Subject Name: Manufacturing Process

Subject Code: ME-3004

Semester: 3rd
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Notes for Unit 4: Production Process

Press Working
SYLLABUS: Press working: Description and operation of processes, process of shearing, punching, piercing,
blanking, trimming, perfecting, notching, lancing, embossing, coining, bending, forging and drawing; press,
tool dies, auxiliary equipment, safety devices, stock feeders, scrap cutters, forces, pressure and power
requirements.

Press Working:
Press working may be defined as, a manufacturing process by which various components are made from
sheet metal. This process is also termed as cold stamping. The machine used for press working is called a
press.
The main features of a press are:
• A f a e hi h suppo t a a o a slide and a bed, a source of mechanism for operating the ram in
line with and normal to the bed.
• The a is e uipped ith suita le pu h/pu hes a d a die lo k is atta hed to the ed.
• A sta pi g is p odu ed y the do a d st oke of the a he the pu h oves towards and into
the die block.
• The pu h a d die lo k asse ly is ge e ally te ed as a die set o si ple as the die .

Press working operations:

The sheet metal operations done a press may be grouped into two categories.
1: Cutting operations
2: Forming operations
In cutting operations the work piece is stressed by its ultimate strength. The stresses caused in the metal the
applied forces will be shear stresses. The cutting operations include:
(a) Blanking (b) Punching (c) Notching
(d) Perforating (e) Trimming (f) Shaving
(g) Slitting (h) Lancing
In forming operations, the stresses are below the ultimate strength of the metal, in this operation, there is
no cutting of the metal but only the contour of the work piece is changed to get the desired product.
The forming operations include:
(a) Bending (b) Drawing (c) Squeezing

Shearing
Shearing is a sheet metal cutting operation
along a straight line between two cut-ting
edges by means of a power shear.

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Blanking and punching

Blanking and punching are similar sheet metal cutting operations that involve cutting the sheet metal along
a closed outline. If the part that is cut out is the desired product, the operation is called blanking and the
product is called blank. If the remaining stock is the desired part, the operation is called punching. Both
operations are illustrated on the example of producing a washer

Bending
Bending is defined as the straining of the sheet metal around a straight edge
Bending means deforming a flat sheet along a straight line to form the required angle. Various sections like
angles, channels etc., are formed by bending, which may then be used for fabrication of steel structures.
Three common methods of bending are illustrated in Fig.

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Other Bending Operation

Springback - the elastic recovery of the material after unloading of the tools

To compensate with the unbending action of the springback, the metal should be slightly overbent.

NOTCHING: A shearing operation that removes a section from the outer edge of the metal strip or part.

BENDING

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Bending means deforming a flat sheet along a straight line to form the required angle. Various sections like
angles, channels etc., are formed by bending, which may then be used for fabrication of steel structures.
Three common methods of bending are illustrated in Fig.
Drawing

Drawing is a sheet-metal operation to make hollow-shaped parts from a sheet blank

DEEP DRAWING In deep drawing process, we start with a flat metal plate or sheet and convert it into cup
shape by pressing the sheet in the center with a circular punch fitting into a cup shaped die. In household
kitchen, we use many vessels like deep saucepans (or BHAGONA), which are made by deep drawing process.
If the depth of cup is more than half its diameter, the process is termed as deep drawing and with a lesser
depth to diameter ratio, it is called shallow drawing. Parts of various geometries and shape are made by
drawing process. The deep drawing process is illustrated in Fig.

COINING AND EMBOSSING

Both oi i g a d e ossi g ope atio s a e do e old a d e ha i al p esses ith pu h a d die a e used
for these operations.

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In embossing, impressions are made on sheet metal in such a manner that the thickness of the sheet remains
uniform all over even after embossing has been done. It means that if one side of the sheet is raised to form
a design, there is a corresponding depression on the other side of the sheet. Basically it is a pressing operation
where not much force is needed. The sheet is spread on the bottom die and the stroke of the punch is so
adjusted that, when it moves down to its lowest position, it leaves a uniform clearance between the
impressions carved in the punch and the die which is equal to the thickness of the sheet being embossed.
The design is transferred on to the sheet by bending the sheet up or down without altering its thickness
anywhere. Many decoration pieces with religious motifs are made in this way.

In coining process, a blank of metal which is softened by annealing process is placed between two dies
containing an impression. The blank is restricted on its circumference in such a manner, that upon the two
dies closing upon the blank, the material cannot flow laterally i.e., sideways. The material is only free to flow
upwards (as a result of which it fills up the depressions in the upper die) and downwards (when it fills up
depressions in the bottom die). The result of the coining operation is that the design engraved on the top
and bottom dies gets imprinted on the corresponding faces of the blank in relief (i.e., raised material) without
the size of the blank-circumference changing. Coins used as money in daily usage are manufactured in this
manner. Here forces required are much higher, enough to cause plastic-flow of material. The embossing and
coining processes are illustrated in Fig.

The main features of a press are:

• A f a e hi h suppo t a a o a slide a d a ed, a sou e of e ha is fo ope ati g the ram in
line with and normal to the bed.

