90.

572
EFFECT OF GRAIN DIRECTION

573
EFFECT OF BURR SIDE

• It is undesirable for the burr side to be located in the outer surface of the
formed piece part, because the burr drags around the bend radius and into
the die opening.

• This causes excessive wear in the die members. If the piece part is loaded
such that burr is located on the inner surface of the formed piece part, the burr
will face towards the punch.

• Since there is no drag between the work piece and the punch, burr cannot
erode the punch.

574
BENDING IN PROXIMITY TO PIERCED HOLES

• Holes pierced before bending will be distorted if they are very close to the
bend area. As a rule distortion will be minimized if the distance P is held to
minimum of 1.5 s

575
BENDING DIES

576
BENDING DIES

• ‘V’ Bending Dies

• ‘U’ Bending Dies
• Multiple Bending Dies
• ‘L’ Bending Dies

577
‘V’ BENDING DIES

578
‘U’ BENDING DIES

579
‘L’ BENDS ON PRESSURE PAD
DIES

• ‘L’ Bends are produced in V dies. They are

also produced in pad type dies. An L bend
is one side of U bend. Since the other leg
of U is missing, self-equalizing qualities of
U bend are not available.

580
Rotary Bending
Traditionally, press brake bending has been performed in one of three
ways: with a V-die, with a wiping die, or with a U-die. In recent years, however,
another (patented) method, rotary bending, is gaining acceptance. The main
advantage of rotary bending is that it significantly reduces the force required to
perform bending.
The rotary bending design eliminates the need for any type of hold-
down pad or device. It provides its own inherent holding action at the same
time the bending operation is proceeding.
.

581
 The rotary bender is comprised of three
components: the saddle (punch), the adjustable
rocker, and the die anvil. The rocker is cylindrical in
shape with an 88˚ V-notch cut out along the length.
The edges of the rocker jaws are flatted and radius
to minimize marking; Three stages of a rotary
bender operation are illustrated in Fig. In view a, the
material is clamped and the rocker rotation has
begun; view b shows that humping is controlled and
limited to space between edges of the rocker; and
view c shows how the rocker clamps the work piece
in position and Over bends it sufficiently to allow for
spring back. The primary application for rotary
benders is in progressive dies. Z-bends and short
leg bends can be made in a single operation; and
where needed, dart stiffeners can be rolled into the
work piece at the same time it is being bent

582
Draw backs of ‘L’ Bending

The two problems encountered are:

• The one sided lateral thrust imposed upon the punch.
• The work piece tends to pullout of the die opening.

583
‘V’ BENDING IN PRESS BRAKES

584
PRESS BRAKES OPERATIONS

585
MATERIALS FOR BENDING

HARD
• Avery stiff; springy, cold rolled strips
intended for flat work, where ability to
withstand cold forming is not required.

586
HALF HARD

• A moderately stiff cold-rolled strip

suitable for limited bending. Right
angled bends may be at 90 to the
grain direction around a radius equal to
thickness

587
QUARTER HARD

• A medium soft cold-rolled strip suitable for

limited bending, forming, forming and drawing.
May be bent to 180 across the grain and to the
90 parallel with the grain and a radius equal to
the thickness.

588
SOFT

• A soft, ductile cold rolled strip suitable

for fairly deep drawing operations
where surface disturbances such as
stretcher strains are objectionable. Strip
of this temper is capable of being bent
flat upon it self in any direction.

589
DEAD SOFT

• A soft ductile, cold rolled strip produced

without definite control of stretcher and
fluting it is suitable for difficult draw
applications where such surface
disturbances may be tolerated. It is
suitable for bending flat upon itself in
any direction.

590
 ‘V’ BENDING TOOL
In ‘V’ bending tool the shape of the punch and dies is in the form of the
letter ‘V’. It is used to produce the ‘V’ bending in the components.

591
 U BENDING TOOL
U Bending Tool is shown in Figure
The component is located in the nest. When the punch enters the die, the
shedder acts as a pressure pad and supports the component during bending
. Once the bending operation is over and the punch withdraws from the die, the
compression spring pushes the shedder up. The component is thus ejected.
Figure

592
Top plate
This is the plate to which the punch holder or punch is held. Top plate also
holds the shank and guide bushes.
Bottom Plate
It is the palate on to which the die and pillars are fitted
Bending Punch and Bending die
These are the bending elements of the tool. These are made of High Carbon
steel and are hardened and tempered to 55-58 HRC
Locating Plates
The component to be bent is located by means of locating plates or nest pins
depending upon the shape of the component
Guide pillars and Guide bushes:
To achieve a well guided movement of the moving parts with respect to the
fixed parts, the guide pillars and bushes are used.
Shank
It is the part which connects the moving half of the tool to the press ram.
Screws and Dowels
The main fastening member which holds the plates together is the screws.
The locations of each plate accurately is done by the dowels. The number and
size of screws and dowels depends upon the size of plates and load on them
593
DEEP DRAWING
 DRAWING

One of the most common metalworking

methods is drawing, which involves forming flat sheet
metal into “cup-shaped” parts. If the depth of the
formed cup is equal to or greater than the radius of
the cup, the process is called deep drawing.
Deep drawing is a process of cold
forming a flat pre cut blank in to a hollow vessel .
In an idealized forming operation in
which drawing is the only deformation process that
occurs, the clamping force of the hold-down dies is
just sufficient to permit the material to flow radically
into the die cavity without wrinkling. Deformation of
the sheet takes place in the flange and over the lip of
the die; no deformation occurs over the nose of the
punch.
 Analysis indicates that the flange is
compressed circumferentially and pulled radically in
the plane of the sheet into the side wall of the part.
This is analogous to wire drawing in that a large
cross section is drawn into a smaller cross section of
greater length; and for this reason, this kind of
forming process is called drawing to distinguish it
from stretching.

The capability of the metal to withstand drawing

depends on two factors.

1. The ability of the material in the flange region to

flow easily in the plane of the sheet under a
condition of pure shear. This means it is desirable
to have low flow strength in all directions of the
• When the punch of the drawing tool forces the metal
blank through the bore of the drawing die, different forces
come into the action to cause rather complicated plastic
flow of the material.
• The volume and the thickness of the material of the metal
remain essentially constant and final shape of the
component will be similar to the contour of the punch.
• The relationship between the diameters and depth of the
drawn sheets vary widely and relationship is an important
factor in the design of the drawing dies.
• If the drawing ratio exceeds a certain limit the material
will fail due to excessive stresses.
• Then it is necessary to draw the component in two or
more stages. This increases the tool cost.
SUMMARY OF METAL FLOW

Little or no metal deformation takes place in

the blank area which forms the bottom of the cup.
The metal flow taking place during the forming
of the cup wall uniformly increases with the cup
height.
The metal flow of the volume elements at the.
periphery of the blank is extensive and involves a
increase in metal thickness caused by severe
circumferential compression. This increase in the
wall thickness caused by severe circumferential
compression. This increase in the wall thickness is
at the open end of the cup wall. The increase is
usually slight because it is restricted by the
clearance
between the punch and the bore wall of the die
Wrinkling and Puckering
Deep drawing necessitates severe cold
working and involves plastic flow of the metal.

The metal may buckle rather than shrink,

‘wrinkles’ occur at the edge of the blank and
‘puckers’ appear on only one part of the blank.

