1

Matthew De Kam

Metal Stamping Press Load Sensing: Integration

of Load Measurement in Press Control Systems

Abstract Load monitoring in metal stamping presses has been

an important method of measuring press performance for
decades. This monitoring capability is now particularly of use in
the increasingly automated manufacturing environment.
Modern control systems can use load sensing data to improve
press performance and diagnose reliability issues. This paper
identifies the main factors that contribute to press loading,
presents load sensing system options, and explores the
implementation of load data into automated process control
systems.
The main focus of the examples in this paper is a custom
metal stamping press in use at a third-tier automotive supplier.
Some of the systems and methods discussed in this paper were
put into use and tested on this press.
Index TermsStamping press, strain gauge, load sensing,
progression die, Wheatstone bridge.

I. INTRODUCTION

etal stamping presses are widely used in current

manufacturing processes. These machines make
everything from deep-drawn automobile body panels to the
change in our pockets. The stamping press is not a new
technology at all. Presses have been rhythmically shaking
factory floors for decades. As sensing and control technology
have advanced, so has the capability of stamping presses. The
automated production lines of today can benefit from
improved load sensing on stamping presses.
The loads stamping presses are subjected to are dynamic, and
depend upon multiple factors in the press setup, die design,
and material used. There are also multiple methods used to
measure press loads. Most sensing methods use some type of
transistor to convert displacement measurements into
electrical signals. Once the load data is determined it can be
applied in several different ways ranging from simple fail
switches to complete statistical analyses. This paper presents
the causes of press loading, load sensing methods, and
application of load data into press control systems. The study
will begin with an overview of the topic then focus on a
specific example using a press from a local manufacturer.

will have a large effect on the press loading. The shear

strength is determined mostly by the toughness and hardness
of the metal. Soft metals like aluminum take little force to
punch and form. Hard metals such as steel will require a
higher press loading.
For each type of metal there are also differing levels of
hardness. Higher hardness alloys will require higher press
loadings.
Stock thickness will also determine the press loading. As the
stock metal becomes thicker, the press will experience more
force.
Finally, the length of the cuts being made in the stock will
contribute to the final press loading force.
The relationship between the preceding properties of the stock
material and the press loading force may be calculated using
the following equation:

S t L

This equation relates the load force (F) to the shear strength
of the material (S), the thickness of the material (t), and the
length of the cut (L).
B. Cutting Clearance
The clearance between the diameter of the punch and the
diameter of the blanking die will affect the overall press
loading. The clearance between punches and die holes
depends on the thickness and hardness of the stock material.
The following equation relates these variables to clearance:

c=at
The clearance (c) depends on material thickness (t) and an
allowance constant (a). The allowance constant is based on
material properties and increases with hardness as shown in
the chart below.
Metal Group
1100S and 5052S Aluminum
2025ST and 6061ST
Aluminum; prass; soft coldrolled steel, soft stainless
Cold-rolled
steel, half-hard;
steel
stainless steel, half-hard and
full hard

a
0.045
0.060

0.075

Fig 1. An allowance constant chart for the clearance equation.

II. CONTRIBUTING FACTORS IN PRESS LOADING

A. Working Metal Properties
The properties of the metal being punched, cut, and formed
by the stamping press have a great impact on the load the
press is subjected to. The shear strength of the working metal

M. De Kam is a student at Calvin College in Grand Rapids, MI with a

Bachelor of Science of Engineering with a concentration in mechanical
engineering.
e-mail: mjd2@calvin.edu

C. Tool sharpness
It is straightforward to see the relationship between tool
sharpness and the press force necessary. Dull punches and
dies will contribute to increased press load. It is helpful to be
able to sense the load on the press in order to evaluate if it is
time to sharpen punches and dies.
D. Cutting Shear
Good die design will make use of a shear angle on punches
and cutting surfaces. The angle creates a scissors-like action
between the punch and the die. The cutting operation is then

spread out over a longer time, and the instantaneous cutting

length is much smaller. A good die designer will extend this
principle to the entire die by staggering the height of each
punch. This method ensures that all the punches are not
engaging the stock at the same time. As an added bonus the
phenomenon of negative press loading can be used as an
advantage with this die design feature. Negative press loading
occurs because of the tremendous energy that is stored up
when pushing the punch through the material. When the
material yields and the punch breaks through a force equal
and opposite to the initial press load must be used to stop the
upper portion of the press and pull it back up. If one punch is
just starting to penetrate as the previous punch has fully
yielded the material then the reverse loading will be absorbed
in pulling the next punch through the material. Taking
advantage of this concept can greatly reduce the press
loading. The following diagram illustrates punch staggering.