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• The a is e uipped ith suita le pu h/pu hes a d a die lo k is atta hed to the ed.
• A sta pi g is p odu ed y the do a d st oke of the a he the pu h o es to a ds a d i to
the die block.
• The pu h a d die lo k asse ly is ge e ally te ed as a die set o si ple as the die .

These presses are available in two configurations:

(i) Open frame type, and

 Open frame type presses are less robust as

(ii) Closed frame type.

compared to closed frame type, but

provide greater access for loading material
as they are open in front as well as sides.
Due to their appearance, they are also
referred to as C-frame or gap presses as

 Closed frame type presses are used for

well.

heavier work. The capacity of the press is

indicated by the force (or tonnage), the
press is capable of exerting.

Fundamentals of Press Operation

The force by which press ram is able to exert safely is called tonnage of the press. Press slides exert a force
which is greater than the rated tonnage because of built-in safety factor. The tonnage of hydraulic press is
equal to the product of the piston area and oil pressure in cylinder. The tonnage is varied by changing the oil
pressure. Tonnage of mechanical press is equal to the size of bearings for the crankshaft or eccentric. The
tonnage of mechanical press is approximately equal to the product of shear stress of crank shaft material and
area of crankshaft bearings. The tonnage of mechanical press is maximum when the slide is near to the
bottom of its stroke.
Stroke
Reciprocating motion of a press slide is called the stroke. Stroke is expressed as the number of inches
between terminal points of the motion. The stroke is constant for mechanical press while it is adjustable
for hydraulic press.
Shut Height
The distance from the top of the bed to the bottom of the slide with the stroke down and the
adjustment up is called shut height.
Die Space
Die space is the area available for mounting dies in the press.
Press Working Terminology
A simple cutting die is shown in Figure

Bed
The bed is lower part of press frame that serves as a table on which a bolster plate is mounted.
Bolster Plate
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Bolster plate is a thick plate secured to the press bed, which is used for locating and supporting the die
assembly. Its thickness is usually 5 to 12.5 cm.
Die Set
Die set is unit assembly which incorporates a lower and upper shoe, two or more guide posts and guide
post bushings.
Die
Die is the female part of a complete tool for producing work in a press. It is also referred to a complete
tool consisting of pair of mating members for producing work in press.
Die Block
It is the block or a plate which contains the die cavity.
Lower Shoe
The lower shoe of a die set is generally mounted on the upper plate of a press. The die block is mounted
on the lower shoe. The guide posts are also mounted in it.
Punch
Punch is the male component of the die assembly which is directly or indirectly moved by or fastened
to the press ram or slide.
Upper Shoe
It is the upper part of the die set which contain die post bushings.
Punch Plate
The punch plate or punch retainer fits closely over the body of the punch and holds it in proper relative
position.
Back Up Plate
It is also called pressure plate. It is placed so that the intensity of pressure does not become excessive on
punch holder. The plate distributes the pressure over a wide area and intensity of pressure on the punch
holder is reduced to avoid crushing.
Stripper
Stripper is a plate which is used to strip the metal strip from a cutting or non-cutting punch or die. It
may also guide the strip.
Knock Out
Knock out mechanism is used to remove the workpiece from a die. It is connected to and operated by
the press ram.
Pitman
Pitman is a connecting rod which is used to transmit the motion from the main drive shaft to the press slide.

Types of Die
Dies are classified according to the type of press operation and according to the method of operation.
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According to the type of the press operation, dies are classified as cutting dies and forming dies.
Cutting Dies
Cutting dies are used to cut the metal. They use cutting and shearing action for cutting the metal.
Examples of cutting dies are blanking dies, piercing dies, perforating dies, notching dies, trimming
dies, shaving dies and nibbling dies, etc.
Forming Dies
Forming dies change the shape of the blank without removing any stock. Example of forming dies
are drawing dies, bending dies and squeezing dies.
According to the method of operation, dies are classified as simple dies, compound dies,
combination dies, progressive dies, transfer dies and steel rule dies, etc.
Progressive Die
It is also called a follow on die. The progressive die is shown in Figure. It performs two or more operations in
one stroke of a ram at different stages. First operation is punching, which is followed by blanking. The metal
strip is transferred to the next station in between the stroke to produce a complete workpiece.

When the piercing punch cuts a hole in the strip, the blanking punch draws out a portion of the metal strip
in which a hole had been pierced at a previous station. The metal strip is fed into the die mechanically or
manually. The primary stop is pushed in by hand and lead end is then made to contact with it. The press is
now made to operate to pierce a hole at station 1. As the primary stop is released, the strip is transferred to
the station 2. The strip contacts with automatic button die stop at station 2.

