CHAPTER-1

LITERATURE REVIEW

Knowledge for selection of materials of press tool components obtained from die designers,
tool manufacturers etc. It has been analyzed, tabulated and incorporated into a set of
production rules. The proposed intelligent system has been tested for variety of sheet metal
components and proved to be powerful and easy to handle because of its rich knowledge base
and highly interactive nature. The sample run of the system using an industrial sheet metal
part has demonstrated the usefulness of the system. The system supports mainly tool steels,
however its knowledge base can be modified and updated depending upon the availability of
new materials and advancement in technology.
Sufficient research and deliberation using the proven QC tools backed up with CAE software
support (HYPERFORM) has offered a feasible solution to the problem at hand. Steel material
like HCHCr (High carbon High Chromium) & OHNS (Oil Hardening non Shrinkage) grade
for both punch and die block to suit the components having EDD (Extra Deep Draw) is
recommended per the practices found in the industries. The operating condition involving the
magnitude of blank holding pressure is varied and the results analyzed. The experimental
investigation of the sheet metal blanking process makes it possible to study the effects of
process parameters such as the material type, the punch-die clearance, the thickness of the
sheet and their interactions on the geometry of the sheared edge especially the burrs height.
Various methods are used in order to obtain a better understanding of the blanking
manufacturing response. The investigation shows that, the blanking load increases with a
reduction in the tool clearance in the case of both single and double blanking. It is observed
that the diagonal angle () increases linearly according to the clearance, the crack propagation
angle () evolves nearly constant. One clear trend is that optimum clearance decreases as the
material elongation increases.
A new Blank Holder Force System (BHF) device with six-bar linkage mechanism has been
designed and manufactured. Whole control system of the new BHF technique was developed,
and the basic structure of the hardware configuration of the system was given. Software
analysis, implementation and division of the functional modules have been done. Also, the
control software in data acquisition and processing module has been developed in the
relevant technology of the BHF control system for the requirements of real-time, stability and
accuracy.
Tool design of oval punching was carried out by following three steps:
Step1. Identify the type of wear:

1
Factors Considered:
1) Type of sheet material
2) Hardness of sheet material
3) Presence of hard particles in the sheet material.

Step2. Occurrence of chipping or plastic deformation:

1) Type of operations to be performed on press tool.
2) Thickness and hardness of sheet material
3) Geometrical complexity of parts to be produced.

Step3. Risk of cracking:

1) Type of operations to be performed on press tool
2) Geometry of part to be produced
3) Die design and die size
4) Thickness and hardness of sheet material.
This was accomplished to identify the factors influencing the selection of materials of press
tool components.
This paper investigates the realization of two sensing methods to create a tooling-integrated
sensing system: mutual inductance-based displacement measurement for sheet draw-in, and
distributed contact pressure measurement at the toolwork piece interface. The two sensing
systems are complementary in nature, and together, they significantly enhance the on-line
observability of the stamping process. The performance of the draw-in sensor was evaluated
using numerical simulations and experiments in a small-scale and a large-scale lab setup, and
its effectiveness has been confirmed under the presence of wrinkled sheet Real-time
monitoring of local draw-in amount and local contact pressure in a deep drawing process is
highly desirable for effective process control and for the time reduction needed for die trial
out. Two tooling-integrated sensing methods were quantitatively evaluated using
experimental setups.
A greedy algorithm to form part family using a bottom-up approach that makes use of the
mixed integer linear programming formulation for generating shared setups for each part
family. Secondly, mixed integer linear programming formulation to generate a shared setup
for a given set of parts if such a setup exists. We expect that by producing many different
types of parts on the same setup, we can significantly reduce the number of setup operations,
improve machine tool utilization and enable cost-effective small-batch manufacturing.

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 CHAPTER-2
INTRODUCTION

2.1 What is a tool?

Tool is the assembly or device which is necessary to produce any product by means of
different kinds of manufacturing processes is called tool.

2.2 What is tool design?

Tool Design is the process of designing and developing the tools, methods and
techniques necessary to improve manufacturing efficiency and productivity. It
gives industry the machine and special tooling needed for today high speed,
high volume production. It does this at a level of quality and economy that will
ensure that the cost of the product is competitive. Since no single tool or process can
serve all the forms of manufacturing, tool designs an ever changing, growing
process of creative problem solving.