Fig 3. A uni-axial strain gauge. As the gauge is stretched or compressed the

metal in the grid becomes more narrow, or thicker. This change in thickness
alters the resistance to current flowing through the gauge.

Different arrangements of strain gauges can be used

depending on the geometry of the press. Clusters of gauges
will generally account for more of the strain in press members
and therefore result in a more accurate reading of load.
Before deciding the location of the strain gauges it is
generally helpful to have a stress-strain analysis of the press
structure. This type of analysis (normally Finite Element
Analysis) will indicate any stress concentrations, and where
on the press an accurate reading of strain might be taken. For
a straight sided press the four columns or tie rods at the four
corners of the press are generally the best place to sense the
load.
Strain gauges need some additional circuitry to power the
system and condition the signal. The change in resistance of a
strain gauge is typically very small compared to the nominal
resistance. In many situations the resistance only changes by
three percent. This obstacle is overcome by using a
Wheatstone bridge and an amplifying circuit.

Fig 2 A diagram of typical punch staggering.

D. Ram Velocity
The last contributing factor to press loading is the velocity of
the press ram. Increasing the velocity of the ram will increase
the force according to the following equation:
d v
f m

dt

Fig 4. A Wheatstone bridge circuit in a quarter-bridge setup.

The Wheatstone bridge outputs a voltage that is proportional

to the change in resistance of the strain gauge. This signal is
then amplified and fed to the control system or a digital
readout.

Most people want to maximize the output of their presses, so

increasing the cycle time is not an option. However, sensing
the load as the press velocity varies is beneficial to find the
maximum allowable speed that the press can reliably run at
for a certain product.
In terms of control systems this is the one factor of press
loading that could be adjusted by using an automated control
system. The motor speed could be controlled by a system
which continuously checks the press load curve.

B. Load Cells
Small load cells are also used to determine press loadings.
Load cells can be placed between the die and the press ram to
determine the press loading. These load cells output a voltage
that is proportional to the loading of the press. This voltage is
conditioned with amplification and filtration circuitry. These
types of miniature load cells are generally used during die
setup, and are not generally intended for permanent control
applications.

III. LOAD SENSING METHODS

C. Piezoelectric Transducers
Piezoelectric transducers are a more recent technology that is
useful for determining press loading. The transducers are
mounted to the press frame in the same positions as strain
gauges. These transducers are easier to mount, and require
much less additional circuitry to condition the signal. The
output signal is strong, clean, and can in some cases be
outputted directly to a digital readout.

A. Strain Gauge Systems

Strain gauge load sensing systems are the standard method of
load sensing in solid mechanical members. These
mechanical/electrical signal translators increase in resistance
as the member they are rigidly attached to stretches due to an
applied load.

D. Calibration
Each of the load sensing methods mentioned requires a
precise method of calibration in order to obtain meaningful
results. This calibration must be very accurate to allow the
load sensing system to display true data. Calibration is
generally performed by applying several known loads to the
press. These known loads should be in the middle of the
expected load range of the press. By applying known loads
and comparing them to the load sensing system readouts a
calibration curve for the system can be obtained. This
calibration curve is then used to interpret all further results of
the load sensing system. Current calibration techniques are
complex, and the hardware required can often cost as much
as the load sensing system.
IV. LOAD SENSITIVE CONTROL SYSTEMS
A. Digital Readout
One option for using the load data is simply to have a digital
readout near the press controls. When the operator of the
press sees any strange load profiles or any high load values
the press can be shutdown and adjusted.

V. INDUSTRY APPLICATION
A. Background
Currently in the manufacturing industry, a third-tier
automotive supplier uses metal stamping presses extensively
in production. These presses generally run progression dies
as explored previously in this paper. This manufacturer is
interested in determining the actual press loading so that it
can better evaluate the condition of its many stamping
processes. The improved diagnostics are focused on providing
more accurate assessment of die wear and press performance.
B. Press Design
The presses used by this manufacturer are primarily of the
same design. The press design was done specifically to
provide this manufacturer with a quality press for a low,
predictable cost. Two models with two different tonnage
ratings are primarily used in this facility; a twenty-ton press
and a sixty-ton press. These presses are of a unique design,
as can be seen in the figures below.

B. Load Limit Switch

The load data could be integrated into a press control system
by configuring the press controls to stop the press if a certain
maximum load is exceeded. The press PLC would receive an
analog input from the load sensor. If the analog input exceeds
a certain preset value, the press should shut down.
C. SPC Analysis Tracking
Another option for integrating the press load data into the
control system is to perform a complete SPC analysis on the
data. This option would require the system to record all the
past load profiles. These profiles could be parameterized and
compared to each other. In this way the software could learn
what a normal load curve is for a given product and warn the
user of any load curves that are outside of the control limits.
This option is useful because it provides a record of process
quality which is increasingly desired in the manufacturing
world.
D. Variable Velocity Press
A final method of integrating the load data into the press
control system is to create a feedback loop that would alter the
speed of the press motor to compensate for excess load. This
system would know the desired load based on the SPC data,
and could alter the press velocity to keep the process within
the control limits. This option has complications because
there are many components that actually contribute to the
press loading besides ram velocity.