Cause Remedy
Insufficient the blank Increase spring
holding force (mostly in pressure
flanges).
Redesign punch
Too large area of and die
unsupported metal between
Use draw beads
punch and draw ring
Use
Broken spring behind blank
homogeneous
holder
material
Puckering

Cause Remedy
Wrinkling is called as Reset correct
puckers if they appear in clearance
any other part of the cup
Use optimum die
like sidewall. It may be due
radius
the improper clearance
between punch and die. Proper blank
holding force
In addition, it will occur
when the die radius is too
large.
Sequence of drawing operation on double action
press
Deep drawing involves placing a sheet
metal blank over a shaped die and pressing the metal
into the die with a punch. The piece produced may be
cylindrical or box-shaped with straight or tapered sides
or with a combination of straight, tapered, or curved
sides.
The punch must provide enough force so
that the metal is drawn over the edge of the die
opening and allowed to flow into the die.
Sequence of drawing operation on single action
press

Single-action drawing with a draw cushion

works the other way round:
The forming force is exerted by the slide
above through the die and the blank holder onto the
draw cushion in the press bed (Fig.)
The draw punch and the blank holder of
the drawing tool are both located in a base plate on
the press bed. Pressure pins, which come up through
the press bed and the base plate transfer the blank
holder force from the draw cushion onto the blank
holder.
The female die and the ejector are
mounted on the press slide. At the start of the forming
process the blank is held under pressure between the
draw die and the blank holder. The slide of the press
pushes the blank holder downwards over the draw die
against the upward acting force of the draw cushion.
The part is formed via the downward
movement of the die over the stationary draw punch.
The press slide must apply both the pressing and the
blank holder forces.
 Thus, using a single-action tool, the part
does not have to be rotated after the drawing process.
Furthermore, today the use of hydraulically controlled
draw cushions, even with deep drawing processes up
to depths of 250 mm, produces a work piece quality
comparable to that of double-action presses.
Sequence of operations in reverse drawing

An energy saving and cost effective

alternative in stamping is counter drawing or reverse
drawing (Fig.)
In this operation, once again, a single-
action press with a draw cushion is used normally a
hydraulic one. The top die is attached to the slide. The
lower die is mounted on the press bed with the blank
holder.
 The punch is located in an opening in the
center of the press bed on the draw cushion. During
deformation, the blank holding force is transferred via
the slide from above and the draw punch force acts
from below through the active draw cushion.
The punch forms the part by means of its
upward movement while the blank holder rests on the
die. The active counter drawing combines the
advantages of static blank holding and the low power
usage of double-action dies with the, advantage of a
single action die, in which it is not necessary to rotate
the part.
Admittedly, it is necessary to have a
special
modification of the dies for performing this operation,
since the forces operate in the opposite direction to
those of a normal single-action deep drawing press
with draw cushion. Thus, these dies cannot be
installed in a normal single-action press.
Lubrication for deep drawing.
The punch must provide enough force so
that the metal is drawn over the edge of the die
opening and allowed to flow into the die. The sheet
metal blank must be strong and ductile enough to
avoid breaking in areas where the metal flows from the
punch face to the sides of the punch.
Characteristic of deep drawing is the high
pressure on the order of 100,000 pounds per square
inch (PSI) involved in the operation. To deal with such
force, the choice of lubricant is critical to the success
of the operation.
Under such pressure, the drawing lubricant should:
1. Cool the die and the work piece.
2. lubricate between the die and the work piece.
3. Prevent metal-to-metal adhesion or welding.
4. Cushion the die during the drawing operation.

Drawing compounds used in deep drawing

are known as boundary lubricants. The tooling and
sheet metal surfaces are pressed so tightly together
that the liquid is squeezed out and only a very thin
adsorbed film remains.
Different types of drawing lubricants are
used, depending on the depth of a particular draw.
Generally, the effectiveness of a deep drawing
lubricant depends on its ability to form an adsorbed
film of sufficient strength and oiliness on the metal
surface being drawn.
Three types of drawing lubricants are used:
Drawing oils. Drawing oils form an
adsorbed film, and they take the form of light or
soluble oils such as straight mineral oil or emulsions of
soluble oil and soap, or of heavy oils, fats, and
greases such as tallow or lard oil.
Emulsions. Aqueous solutions of nonoil
lubricants containing some suspended solids are
called emulsions. These lubricants are not widely used
in deep drawing because they contain little or no oil.
Lubricants containing both oil and solid
substances. Used in applications involving severe
drawing, these lubricants contain oily components that
reduce friction and heat. The combination of the oil
and the solids together produces enough lubrication
for severe drawing applications such as deep drawing.
A lubricant compound can be used as a
paste or as a liquid after being diluted with water,
depending on the required concentration and the
severity of the drawing operation. Methods for applying
lubricant to sheet metal include dips, swabs, brushes,
wipers, rollers, or recirculation.

Of these, the three most common are:

1. Manually wiping lubricant onto a surface with a
rag.
2. Roll coating, during which metal blanks pass
through rollers that apply the compound.
3. Flooding, during which tooling and metal sheets
are drenched with lubricant, and the excess liquid
is recovered via a filtration and recirculation
BLANK DEVELOPMENT
(Cylindrical shell)

The first calculation to be made to

determining the blank diameter. How much material
will it take to produce the final draw?
This is done by calculating the area of the
final draw and then adding enough material for
trimming and carrying the part.

This can be done by;

• Algebraic method
• Graphical method
• Area of element method
• Layout method
• Center of gravity
• Centre of stock

The next step is Determining how many draws or

redraws are needed to make the final product, this is
calculated as a percentage of reduction from blank
diameter to final part geometry. As a general rule, the
maximum reduction for most materials is about 40%.
After we have the calculations, we then can develop a
tooling approach.
Algebraic method

The following equations may be used to calculate

the blank size for cylindrical shells of relatively thin
metal. The ratio of shell diameter to corner radius can
effect the diameter and should be taken into
consideration. The cylindrical shells can be considered
as consisting of circular pipes or disc.

D = Blank Dia.
d = Shell dia
h = Shell dia.
R= Corner radius.
Solved Examples: (Algebraic method)

Determine the blank size

required to produce a cup of Ø65mm ,
height 75mm, corner radius 3.5 drawn
from a 1mm of DD Quality steel

Solution:
Given: Cup dia = 65
Cup height = 75
Conner radius = 3.5

D/r = 65 / 3.5
= 18.6

As d / r is in between 15 and 20
following equation can be used

D = √( d2 + 4 d h ) -0.5R

D = √( 652 + 4 x 65 x 75 ) - 0.5 x
3.5
D = 152.2
Graphical method

Knowing the finished shell dimensions it is

possible to graph the diameter using the reference
plane.
Step 1.
From O reference plane Raise the
perpendicular to height h
Step 2.
From the top[ of the perpendicular Draw
hypotenuse of length h+(d/2) to intersect reference
plane.
• The horizontal component x between the
intersections on the reference plane, equal s
the
radius of the necessary circular blank diameter
D
Solved Examples: (Graphical method)

Determine the force required to

produce a cup of Ø65mm , height 75mm,
corner radius 3.5 drawn from a 1mm of
DD Quality steel

Solution:
Given: Cup dia. = 65
Cup height = 75
Conner radius = 3.5

Acceding to PYTHAGORUS Theorem

(h+ d/2)2 = h2 + x2
x2 = (h+ d/2)2 – h2
= ( 75 + 65 /2 ) 2 - 75 2
Area of element method