During the next stroke, the pilot on blanking punch enters the previously pierced hole which ensures the
exact alignment of the strip to be blanked next. The die stop activation pin pushes the die stop pin below the
edge of the blank. Hence the strip is transferred to next station on return stroke of the ram. The button die
stop pin returns to its normal position and holds the strip on the inside wall of the blanked hole. During the
third stroke, another complete part is produced and thereafter parts are produced at each stroke of the ram.
In a progressive die, force required is reduced to a large extent due to the staggering of punches. The
disadvantage of progressive die is that it makes balancing of the punches difficult.
Combination Dies
In a combination die, cutting action is combined with non-cutting actions, i.e. forming. Non-cutting actions
may be bending, drawing, extrusion or embossing. More than one operation is possible in one stroke at a
single stage, but the die is more useful for two operations only. The principle of working of a combination
dies is shown in Figure Design of Metal Shaping Tools

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Press room accessories include: hydraulic shock dampers, stock/scrap cutters, die lights, shock/vibration
mounts, rotary limit switches (cam switches), and stock nibblers.
These help to reduce press damage and press repair cost, better handle scrap and recapture scrap material
value, improve die setup, and optimize press operation.
Hydraulic shock dampers to prevent/control press snap through shock loads; thereby, reducing expensive
press repair and downtime.
Rapid-Air stock cutters/choppers for cutting coil stock and skeleton stock at the end of a progressive die or
similar process. Our flat or round stock cutters can also be integrated into a complete cut to length line or
integrated with existing equipment to complete a cut to length or cut off operation.
Die lights are ideal for increasing visibility at the point of operation to assist in setup, trouble shooting, and
die maintenance. The die lights are available in a variety of sizes and optional magnetic mounts. They are
easily located in place and are shock and lubricant tolerant.
Vibro/Dynamics shock, vibration, and leveling mounts are designed for power presses and similar machines.
Leveling the press prevents stressing the frame and other drive components. This reduces maintenance,
increases press life, and often results in improved part quality. The shock mounts also reduce the amount of
shock and noise transmitted to surrounding areas and structures.
Electro mechanical adjustable rotary limit switches (cam switches) are used to precisely time/energize
electrical devices to a machine stroke or cycle. When used with power presses the rotary limit switch (RLS)
may be used to set press control timing such as automatic upstroke timing or top stop position; feed
advance/pilot release timing, control part blow off, and in die lubrication timing.

Press Coil Stock Feeding Devices

Many years ago, the majority of blanks were fed into presses by hand. Some simple progressive dies are hand
fed with stock sheared from rectangular rolled sheet stock if production volume is not high. Many older
pressworking methods were somewhat dangerous.

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Types of Feeders
Press feeders are available in many different configurations depending upon the application. However, most
feeders fall into two main classifications, which are:
1. Roll feeders, which advance the stock into the die by a pair of power driven rolls. The feeder may be
powered directly by the press crankshaft or a motorized drive system.
2. Hitch or grip feeders, which advance the stock into the die by mechanically gripping the stock and
advancing it the required amount. These also may be directly actuated by the press ram, Crankshaft or
separately powered. The most common power source is compressed air.

Blank punch diameter = Db-2c

Blank die diameter = Db
Hole punch diameter = Dh
Hole die diameter = Dh +2c
Angular clearance of 0.25o to 1.5o
Cutting forces: F =S*t*L=0.7*TS*t*L
Where, S= Shear strength
t=thickness
L=length of cutting edge
TS =Ultimate tensile strength

RATING OF A PRESS (Israr et al., 2015)

A press is rated in tonnes of force that can be applied to the slide without undue strain and without affecting the
structural strength of the press. The tonnage of a mechanical press is determined by the size of the bearings of the
crankshaft or the eccentric. It is given by the relation:

Tonnage capacity = shear strength of the crankshaft material * area of the crankshaft bearing
The tonnage capacity of a mechanical press is always given when the slide is near the bottom of its stroke, because it
will be maximum at the point or with the crank turned through an angle of not more than 30 from the bottom zero
position. The tonnage capacity of a hydraulic press is given by: Tonnage capacity = piston area * oil pressure in the
cylinder. As noted earlier, the capacity of a hydraulic press can be varied by changing oil pressure. In double action
crank presses, the tonnage of the inner slide determines the maximum drawing pressure, while the maximum blank
holding pressure depends upon the tonnage of the outer slide. To keep the strains and the deflections of the press
structure small, it is a usual practice to choose a press rated 50% to 100% higher than the force required for an
operation. In case of single, double and triple action hydraulic presses, the rams may all be driven from a central
hydraulic accumulation fed by pump, or have individual drives from one or more pumps.

REQUIREMENTs OF A PRESS TOOL DESIGN (Israr et al., 2015)

1) The dimensional accuracy and surface finish of stampings should confirm to the drawing and specific action. 2) The
working parts of the press tool (die or punch) must be adequately strong, durable in operation and easily replaceable
when worn out. 3) The die should ensure the required hourly output, easy maintenance, safe operation and reliable
fastening in the press. 4) The die should be designed in such ways that as far as possible standard components are
used for its manufacturing. As few special parts as possible should be used in its design.

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For further reading, you may refer the following research paper-

Mohammad Israr, Amit Tiwari, Anshul Gangele, 2015. Design & Optimization of Power Press Machine, IJETI
International Journal of Engineering & Technology Innovations, Vol. 2 Issue 1, January 2015, pp 5-12

This is available online at- http://www.ijeti.com/papers012015/ijeti_012015_02.pdf

***

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