Fig 5. Progression die metal stamping press.

The geometry of these presses made stress and strain

calculations difficult. An approximate cross-sectional area of
the links which hold the top and bottom half of the press
together was obtained and used to perform preliminary
calculations. A Finite Element Analysis of this press design
would be ideal for finding the stress concentrations, and
determining the most reliable place to locate the load sensors.
However, in this case such an analysis was no longer
available.
C. Load Sensing Application
One press, rated at sixty tons, was chosen for the application
of this load sensing system. The maximum rated load was
used to calculate estimates of the stress and strain in the
press.

Cross Sectional Area

Tie Bars

At

Rear

6 .5

( 10 34) .5 2

Ar

4A t A r

A xs

Tonnage Rating
Fpress

120000 (This value corresponds to 60 tons)

Stress

Fpress

A xs

7.143 10

Fig 6. Strain calculations based on maximum rated press load.

These estimates were then used to size a strain gauge load

sensing system. This load sensing system used the following
components:

Fig 8. Stamping press drive linkage. The geometry of this dynamic system was
used to find the transfer function for the press.
m 30

f rm

rm

rf

26.742

rc 4.5

m 3000

c( t ) f t

rf

xc( t) rc cos c( t )

3.607

xb ( t ) xc( t )

yb ( t ) .45 xb ( t )
4
2
y b( t ) 0
2
4

vb ( t )

0.5

d
yb ( t)
dt

1.5

1.5

1.5

t
10

Fig 7. This sensor circuit incorporates a typical Wheatstone quarter-bridge with

an amplification circuit.

D. Control System Application

Given the sixty-ton stamping press and the strain gauge load
sensing system, each of the control system options were
simulated using modeling software. To obtain meaningful
results in the simulation, a transfer function for the
mechanics of the press was needed. Given the geometry of the
press drive system a transfer function was calculated that
traced the motion from motor velocity to die velocity.

vb( t ) 0

ab ( t )

d
vb ( t)
dt

10

0.5
t

f( t ) m ab ( t )

1 10

f( t )

1 10

0.5
t

Fig 9. These calculations show the typical position, velocity, and force profile for
the given drive system. These calculations were used to find a transfer function
for the press.

The simulations performed in this study used an ideal force

profile as the desired signal. In this signal the force of
stamping is negligible.

press load curve and tested to see if the load was within
specified constant lower and upper bounds. These bounds
were set at the specified press load rating.
Fig 13. A load-limiting control system. This system simply cuts power to the
press when the load becomes larger than the specified limit magnitude.

This system successfully simulates how a press control system

could simply stop the process if the magnitude of press
loading became too large. The following output shows how
this system
Responds to a press load over the given limit:
Fig 10. Desired press force profile created using signal builder modeling
software.

1) Digital Display
This simple type of control system relies heavily on the
machine operator to monitor the load, and take action if it
exceeds the presses limitations. This system was simulated
using Simulink software.

Fig 14. System output for a load exceeding the specified load limit of sixty tons.

This system demonstrates how the control system would

respond to a press loading greater than the rated press limit.
This type of system could easily be integrated into the
automated control system of this manufacturer.
Fig 11. Block diagram for digital display control system.

In all of these simulations the disturbance signal was

generated using the signal builder in the software package.
This signal was modeled to represent the force encountered
under typical stamping conditions.

3) SPC Analysis Tracking

If the load curve results from each press hit were recorded in
a central database, this control system could easily take
advantage of Statistical Process Control to better evaluate this
stamping process. Having multiple load curves stored in
memory would allow a control system to calculate upper and
lower control limits for the stamping process.

Fig 12. Disturbance signal for all simulations. This signal simulates both the
positive and negative force encountered by the press ram during the piercing
operation.

2) Load Limit Switch

A basic model of this type of control system was constructed
in Simulink. This model simply received the most recent
Fig 15. This feedback control system keeps the press load
within acceptable limits.