To calculate the blank diameter for complex

Circular shells, it can be divided into simple elements
Of shapes. The elements are numbered 1,2,3,..etc.,.
Then each element is calculated for it’s development
by using the equations given bellow. Then all divided
elements are added and root of the answer will be the
required diameter of the blank.
height 40, and corner radius 10
Solution:

In the example shown the elements are

numbered 1, 2,3 etc
1 is a cylinder
2 is a portion of cylinder.
3 is a disc.
The area of these elements can
be found by using equations given in the
standard chart. From the total area the
diameter of the blank can be calculated
Element 01 (cylinder)
=πxdxh
= π x 50 x 40
Element 02 (disc)
= d2
= 30 2
= 900

So Total area of cup D=

D = √ (Element 01+ Element 02+

Element 03)
D = √ (6283.2 + 2122 + 900 )
D = 96.5 mm
Layout method

The graphical or layout method for determining the

blank diameter for the same shell or cup is as follows:
Make an accurate layout of the part
including a line through the centre of the stock.
Number each dissimilar section starting
from the extreme edge of the part.
Draw a vertical line x y and mark off the
length of each section accurately starting with section
1 at the top of the line (i.e.. the length of sections).
Number each section to correspond with
the same section of the shell.
Through the centre of gravity of each
section draw a line downward parallel to x y.
 From point x and y draw a line A and D at
45°. Mark the meeting point at these two lines as P
draw line to end at each section. 1 and 2 mark lines as
B and C is about midway between x and y.
Draw a line A' parallel to A intersecting the
lines drawn through the centers of gravity.
Draw parallel lines B'. C' and D'. B' starts
where A‘ intersects the first centre of gravity line and
so on until where D' starts where C' intersects the third
centre of gravity line and continues to intersect A'.
Through the intersection of A' and D' draw
a horizontal line Z to the centre line of the shell.
Construct a circle using y as centre and z
as diameter.
Using x as centre draw an arc tangent to
the circle.
Draw a horizontal line tangent to the top of
the circle until it intersects the large arc.
The distance from this intersection to the
line x y is the radius of the blank.
Centre of gravity method.
The blank size for a symmetrical drawn
cup can be determined by Guldinuss theorem.
Guldinuss rule states that the area is equal to the
length of the profile lines the length of the path of its
centre of gravity.
The centre of gravity point in this method
can be found out graphically or can be calculated
arithmetically.

The centre of gravity distance can be

calculated arithmetically from the formula.
Centre of stock method
Drawing force

It is the force required to draw the blank

in to the die to form it to cup shape.
This can be determined by the following formula.

Where.
d = Diameter of cup in mm
s = Thickness of material in mm
a 0.4
= Ultimate
0.45 0.5 0.6
tensile
0.65
strength
0.72 0.86
of 1
material.
d/D 0.8 0.775 0.75 0.7 0.675 0.65 0.6 0.55
a = constant

Draw force can all so be calculated by relation.

Where.
d = Diameter of cup in mm
D = Diameter of blank in mm
s = Thickness of material in mm
= Ultimate tensile strength of
material.
c = constant (between 0.6 and
0.7)
 = 450 N/mm2
Ultimate tensile stress
= 600N/mm2
Area of cross section of cup
= 400mm2
Sheet thickness
= 1mm

Solution :
For drawing force .

= (450 + 600) / 2 x 400

= 210 KN/mm2
Press force

The capacity of the press must be greater

because about one third of the capacity of the press is
used by the blank holder.

Blank holding force

Optimum blank holding pressure is

necessary for successful draw.
Very low blank holding pressure leads
to wrinkle formation. High blank holding pressure
leads to tearing.

Blank holding is not necessary when

• Deformation of component is small (Shallow draw)
i. e. d/D ≥ 0.2
or percentage of reduction is ≤ 0.2
• If blank is relatively thick

• In general if D/s ≤ 45 to 50, blank holder is not

necessary.
• By adopting the edge profiles shown in figure deeper
draws without blank holding can be achieved than
with other edge profiles with blank holder

Blank holding force calculation.

Method 1.
The recommended blank holding pressure
varies from 80 to 200 N/mm 2. Bigger values are used
for thinner materials.

Blanking holding force =

Blank holding pressure x blank holding area
Method 2.
Blank holding pressure is inversely
proportional to the blank thickness. The blank holding
factor 'X' can be taken from the graph depending on the
sheet thickness.
In this method the blank holding force is not
calculated separately but the total drawing force
(including blank holding force) is arrived at

Total drawing force = X x Drawing force.

Method 3.
Blank holding can be calculated from the graph.
The pressure varies according to the sheet thickness,
Cup diameter, D/d ratio (ß) and the strength of material.
Procedure:

Example 1:
Find the blank holding pressure for the
following draw:
Sheet thickness =
1.6mm
Blank diameter =
200mm
Cup diameter =
100mm
= 160
N/mm2
= 200
=2
100
Proceed from sheet thickness
and follow the line a long the arrow.
Blank holding pressure from graph
Drawing Clearance

The clearance between the punch and the

die must be greater than the thickness of the material
to be drawn.
•Too large clearance will result in wrinkles.
•Too small clearance will result in tearing.

The clearance should be proportional to

the metal thickness plus an allowance to prevent wall
friction.
Normally 7% to 20 % of the metal
thickness is allowed as clearance depending upon the
type of operation and metal.
 The following emprical relations can be used to
determine the clearance in draw tools.

For deep drawing quality steels

Clearance = s + ( 0.07 √10.s )

For Aluminum
Clearance = s + ( 0.02 √10.s )

For other non ferrous materials

Clearance = s + ( 0.04 √10.s )

The table provides guidelines for draw clearance.

Blank thick First draw Redraw Sizing draw

Up to 0.4mm 1.70-1.09s 1.08-1.1s 1.04-1.05s
0.4 – 1.3mm 1.08-1.1s 1.09-1.12s 1.05-1.06s
1.3 – 3.3mm 1.1-1.12s 1.12-1.14s 1.07-1.09s
3.3 above 1.12-1.14s 1.15-1.16s 1.08-1.1s
Punch and die radius

The draw radius of the die should be kept

as large as possible to aid metal flow. If it is too large
the material will be released by the blank holder too
soon and wrinkles will result.
When the radius is too small the material
will rupture as it is bent around the draw edge. A taper
or an elliptical curve may be used instead of a radius
to aid the flow of the metal into the die.
To prevent excessive thinning at the
bottom of the cup the punch nose radius is made 4 to
10 times the metal thickness
When more than one drawing operation is
required for the component the nose radius should be
proportionately smaller than the succeeding shell.
Draw Beads

These are the small projections on the

surface of draw die near to the opening of the die. It is
provided to control the material flow. Disadvantage is
the increased raw material.
The beads need not be continuous around
the die. More than one may be placed in areas where
greater retardation to metal flow is required. The draw
beads reduce the blank holding pressure.
When the metal flows over the draw beads
it gets heated up. This heat development stress
relieves and anneals the materials and improves its
drawing characteristics.
 Beads are also used to deflect metal into
or away from local areas. As an alternative to using
excessive blank holder pressure beads are placed in
the blank holder surface to retard the movement of the
metal into the die cavity.
Two or more beads may be placed in
areas requiring greater control of the metal. Normally a
single bead is placed around the die cavity and
additional beads are placed in local areas only as
required.