Press tool form a vital and an integral part of our modern production
houses. These tool act as the backbone for the production of stampings which
range from the most general items like your wrist watch parts to the most
sophisticated and complex items like the Skelton of automobiles, streamlined trains,
aircraft, missiles etc.

A great knowledge in the theory of design of press tools helps to have a better
scientific background instead of using thumb rule method. The designs should be
feasible for manufacturing with the available machinery and the equipment.
Standardization of tooling element reduces the time and the cost of
manufacturing, follow up the action of every stage of manufacturing and
working of the tool helps the tool designers considering to arrangement his
knowledge and development of skills.

The project involves the designing tools for the driving shield of bed clamp. To
produce the component in just one go is impossible and thus a gang of press comes
into frame.

2.3 What is press tool?

The metallic parts having thickness in between 0.4 mm to 6 mm is sheet metal. The kind of

3
assembly or device to produce sheet metal parts by the application of pressure without the
formation of chips is called press tool. Press tools are used to produce a particular component
in large quantity, out of sheet metals where particular component achieved depends upon
press tool construction and its configuration. The different types of press tool constructions
leads to different operations namely blanking, bending, piercing, forming, drawing, cutting
off, parting off, embossing, coining, notching, shaving, lancing, dinking, perforating,
trimming, curling etc. The press tool used is for blanking operation is called as blanking tool,
if piercing operation it is piercing tool and so on based on operation that we perform. The
application of press operations are widely used in many industries like food processing,
packing, defence, textile, automobile, aircraft and many apart from manufacturing industry.
2.4 What is sheet metal press working process?
The process which involve exertion of the pressure by means of punch and dies to produce
sheet metal finished parts is called sheet metal press working process.

Sheet metal processes can be broken down into two major classifications and one minor
classification.

Shearing Processes:- Processes which apply shearing force to cut, fracture or separate the
material.

Forming Processes:- Processes which cause the metal to undergo desired shape changes
without failure, excessive thinning, or cracking.

Finishing Processes:- Processes which are used to improve the final surface characteristics.

2.5 Need for press tool design

Sheet metal Press working is a chip less manufacturing process comes under cold
working. It is also called as stamping. So, design process used for this type of
tool called as press tool design. In this the deformation of sheet metal is brought
about by the process of slip of planes. It produced an improved surface finish,
scale free and bright surface and closer dimensional tolerances. Press
components are applicable in automobiles, electrical equipments, electronics,
utensils, mining equipments, ships etc.

2.6 Design of press tool

Design of any press tool involves following steps:-

1. Determination of force (press tonnage) required for the operation.

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2. Selection of press for required force, work piece size and shape.

3. Determination of shut height of the tool.

4. Strip layouts and comparing material utilization.

5. Computing all plates thickness and margins.

6. Design of locating elements.

7. Draw the die plan and selection of pillar die set.

8. Calculate the punch lengths and select mounting methods.

9. Find the centre of pressure.

Fig. 2.1 Design Flow Chart

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 CHAPTER-3
TYPES OF PRESS TOOL
1. SIMPLE PRESS TOOL:- The simple press tool is a tool designed to perform piercing or
blanking in a single stage by a single stroke at a single station. Single action dies perform a
single opertion for each stroke of the press slide the operation may be cutting or non cutting.

Fig.3.1 Simple Press Tool

2. COMPOUND PRESS TOOL:- The compound tool is a tool designed to perform multiple
cutting operation including blanking in a single stage by a single stroke at a single station.

Fig.3.2 Compound Press Tool

3. COMBINATION PRESS TOOL:- The combination press tool is a tool designed to

perform cutting and non cutting operation including blanking in a single stage by a single
stroke at a single station.

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 Fig.3.3 Combination Press Tool

4. PROGRESSIVE PRESS TOOL:- A tool containing a series of stations that perform one
press operation after another in series. A progressive die gradually forms a part as it moves
through the die, and the last operation (i.e. blanking) separates the part.

Fig.3.4 Progressive Press tool

5. BENDING TOOL:- This tool is used to bend the component in specified shape.
V-Bend Tool
U-Bend Tool

7
 Fig.3.5 Bending tool

6. DRAWING TOOL:- Drwaing is a process of axial elongation through application of axial

force.

Fig.3.6 Drawing Tool

NOTE:

Stroke:- The occurrences which has taken place during the exertion of the pressure by punch
during downward movement of the top half assembly may be called stroke.