These limits would be based on actual manufacturing floor

stamping data instead of idealized design calculations. Once
stable control limits for the process are established the control
system could stop the process, or alert an operator if the
control limits are exceeded. This type of statistical process
tracking is valuable for keeping accurate records of quality
data, which many customers are now demanding along with
the product.
4) Variable Velocity Press
Current press technology incorporates the flexibility and
accuracy of servo controls into stamping applications. A
servo motor can provide variable velocity at different points in
the stamping process. A key attribute of this technology is
that servo motors can vary the velocity of the press action
while still offering nearly the same amount of energy. This
means that the punching and forming points in the stamping
process can be slowed down to decrease press load while still
not having much of an impact on overall press cycle time.
In this situation a feedback control system is ideal to keep the
press from exceeding load limits. The following diagram
shows one system of this kind:
Fig 16. This feedback control system keeps the press load within acceptable

Fig 17. System input and output load profiles.

It can be seen from these graphs that using a servo motor to

control the velocity of the press can keep the press within its
load limitations. This control system also reduces the negative
load experienced by the press just after piercing the metal.
This feature will extend the life of the press greatly.
Although this system does smooth the disturbance signal it is
still relatively noisy. Also it is still possible to run the press
beyond its load limitations with this control system if the
disturbance force becomes too high. An additional
component can be added to the control system to ensure that
the load will never exceed the set limits. If a saturation block
is included before the integration block the force signal can
be strictly limited not to exceed the sixty ton limit.

limits.

This control system takes a desired force profile and amplifies

it to correspond with the rated load. A disturbance signal is
then added to the force signal to represent the force
encountered when forming the metal. This signal is then
integrated to obtain a velocity profile. The signal is run
through the press transfer function and then goes through a
derivative to get it back into force form. The feedback loop
has the function of smoothing the disturbance force and
conforming it to the desired press load curve. The following
simulation outputs compare the desired load profile with the
actual load profile seen by the press:

Fig 18. This feedback control system saturates the press load to keep it within
acceptable limits.

When a large disturbance force is applied to this system it is

limited to not exceed sixty tons. This disturbance force would
exceed the load limits when applied to the previous
unsaturated control system.

servo motor is able to supply a nearly constant rate of energy

with variable velocity. In this type of design the mechanical
advantage is usually in a mechanical linkage. There is no
need to have energy stored up in a large moving mass in this
type of design.

Fig 19. The output of the saturating load control system. Notice the smooth peak
stays below sixty tons.

This saturation effect depends on the ability of the servo

motor to supply enough energy to the system to complete the
work even at the reduced velocity.
E. Press Design Constraints
While the servo motor powered press offers some distinct
control advantages, it also constrains the design of the press.
Typical mechanical presses which run on constant speed
motors utilize a flywheel, clutch and brake to generate, store,
and apply energy to the process. The constant speed motor
turns a large flywheel. Energy is stored in the large rotating
mass of the flywheel. When the press is called into action the
brake grabs the flywheel and send the press ram into motion.

The press studied in this case is a combination of these two

techniques. The motor only runs when the press ram is in
motion. However energy is stored up in the moving mass of
the large steel blocks which contain the cam profiles. In a
conventional press the motor is constantly running and
turning the flywheel. Further study would need to be done in
order to determine if this press would be a candidate for a
servo motor drive. A changeover to servo technology could be
as easy as changing the drive motor to a servo motor if the
mechanics of the press allow for it in this case. The required
mechanical advantage may not be present in this press design
as it is in the designs outlined below.

Fig 21. Alternative servo press designs.

An additional benefit of a servo controlled press is the ability

to accurately sense the press ram position and dwell at certain
points in the stamping process. This ability to dwell during a
stamping process allows secondary operations to be
performed on the part while the press is in the middle of its
cycle. An example of this type of secondary action could be
punching a hole in the side of a part using lateral cylinders or
cams.
VI. CONCLUSIONS
In conclusion load sensing technology can increase the
capability and quality of a metal stamping process in many
ways. The most promising form of load sensing utilizes a
feedback control system in conjunction with a servo motor to
control the press ram velocity. However, many other solutions
exist in the range of no load sensing to load sensing, control,
and documentation. Each company should evaluate the costs
involved with such a project to ensure that it is worthwhile to
develop such a sensitive technology on the well established
process of metal stamping.
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Fig 20. Conventional press design, and a servo press design.

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rotating flywheel. In this situation if the press cycles too often
the flywheel will not have enough time to restock its energy
by getting back up to speed. This can cause the press to stall
on jobs which a well under rated press loading. A press with a

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Matt DeKam was born in Sioux Falls South Dakota

in the United States of America on October 18, 1981.
He graduated from Southwest Minnesota Christian
High School, and studied at Augustana College. He is
currently pursuing an Engineering degree at Calvin
College in Grand Rapids, Michigan.
His employment experience includes designing
and building industrial control panels for Affinity
Solutions in Sioux Falls, SD, and manufacturing
engineering work at Innotec in Zeeland Michigan.