Air vents

An air vent should be provided in the

punch and the die to eliminate air pockets, which tend
to collapse the cup when stripped from the die. On
non-cylindrical shapes two or more air vents are
provided. To prevent plugging of the air vents with the
drawing compound and dirt they must be placed in
such apposition that they can be easily cleaned.
 Die requirements for deep drawing of
cylindrical shells

The clearance between the punch and the

die must be greater than the thickness of the material
to be drawn.
Too large clearance will result in wrinkled
and too small clearance will result in tearing of the
component.
The clearance should be proportional to
the material thickness plus an allowance to prevent
wall friction. This allowance ranges from 7-20percent
of the material thickness depending on the type of
operation and the metal.
As the shear strength of the stock
decreases the allowance should be increased.
Determination of number of draws.

It is not possible to draw the deep cup to

its length some time. If it is forced to draw sheet will
get thin at is corners and tends to tear off. So to avoid
it we should draw component in different stages.

This can be achieved by.

• Consideration of strain factor

• Relation between strain
hardening, strain factor and
tensile strength.
• Consideration of d / D ratio
• Consideration of % reduction
• Consideration of diameter
thickness ratio.
Method 1.

Consideration of strain factor

A drawn cup is subjected to excessive

strain during the drawing process.
The ratio h/H is a measure of tensile strain.
This strain should be limited within safe limits. The
recommended values of the ratio for the first draw are
given below.

Material h/H = ec
Aluminum Alloy 1.4
Aluminum heat treatable. 1.3
Brass 70/30 1.5
Brass 63/37 1.5
Bronze, Tin 1.5
Steel low carbon 1.4
Steel, Austenitic stainless 1.5
In case of multiple draws the total strain factor

et = e 1 + e 2 + e 3 + e 4 + - - - - + e n

A strain factor of 1.12 to 1.18 is

recommended for equal draws
Method 2.

Relation between strain hardening, strain factor

and tensile strength.

Drawn cups are subjected to work

hardening and have an increased elastic limit,
hardness, yield point and ultimate strength.
A strain factor e = 1 is associated with soft
metal having yield strength σs. When the metal is
work hardened (drawn) its ultimate strength σ u and
the ultimate strain factor e max are reached.

Where: δ = is maximum elongation at fracture.

During redraws the e max value cannot be

safely reached since the fracture is imminent. Number
of redraw stages should be so chosen that the upper
portions of the cup wall do not reach their ultimate
Strengths.
Method 3.

Consideration of d / D ratio
The number of draws can be determined
on the value of d / D ratio.
The recommended value of d / D value = (d / D = m)
for first draw and subsequent draws are given below.

Material 1st draw 2nd draw

Cold rolled steel 0.6 0.8
Annealed steel 0.56 0.78
DD steel 0.52 0.72
Soft brass 0.54 0.72
Copper 0.52 0.72
Aluminum 0.52 0.72
Method 4.

Consideration of % reduction
This relation also represents the same
principle as strain factor D – d / 2 x 100 and another
ratio is denoted as % reduction.

Hence the values of M given is valid in this approach

also.

% of reduction % of
Material in 1st draw reduction in
2nd draw
Cold rolled steel 40 20
Annealed steel 44 22
DD steel 48 28
Soft brass 46 28
Copper 48 28
Aluminum 49 28
Method 5.

Consideration of diameter thickness ratio.

Since the sheet metal thickness and blank
diameter are the beam width and length in buckling
slowly, it is logical that these sizes be used to predict
the severity of wrinkling.
If D / s = 25 a single action die and a
relatively small strain factor of about 1.5 is permissible
even for quite ductile metals.
D / s = 50 a total strain factor of 1,7 to 1,8
is possible and cupping may be followed by a single
redraw without anneal
D / s = 63 A second redraw may follow the
first redraw without anneal
D / s = 160 and above - For double action
tools, the minimum ratio is about 160 and additional
redraws may be possible if D / s is larger than 250.

All the above cases provide an accurate

measure for determining number of draws when a
flangeless cup is drawn.
s = sheet thickness in mm
Solved Examples: ( Number of draw
calculation)

Determine the no. of draws

required to produce a cup of Ø10mm and
height 18mm drawn from a 1mm DD
Quality steel.
Also determine the cup diameter & height
during each stage.
Draw ratio for first draw = 0.52
Draw ratio for redraw = 0.72

Given : Diameter of cup of = 10mm

Cup height = 18mm
Sheet thickness = 1mm
Material DD steel
Draw ratio for first draw = 0.52
Draw ratio for redraw = 0.72

Solution:
First calculate for blank diameter.
D = √(d2 + 4dh)
= √(102 + 4 x 10 x 18)
D = 28.63
 So three draws with 0.52, 0.72,
and 0.90 ratios
are needed.
As the reduction at the final
stage is very less, safer values with 0.55,
0.75, and 0.9 are selected.

To find the cup diameter at each draw

Cup diameter after 1st draw (d1) =Dx
m1

=28.63 x 0.55

=15.75 mm
Cup diameter after 2nd draw (d2) = d1 x
m2

=15.75 x 0.75

=11.81 mm
Cup diameter after 3rd draw (d3) = d2 x
m3

=11.81 x 0.9
Drawing flanged cups

While drawing flanged cups the cup

diameter d should be considered and not the diameter
at flange. While taking a d/D ratio if the flange
diameter is considered for d it will lead to wrong
results. Consider an imaginary blank diameter D which
required to draw the unfledged portion of the cup. The
portion within
(D –d) will form a vertical portion of the cup.

The vertical portion

Thus value of  can be used to decide the

number of draws
 When redrawing flanges and cups the
surface area of the vertical wall after the first operation
remains equal to that after redrawing and the depth of
the cup increases in the same ratio as the diameter is
reduced
Equating the area of the cylindrical walls

There is no further reduction of the flange

diameter D1 by the redraw because the steel is not
drawn full depth into the die . the portion of bottom
between the two diameter (d1 and d2) is redrawn back
into the flange.
For a flange cup the diameter of flange
D1is given as

Flanged cup depth of draw attainable can

be found using this formula.
BLANK
DEVELOPMENT

(Rectangular shell)

The box ABCD represents the plan view of

the inside shell. Because the walls are formed
conventionally the wall height is determined using
standard bend allowance formulas.
The Re radius represents a quadrant of
metal that is needed to draw form.

Where
R = Corner radius
h = Height of straight wall
r = Bottom radius
 This represents the quadrant
radius and must be blended with the
corners by the metal from the side walls
and adding it to the quadrant. The
following slides illustrates the method of
blending.

Calculating the corners for a

rectangular shell.

A straight line is produced when Re = 0.54

(h + 1.57r)
 The number of draws required to make
rectangular parts is governed by several factors.
They are the
Raw material
Material thickness
Corner radius
Bottom radius at the corners
Square boxes can be drawn to a depth of
approximately 80% of the width with a relatively small
corner radius. Rectangular boxes usually can be
drawn much deeper than square boxes.
Generally, a part can be drawn in one
station to a depth of 4 to 6 times the corner radius. The
amount of reduction between draws for a rectangular
part depends upon the corner radius and it diminishes
as it becomes smaller.
Metal reduction - rectangular draws
The reason for using a
large corner radius for the first die
is that when the larger corners are
reduced to the smaller radius in the
second die, a large part of this
compressed
metal is forced into the side walls.