Stage:- When complete sheet metal parts may not be possible to produce by means of single
stroke with the help of single set of punch. In that case it may be the requirement to split the
whole operation sequence into a number of segment so that gradually one after another the
portions of the object can be created by multiple number of strokes. That segment of
operation may be termed as stages.

Station:- When sheet metal parts needs to be manufactured by stages by stages operation
with the application of number of strokes (in the case of progressive tool) then it is necessary
to stop its movement just during the exertion of pressure of punch just during each and every
stroke. The location where the sheet is needed to stop its movement for the purpose of
exertion of pressure on sheet metal may be termed as station.

8
 CHAPTER-4
TYPES OF PRESS TOOL OPERATIONS
There are two types of operations:-
Cutting Operations
Non-Cutting Operations

4.1 Cutting Operations:

Processes which apply shearing force to cut, fracture or separate the material. Also known as
shearing operations.

i). Piercing:- Holes are cut on the sheet metal.

Fig.4.1 Piercing

ii). Blanking:- The cutting action must be about a complete or enclosed contour.

Fig. 4.2 Blanking

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iii). Notching:- It is an operation for removing a piece of scrap from the edge.

Fig. 4.3 Notching

iv). Lancing:- Three side cutting and one side bending operation.

Fig. 4.4 Lancing

v). Parting Off:- Cut the material between two components to separate it from parent metal.

Fig. 4.5 Parting Off

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vi). Cutting Off:- The cutting action must be along a line.

Fig. 4.6 Cutting Off

vii). Cropping:- Cutting operation to control the strip movement.

Fig. 4.7 Cropping

viii). Perforating:- Maximum number of holes are pierced in single stroke

Fig. 4.8 Perforating

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ix). Nibbling:- To cut out the sheet to size with help of punching.

Fig. 4.9 Nibbling

x). Louvering:- Three side forming and one side cutting operation.

Fig. 4.10 Louvering

xi). Trimming:- To cut excess material which is left out on the flange of the drawn
component.

Fig. 4.11 Trimming

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xii). Shaving:- To give finish cut to the blanks and pierced holes.

Fig. 4.12 Shaving

4.2 Non-Cutting Operations:-

Also known as forming operations. Processes which cause the metal to undergo desired shape
changes without failure, excessive thinning, or cracking.

i). Bending:- To bend the sheet at specified angle.

Fig. 4.13 Bending

ii). Drawing:- It is process of changing flat, precut metal blank into hollow vessel.

Fig. 4.14 Drawing

13
iii). Embossing:- Shallow forming operation at equal thickness.

Fig. 4.15 Embossing

iv). Coining:- It is operation of making impression and depression on sheet metal.

Fig. 4.16 Coining

v). Bulging:- It expands the cups along a narrow band and at the same time reduce the height.

Fig.4.17 Bulging

14
vi). Hemming:- To join the two sheets.

Fig. 4.18 Hemming

vii). Seaming:- It is the operation of pushing the material inside/outside all around the
periphery.

Fig.4.19 Seaming

viii). Curling:- It is the operation of turn the edge inside.

Fig.4.20 Curling
15
 CHAPTER-5
COMPONENT & TOOL DETAILS

5.1 Component Analysis:

Lets take an example that a letter I (60*60) is to be made of
Thickness = 2mm
Area = 1600mm2
Perimeter = 340mm
Shear Strength of the stock material = 240N/mm2
Material = Cold Rolled Cold Annealed Steel (CRCA)

Fig. 5.1 3D View of I Component

Fig.5.2 2D View of I Component

16
5.2 Strip Layout:
The graphical representation of sheet or strip through which methods of profile cutting can be
interpreted so that maximum utilization of the strip is ensured.

Fig.5.3 Strip Layout Flow Chart

5.2.1 Types of strip layout:

i). Single row one pass
a). Wide run b). Narrow pass

Fig.5.4 Single Row One Pass

17
ii). Single row two pass

Fig.5.5 Single Row Two Pass

iii). Gang strip layout

Fig.5.6 Gang Strip Layout

5.2.2 Strip Layout Calculation:

To compare the maximum utilization of the strip through strip layout, create at least 3
alternative strip layouts and calculate the efficiency (economy factor) by the following
formula
Economy Factor(%) = Area of blank * No. of Rows * 100
Width of Strip * Pitch

For letter I, only single row one pass strip layout is possible.

18
For wide run

Fig. 5.7 Single Row One Pass Wide Run Strip Layout for I Component
Pitch:- The distance between the two similar and consecutive points on a strip layout or on a
profile.
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.