The drawing operation

would be more difficult since the
drawing action is restricted to the
corners for square and
rectangular boxes.
 The force required for rectangular
drawing can be found from the following equation

P= σ s (2π R c1 + Lc2)

σ= Ultimate tensile strength (N / mm2)

s = Thickness of blank (mm)
R = Corner radius between the sides
(mm)
L = Length of box (mm)
c1 = Constant = 0.5 for very shallow
draws and cup up to 2
for a shell having 5 or 6 times R
c2 = constant = 0.2 for easy draw raids
more clearance and
no blank holding pressure.
0.3 for easy draw radius more
clearance and nominal
blank holding pressure.
Sl. No. h/R
Value up to 1 are used No. of draws
depending up
on the 1blank Up to 6 1
2
holding force.7 - 12 2
Number of 13 – 18for Rectangular
3 Draws Required 3 Cups
4 Number of 19 draws
- 24 necessary for
4 producing
a rectangular box depends upon ratio h/R, between
the box height (h) and the finish radius (R) joining the
Solved Examples:

Find the force required for drawing a box

made from 2 mm thick M.S. Sheet having 250 mm
length and 150 mm width. The radius between the
sides R is 25 mm whereas the radius joining sides to
bottom r is 8 mm. The box is 50 mm deep.
The tensile strength of blank, ft = 420 N/ mm2

Solution:

C1 and c2 are constant so values are

considered as 0.5 and 0.25 respectively.

P= σ s (2π R c1 + Lc2)

P= 420 x 2 ( 2π 25 x 0.5 + 250 x 0.25 )

= 118473.4 N
= 12 tones
BLANK DEVELOPMENT
(Kidney shaped shell)

The above illustrates an irregular kidney

shaped drawn shell. The blank layout Is produced by
off setting the finished shell outline by a distance B.
the distance B is the bend allowance for the walls. By
blending the remaining corners to tangency, this
method can produce an accurate blank profile. Most
irregular shapes can be calculated by using this
approach, then simply offsetting the shape using the
bend allowance and height.
The carrier and scrap ring must be added
to the blank. As a general rule 2 to 5 times metal
thickness can be used. The thicker the raw material,
the less required. conversely, the thinner the raw
material, the more material require
BLANK DEVELOPMENT
(Elliptical shell)
The above illustrates an irregular elliptical
shaped drawn shell. The blank layout Is produced by off
setting the shell outline by a distance got after calculation
for R1 and R2. This method can produce an approximate
blank size for the drawing.

• Draw the major axis vv’ and minor axis BB’

perpendicular to each other and bisecting at point O
• With centre o and radius BO draw an arc to intersect
At axis C.
• Join VB and locate point D on VB Such that BV=VC.
• Draw a perpendicular bisector of VD to intersect the
major axis at O1 (Centre for R1) and Minor extended
at O2 (Centre for R2). Hear O1 (R1) and O2 (R2)
forms centre for the arcs forming ellipse.
• Locate the other centre O3 and O4 by taking OO3 =
OO1 and OO4 = OO2
• With centers O1 and O3 by and radius equal to VO1
draw an arc.
• With centers O2 and O4 by and radius equal to O2B
draw an arc.
• Then calculate for R1 and R2 by given formulae and
draw the required blank
 OTHER
DEEP DRAWING
OPERATIONS
Other drawing operations

1. Ironing
Ironing is a method of redrawing a shell to
reduce the wall thickness and to improve the surface
finish. The process is also used to correct the natural
thickening of the wall.
The clearance between the punch and
die is less than the thickness of the shell wall.
During drawing the metal is thinned and the length of
the
shell is increased. In between the ironing process the
shells are to be annealed.
The strain caused by ironing is
expressed by the ratio of the wall thickness before
and after ironing.

For ductile material ratio is 2 : 1

For ductile and fully annealed alloy the ratio is 2.5 : 1
2. Reverse drawing
In reverse drawing a pre drawn shell is
drawn in the reverse direction of that of the previous
draw. Reverse drawings are employed for redraws of
shells or to produce reverse type flanges on drawn
cups.
The advantage of reverse drawing method
over the regular drawing method is that a greater
amount of reduction in the diameter is obtained.
In some cases it will be economical to
make a two stage draw component in a single tool with
one straight draw and one reverse draw other than
making two separate tools.
Comparison Design for Regular and Reverse drawing die
3. Eyelet Drawing
Eyelet drawing is the process of producing
small diameter cups by drawing progressively. The
main feature of eyelet drawing is that the depth of the
shell is more compared to its diameter. Hence the
overall draw ratio is very high. This indicates that these
shell cannot be drawn in one stage and manufacturing
number of tools to produce these components are
uneconomical.
In this method number of stages required
are stacked with a single die set, so that the operation
can be made in the progressive style.
The tool is similar to progressive tool.
Pieces are drawn from the stock strip in single or
multiple rows. However, it is observed from the
practices the single row method is easier because
enough material can be drawn from all sides.
Materials for Eyelet Drawing
All materials which comes under the group
of ductile materials can be eyelet drawn. Ductile
materials includes both ferrous and non- ferrous.
Some of the important ferrous ductile
materials that are used for eyelet drawing process are
a) Steel
b) Steel, deep drawing quality
c) Steel, Stainless
d) Deep Draw Steel
e) Extra Deep Draw Steel

Some of the important non-ferrous ductile

materials that are used for eyelet drawing process are
a) Aluminum, Soft
b) Aluminum, deep drawing quality
c) Brass,
d) Copper
e) Zinc
f) Tin
Capabilities in eyelet drawing
Rounds, Tapers, Ovals, Squares Other Irregular
Shapes. Secondary Operations which can be
incorporated into primary tooling including:
Threading, Beading, Bottom Piercing, Reverse
Drawing, Step, Drawing, Bumping, Fluting, Curling,
Necking, Side Lettering, Bottom Flanging, Bulging,
Side Piercing, Knurling
 Comparison between Deep Drawing and
Eyelet Drawing

Sl No Deep Drawing Eyelet Drawing

Deep drawing is a stage tool Eyelet drawing is progressive tool
01
process process
Separate tools are involved to have Only one progressive tool is
02
separate stage operations. involved to have all the operations.
Designed for only large Specially designed for small
03
components capsule shaped components.
04 Cost is more Cost is less
Hydraulic press technology is Transfer press technology is
05
adopted adopted
Small or thin features necessitate
Bigger features necessitate thick
very thin tooling, which is subject
tooling subjected to less cyclic
06 to intense, cyclic shocks that can
shocks, less degradation and less
lead to tool degradation and
breakage of tools
breakage.Tool set up time
Tool set up time is more to get the Tool set up time is less to get the
07
final component final component
Necessary finishing operations Necessary finishing operations
08 (grinding, polishing etc) of thicker (grinding, polishing etc) of thinner
tooling are not so delicate tooling are more delicate
Removes the finished part from
Removes the material from the
09 the material strip immediately
material strip at the first operation
before ejection from the press
Takes more time to complete the Takes less time to complete one
10
full process of component full process of component
Producing small features requires
Producing big features requires
11 more careful press
less careful press set up
set up
No material feeding is required,
Manual or Automatic feeding for
12 but the blank material is kept
transfer of component is required
blindly
Strip layout for Eyelet drawing
FORMING
EMBOSSING:

Embossing is the shallow forming

operation in which the work piece material is
stretched over a male die and made to conform to a
male die surface by a mating female die surface. The
finished product will have depressed detail on the
other.
The major difference between embossing
and forming is that the displaced pattern. Embossing
is done to stiffen and strengthen a sheet metal part or
to impart a raised or depressed design on the surface
of the part. The circular groove on the bottom of the
sheet metal part or to container is on example of
embossing for stiffness and strengthening.
Embossing simple details such as
stiffening ribs do not require that female die be the
exact reverse of the male punch. Here the metal
stretches over the punch and across the radius edge
of the die face. Radii must be provide on the surface
over which the metal must flows.
Detail containing pattern that are reversed
in both directions require that female die be exact
reverse of the male die, with allowance made for the
thickness of the sheet.
 Pressure pads or ejector pins are to be
providing to remove the embossed part from die
depending on the size and shape of the embossed
form. When embossing non-ferrous metals like
aluminum, copper etc a rubber cushion can be used
instead of the punch made of steel.
COINING:

Coining is the operation of pressing

material in a die so that it flows into space in the detail
of the die face. Coining differs from embossing. In
Coining the metal flows, where as in embossing the
metal does not change in thickness to great extent.
Coining operations are generally performed cold.
Coining has two major advantages

1) Ornate detail can be produced with excellent

surface finish.
2) Tolerances can be held to very closer
values.
CURLING:

A Curling tool rolls a raw edge of the sheet

metal into a roll or curl. The purpose is to strengthen
the raw edge, provide protective edge and improve
the appearance of the part. The curl is often applied
over a wire ring for increased strength.
Size of the curl groove in the die is same as the curl
diameter on the part.
The size of the curl is determined by the
metal thickness. Generally it should have a diameter
of less than four times the metal thickness. Tool use
for making hinges fall under this category.
Whenever Curling is done the tubular profile will not
resemble a true circle .To achieve a rare circular
profile a tilting operation is done prior to
commencement of the curling operation. Tilting is an
operation in which the edge of the component is tilted
slightly to required radius of the curling diameter so
that during curling it acts as flow guide.
FLANGING:

Many sheet metal assembly components

require threaded holes so that they can be fastened
with the other elements of assembly. If sheet thickness
is less it will not be possible to have sufficient number
of threads.
Flanging or collar drawing is a operation in
which a collar is formed so that more number of
threads can be provided. The collar wall can also be
used as rivet when two sheets are to be fastened
together.
 Flanging or collar drawing operation
in which a collar is formed so that more
number of threads can be provided. The
collar wall can also be used as rivet when
two sheets are to be fastened together.

CALCULATION
d 1= diameter of the pierce hole
d2= core diameter of the thread
d3= size of the thread
h= height of the collar
Diameter of the pierced hole is = .45X d2
d4 = d2+ 1.35
h = 0.5d2+ s
PLANISHING:

Certain parts of clocks electronic

equipment and cameras require absolute flatness.
In such occasions an operation called plaiting is
employed. Plaiting is an operation in which fine
impressions arranged in symmetric pattern are
induced on the face of the component. The
inducement of the impressions are done on one face,
in case where the thickness of the component is less
(03. to 0.6) but for the thicker component the
impression can be made on either sides.
Usually the plaiting tool comprises of two
parts. A die and punch. On the die face fine serration
in the form of diamond shape are milled. The depth of
each serration will not be more than 0.2 mm and is
provided on the die and the punch is a flat steel piece
without any impressions. Both the die and punch are
hardened and tempered.
The effect of plaiting is that when
impression penetrates into the component face, breaks
the fibers into short length, thus inducing a permanent
set to the component
 Fine Blanking
Advance press working techniques
what
why
where components
Sheared surface in conventional blanking and fine
blanking.

Production method
-single acting machine
-Material strip not firmly clamped
during blanking operation.

Features
-Sheared surface 1/3 s
-Brittle surface 2/3 s
-Flatness
Deflection of part during the
Blanking operation.
What is Conventional blanking?

Conventional blanking or stamping work produces

parts with sheared surfaces which are only generally one third-
cleanly sheared, the remaining two thirds showing a rough break.
When functional demands are made on these sheared or brake
surfaces concerning tolerances or quality of surface finish, then the
piece parts must be re-worked by such methods as shaving, milling,
reaming, broaching or grinding. For the production of precision
devises it is often necessary that at least two, but generally more
secondary operations are required per piece-part.
Sheared surface fine blanking.

Production method
Triple acting machine
Material strip is firmly
clamped during blanking
operation.

Features
FS = Shear force
FR = Vee-Ring indenter force
FG = Counter force
Material strip is firmly clamped
during the operation by V-ring
Indenter and the counter force.

Fine blanked surface

But in fine-blanking,
Precisely finished components.
Cleanly sheared over the whole material thickness.
One single operation.
Production cost savings can be made.
In order to achieve such quality, a triple action press and
specially constructed tools are required.

Till now max. sheet thick that can be processed in fine blank is
up to 15mm and min. of 0.25

So fine blanking is a unique metal forming process

founded on the technology of metal stamping. Special fine blanking

presses and custom tooling produce parts that are too complex to
make accurately by conventional stamping.
Sheared surfaces of components produced by
fb & cb
Conventional

Fine blanked
 Features of fine blanking
With Fine blanking, components of very high accuracy are attainable
tolerances of ±0.015mm are achievable.
Holes with a dia. as small as 60% of the material thick can be
pierced.
Material up to 15mm thick can be fine blanked.
The edge quality and accuracy of the fine blank process can
eliminate the need for secondary processes e.g. reaming of holes
or shaving to get a square smooth edge.
Components remain very flat.
Components can have features such as countersinks, extrusions, semi-
pierces, weld projections, coined chamfers, counter bores, and offsets
applied to them in the pressing operation.
Tooling is generally of a compound nature. This ensures superior
positional accuracy between features.
Tooling prices are competitive compared with conventional tooling.
Virtually any metal can be fine blanked
Where are fine-blanked parts required?
Office machines.
Household appliances
Communication equipments.
Watch and Clock industry.
Cinema and photographic appliances.
Sound reproduction.
Automobile industries.
Electrical industry.
Measuring and regulation equipment.
Aircraft industry.
General machines and Equipment application.
Surgical equipments.
Typical fine blanking components
 Fundamental principles of the fine blanking.
THE FINEBLANKING TECHNOLOGY is a process of the press
working technique which makes it possible to produce, in one single
operation, precise finished components cleanly sheared over the whole
material thickness, with close dimensional tolerances and being free
from fractures and cracks in their functional areas.
Not only flat parts are produced but also work pieces
incorporating numerous forming operations, such as
Bends
Off-sets
Coining
Extrusions
are also manufactured, fine blanking provides the capability pierce holes
of smaller diameter than material thickness.
Parts with thicknesses from 0.25mm up to 15 mm being made of steel,
copper and aluminum alloys are today produced economically in large series.
 Production Possibilities for f-b parts.
Constructional details of fine-blanked parts.
Radii on sharp corners.
Thickness of Sections.
Hole diameters and slot width.
Tooth forms.
Needle-form protrusions.
Bends.
Offsets.
Counter sinks.
Marking, Semi-piercing, Coining.
Fine-blanking Tolerances
Surface quality of the sheared edges.
Angle Accuracy of the sheared surfaces.
Flatness of the piece-parts.
Die-roll (pull-down).
Burr.
 CHAIN WHEEL PRODUCTION FOR A
MOTOR CYCLE.

8.
1.
6.
3.
2.
5.
4.
9. Boring
Blanking
Milling
Piercing
Piercing
7.Turning holes
thethe
four
the
Bevel turning
the
Levelling;
Grinding and
teethof in
inside de
outside
windows;
inside burring;
thecontour;
stack;
hole;
tooth
hole tips
and on both sides;
chamfering;

2.
1.
3. Bevel
Fine blanking;
turning of tooth tips on one side;
De burring
 In order to carry out fine blanking successfully it is
necessary to master the FINEBLANKING TECHNOLOGY.

The technology includes the following areas:

MACHINE(PRESS)
Fine blanking TOOL
MATERIAL
LUBRICANTS
Fine Blanking Machine (Press)
Construction and Requirement of Fine-blanking Presses
Fine-blanking presses are constructed and built to meet requirements of
fine-blanking.
Main feature of the Fine blanking machine.
Triple-action machine forces.
Precise ram guides.
Controlled bed movement.
Rigid machine frame.
Safety and protection devices.
Hydraulic drive.
Auto feeder.

Fine blanking press

(S.M.G Feintool 400 ton press)
 FR FR

FS FG FS

Triple action press.

The requirement for fine-blanking is that the
press supplies the three necessary forces, namely:

FS = Shear force
FR = Vee-Ring indenter force
FG = Counter force
Mechanical press
Hydraulic press
Main advantages of the fully hydraulic press:
1. constant force during cutting
2. the force of the hydraulic piston coincides with the cutting direction
3. the ram stroke is adjustable
4. the cutting speed is adjustable without simultaneously changing the
approach and return speed
5. hydraulic presses cannot be overloaded
3LE ACTION PRESS
With auto feeder.
Fine blanking press
 Ram stroke cycle for triple action press
The ram start in fast closing motion from bellow to top and reach ”b”.
Here the tool safety begins and end at “c”.
(Scrap in the toll area, the machine stop.)
(No scrap in the tool area, the machine star cutting at “c”.)
The cutting action starts. (“c” always depend on material thickness.)
The ram is reached the “Top Dead Center”. The cutting sequence is
finished. At “d” the ram is hold on pressure from a start time.
The ram reverse into the return motion and stop at Bottom Dead Center. (With
single stroke action only).
One stroke is finished.
Typical f b tool.
Elements of fine blank tool.
Types of Fine Blanking tool.
Tool with fixed punch.
Tool with sliding (moving) punch.

TOOL WITH FIXED PUNCH

punch
die
Most decisive factors are:
Accuracy of the tool.
Position accuracy between inner and outer forms,
Burr of inner and outer form on the same side.
Cutting elements of tool have to be cylindrical, so that part of identical
dimensions can be produced during the whole tool-life.

Preferably used for:

Parts of any size and thickness.
Parts with any numbers of inner forms.
 TOOL WITH SLIDING PUNCH

die

punch
 Most decisive factors are:
Accuracy of the tool.
Position accuracy between inner and outer forms,
Burr of inner and outer form on the same side.
Cutting elements of tool have to be cylindrical, so that part of identical
dimensions can be produced during the whole tool-life.

Preferably used for:

Parts up to thickness S = 4mm.
Parts with few inner forms.
 fb material
Influence of material.
The property of the fine blanking material can be described by the
following parameters:
Tensile strength
Elastic limit
Elongation
Hardness
Degree of cementite and carbide desperation
The best suitable fine blanking material with a high form changing
capability must present the following properties:
Tensile strength N/mm² Low
Elastic limit N/mm² Low
Elongation % High
Reduction of area % High
Materials suitable for fine blanking.
Working materials that can be fine blanked with good results
include low and medium carbon steel, some alloy steels, some stainless
steels, in the soft (annealed) condition where hardness/strength is low
and ductility is high and copper, brass, German silver and aluminum also
can be blanked.
SCHMATIC REPRESENTATION OF FINE BLANKING PROCESS
WITH SUITABLE (LEFT ) AND UNSUITABLE ( RIGHT )
MATERIAL MICRO STRUCTURE
 design
Design considerations.
Study of the Component
Tool Design consideration
Concept design
Manufacturing consideration
The final design
Study of the Component.
Die roll.
Dimensional accuracy.
Tolerance & surface finish.
Type of material.
Weak areas.
Working area.
Tool Design consideration.
Strip layout.
Scrape bridge.
Position of vee-ring.
Strip width and length of feed.
Feed direction.
Design Calculations.
Cutting Clearance.
Cal. of the blanking (shearing ) force.
Cal. of ‘Vee-ring‘ force.
Cal. of ejection force.
Press force.
Economy factor.
Counter force.
Determination of Vee-ring.

Punch and Die Clearance.

Material for tool.

Standardization.
Die sets.
Fasteners.
Hydraulic couplings.

Constructional Details.
Die plate inserts.
Punch forms.
Ejector pins.
Counter punches.
Air bleed channels.
Lay.
Strip layout.
Strip layout is the first step in design of any tool. It determines the over
all size of the tool, operations to be performed in each stage, no of stages,
width of the strip, scrape bridge, direction of feed Etc. `
Strip layout should be very accurate because it is reflected on the
surface of the die plate and it will be final for the machining.

Strip layout considerations for Fine Blanking.

On sections of the part with no functional requirements on fine-
blanked surface, the ‘vee-ring’ indenter can be eliminated.
For tooth profiled components the tooth profile should be always
opposite to the strip feed direction.
 1.0 R5.0 R5.0
. ACCURACY GRADE JISB1702
CLASS 7
7 DE
SCOPE: AREA
INVOLUTE SPUR GEAR CIR

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7.6 B ( 2:1 ) IF IN DOUBT PLEASE ASKINVOLUTE SPUR GEAR DRIVEN GEAR

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NUMBER OF TEETH SPINNED 12
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DUE CARE IS NECESSARY AT PROCESS

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8.0 +0.15 Mr Praveen M
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D BE 0.9 MIN. 2. NO
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+0.15
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SPH 440 - OD 69842 - O
Scale Mr Praveen M
Mr pandurang P
STRICTION
1. S FO
AFTERR
+0.05
PRESSING, EFFECTIVE WIDTH OF TOOTH FACE SHOULD BE 0.9 MIN. App1:1 ( 2:1 )
2. NO BURRS SUBSTANC
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ENVIRONM 0.3 ENTAL CONCERG NEARIN, DOTSZ000G . Chk
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A 66.2 Sheet :01 / 2005/Trd
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R19.0
4. INVOLUTE GEAR SPESIFICATION SHOULD BE CONTROLED AT OVER PIN DIA. WINDOW REGULATOR DS
RELATERIVE
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App
R5.05. THIS PART SHALL COMFORM TO THE PROHIBITIONS AND RESTRICTIONS FOR
0.00 TRAINING INSTITUTION PDTD 2005- 2006
R5.0R
SUBSTANCSES OF 5.0
ENVIRO NMENTAL CONCERN IN TSZ000G. AN ISO 9001:2000
R97.615+0.15 RELATES TO HUMANSheetSAFTY
NTTF
:01 / 2005/ 12/ 07

R5.0 ( ADDENDAM CIRCLE RADIUS ) PDTD 2005- 2006

DUE CARE IS NECESSARY AT PROCESS
AN ISO 9001:2000 TRAINING INSTITUTION

A CONTROL
34.0
39.0
 COMPONENT STUDY

Part name :Gear, Door Window Regulator Driven.

Material :SPH440-0D
Standard :JIS
Thickness :2.6 mm
Tmax :440 N/mm2
Corner radii :R 0.5
Structure :95-100% Spherical Cementite,
Uniformly distributed.
Accuracy Grade : JISB1702 (Class-7)
Material composition
Element Symbol Min. % Max. %
Carbon C 0.3000
Manganese Mn 0.3000 1.0000
Silicon Si 0.3500
Phosphorus P 0.0400
Sulfur S 0.0400
Iron Fe 98.2699 99.6999
Scrap bridge (stock thickness) =1.5 to 2mm x S
S = Material thickness.

For thinner material higher value,

For thicker material lower the value.
 Design Preparation of f-b Tool

Calculation of resulting actual resulting shear line force.

Arithmetic (Using movements relative to given axis.)
Graphical (Using polygon of Forces.)

Finalizing the Vee-ring dimensions.

Shrink ring dimensions.

 The most important factor for determining the type of
machine to be used is the shear force. In practice the formula
used is as follows:

F = L x S x T max

F = Blanking or shearing force (tones or kg)

L =Total of outer and inner shear periphery lengths (in. or mm)
s = Material thickness (in. or mm)
T max =Tensile strength (t. /sq. in. or N/mm²)
The exact shear pressure is influenced by the
following factors:

Condition of the edges of the cutting elements (punch and die plate).
Punch-Die clearance.
Shear speed.
Geometric form of the part.
Metallurgical structure of the material.
Type and amount of cutting lubricant.
Surface finish of the cutting elements.
Tolerance of the material being worked.
Relation between Shear force,
Vee ring force & Counter force:

If Shear force FS = ‘x’ tones then,

Vee ring pressure FR = 50% of ‘x’ (shear force)
Counter pressure FG = 50% of Vee ring pressure

Total Press force F = FS + FR +FG tones

Note:
Materials between 30-50N/mm²(19-32t./sq.in) tensile ratio =30-50% of ‘x’
For harder materials FR= 100% of ‘x’
The common requirement of the Vee-ring must be implied on die and pressure plate
when the sheet thickness is more than 4 mm.
But in case of minimum die roll Vee may be adopted on both sides even though she
thick ness is less then 4 mm.
GUIDE LINE VALUES FOR VEE - RING DIMENSIONS
Punch Die clearance.
Ideally the distance between the punch and the die at any
given position is ½ of the punch-die clearance. The value given of 1% of the
material thickness is an indicative value which requires.

Outer periphery.
The punch-die clearance is normally calculated at 1% of the material
thickness to be worked.
For gear-wheels the clearance in the areas of the tooth crests and tooth
root are doubled(2%). This also applies to forms which re-enter into the
piece-part.
Slots or other similar forms which re-enter on parts where the ‘vee-ring’
does not follow the outer shear periphery, are to be treated as inner forms.

Determination of of Vee-ring.
 Shrink ring.
Shrink ring is placed to provide extra strength to the die.
To avoids crack formation on the sharp edges.

Shrink ring dimension

Proceedings:
Measuring of Die plate. 0
Obtained dima. Should be within -0.1

Die.
Counter punch.
Shrink ring.
Punch holder.
Bottom plate.
 Concept Design.

Top plate
Pressure pin

Punch

Stripper plate
Guide plate
Alignment pin
Shrink rink
Die plate
Thrust plate
Bottom plate
 Manufacturing considerations.
Type of materials.
Type of materials.
Type Machining.
Heat treatment.
Assembly procedure.
Tryouts.
Materials used for tool manufacturing.
Die plate D6,D2
Large inner form punches D2
Piercing punches &
Small inner forms. M2
Shroud ring. O1,O7
Retainer plates,
Pressure plates,
Backup plates. O1,O7
Pressure pins. O1,O7
All types of bushes,
Pillar, EN31
Alignment pin. E230
 Materials used for tool manufacturing.
CHEMICAL COMPOSITION (average %)
Die plate D6,D2
C inner
Large SiformMn punchesCr Mo VD2 Color Code: Yellow
Piercing
1.55 Heat
punches &
0.30 Treatment
0.30 11.80 0.80 0.95
Small inner forms. 1850ºF to 1950°F, stop atM2
Forging 1500°F, cool slowly.
HeatShroud
Treatment
ring.
Normalizing Do not normalize O1,O7
Retainer
Forging plates,
Annealing
2050 to 2100°F, stop at 1800°F.
1450°F, Cool slowly
furnace-cool, Brinnell 202 max
Annealing EN
Pressure / DIN
plates,
Hardening
1600°F, cool slowly, AISI
max to 150°F. BS
Brinelloil-quench
1475°F, 241 UNI
Preheating Tempering
Backup ~1.2379
plates.
1550°F, soak before to 450°F, averageO1,O7
hardening
300ºF hardness after
Hardening
Pressure2250 to 2275°F, oil heat
pins. quenchtreatment — Rockwell C 61/63.
O1,O7 X155CrVMo12
~X155CrVMo12- D2 ~BD2
Tempering 1000
All types oftobushes,
1050°F, Rockwell C 65/66 1 KU
1
Pillar, EN31
Alignment UNEpin. AFNOR E230JIS GOST
~F5211
~Z160CDV12 ~SKD11 ~Ch12F1
~X160CrMoV12
 Standard die sets.
Fasteners.
Type Machining. Assembly procedure.
Wire EDM.
EDM. Tryouts.
Jig boring.
Profile grinding, Milling.
Milling.
Turning.
Grinding.
Heat treatment.
First pre-heating.
Second pre-heating.
Third pre-heating.
Heating to hardening temperature.
Quenching.
Tempering.
Rounding the cutting edges.

Punch

Die

Radius
Cutting oil.

Properties.
Advantages.
Secondary operations.

De-burring the components.

Following are the types of de-burring.

Tumbling.
Vibro-deburring.
Linishing - belt grinding.
Fine blanking Machinery
Compound progressive die
Future of fine blanking.
Progressive Fine Blanking.
Conventional tools on Fine Blanking press.
Factors effecting TOOL life
Advance press working techniques
 Die life

The production potential of the die is considered in terms

of number of piece parts it can produce from the time it is new
until it is worn-out. It varies according to.

1. Stock material used

2.Material used for the die components
 Side wall Finish.
The quality of side wall finish has direct influence on the
degree of the friction. The smooth finish and the layoff finish are
important for the die efficiency.
 Excessive wear
•Abnormal wear can be caused by any of the following conditions:

1. Cutting clearance - Insufficient or excessive.

2. Entry – Punches enter too far into the die opening.
3. Crowing – Punches are too close to each other.
4. Punch height – Vertical punch height is too great in relation to
the cross sectional area of the punch.
5. Hardness.
6. Finish.
7. Suitability of the material.
8. Secure mounting.
9. Stripping.
10. Excessive runs- producing too many pieces between sharpening.
11. Press condition.
12. Careless setup.
 Characteristic of cutting Wear.
 Newly sharp cutting edges are dead sharp. The dead sharp
condition begins to deteriorate as soon as the die begins to run.
 After a short time the initial edge breaks off to produce the working
radius on the cut edges. It depends on.

1. Type of material used to manufacture.

2. Hardness of die member.
3. Physical properties of the stock material.
4. Thickness of the stock material.
 Wear of Punch and Die.
Punch wears at approximately the same rate as the
die block; in some cases punch may wear twice as
fast as the die block. The wear will be greater for piercing
punches than for blanking punches.
Punch wears during cutting as well as during stripping.
The blanking punches wear slower than the piercing
punches.This is because the blanking punches are
easier to stripping than piercing punches.
 Enragement of the Die opening
due to Sharpening.
 When sharpening extends below the die land, he amount
of increase in the die opening size is directly proportional to the
degree of the angular clearance.
 This increase per side can be calculated from
A= B tan
A=Increase per side
B=Amount removed by the grinding cutting face.
=Clearance angle in degree.