Scrap Bridge:- The portion. of material remaining between the two adjacent openings after
blanking is also called as the scrap bridge.

Strip Width:- It is simply defined as the width of the sheet or strip.

Therefore, Scrap Bridge = 1.2 * thickness of strip or sheet

= 1.2 * 2 mm
= 2.4 mm
Front Scrap = 2.4 mm
Back Scrap = 2.4 mm
Pitch = 62.4 mm
Strip Width = 64.8 mm
Area of blank = 1600 mm2

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 Economy Factor(%) = Area of blank * No. of Rows * 100
Width of Strip * Pitch

= 1600 * 1 * 100 = 39.56 % = 40 %

64.8 * 62.4

For narrow run

Fig.5.8 Single Row One Pass Narrow Run Strip Layout for I Component
Pitch = 62.4 mm
Front Scrap = 2.4 mm
Back Scrap = 2.4 mm
Scrap Bridge = 2.4 mm
Strip Width = 64.8 mm
Therefore, Economy Factor = 39.56 % = 40 %
And for angular layout,

Fig.5.9 Single Row One Pass Angular Run Strip Layout for I Component

20
Pitch = 72 mm
Front Scrap = 2.4 mm
Back Scrap = 2.4 mm
Scrap Bridge = 2.4 mm
Strip Width = 86.8 mm
Therefore, Economy Factor = 1600 * 1 * 100
86.8 * 72

= 25.60 % = 26 %

Comparing the above three strip layouts of letter I, it can be seen that either we can use
wide run or narrow run strip layout because in both the cases economy factor is equal.

5.3 Cutting Force Calculation:

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.
Cutting Force = L * S* max

where, L = Perimeter of the component in mm

S = Sheet or Strip thickness in mm

= Max. Shear strength in kg/mm2

For Factor of Safety,

Cutting Force, FSH = 1.2 * L * S * max

= 1.2 * 340 * 2 * 240

= 195840 N

= 195.840 KN

= 19.58 Tonnes

Therefore, Press Tonnage = 20 Tonnes

5.4 Clearance per side calculation:

The amount of space between the outer edge of the punch and the inner edge of the die
cavity. A proper amount of clearance is necessary for an effective shearing operation. The
ideal clearance can be calculated by the following formula

Clearance / Side = C * S * T max/10

21
 = 0.01 * 2 * (240/10)

= 0.09797 mm

where,

C = constant

= 0.005 for very accurate components

= 0.01 for normal components

S = Sheet thickness in mm

Tmax. = Shear strength of the stock material in N/mm2

5.5 Press Tool Terminology of Simple Tool

After calculating the economy factor, cutting force & cutting clearance per side, we
need to design the press tool in Siemens NX Software.

NX, formerly known as NX Unigraphics or usually just UG, is an advanced high-end

CAD/CAM/CAE software package originally developed by Unigraphics, but since
2007 by Siemens PLM Software. It is used for Design, Manufacturing finished design
by using included machining modules, & Engineering analysis.

Firstly the design is made in CAD. CAD is the use of computer systems to aid in the
creation, modification, analysis, or optimization of a design. CAD is used to increase
the productivity of the designer, improve the quality of design, improve
communications through documentation, and to create a database for manufacturing.

5.5.1 Lower Half Assembly: The lower half assembly is fixed on the bed of the
hydraulic press. It contains

i). Die Block

ii). Bottom Bolster

iii). Guide Rails

iv). Stripper Plate

v). Guide Pillar

vi). Stopper

22
 Fig. 5.10 3D View of Complete Lower Half Assembly

i). Die Block:- The shape and dimensions of the product to be achieved depends on design
of die block. Clearance should be there between punch and die block, otherwise we cannot
perform the operation.
Thickness of die block = Td = 3 FSH
= 3 20 = 27 mm ( calculated)
= 30 mm ( standard)

Fig.5.11 3D View of Die Block

23
 Fig. 5.12 Front & Top View of Die Block

Length of die block = (1.5 * Td) + 60 + (1.5 * Td)

= (1.5 * 27) + 60 + (1.5 * 27)

= 40.5 + 60 + 40.5

= 141 mm ( calculated)

= 145 mm ( standard)

Width of die block = 145 mm

ii). Bottom Bolster:- The bottom plate is the lower working member of the die set. It is the
base of the tool. Usually the bottom plate is made thicker than the top plate. The die block
and guide pillars are fitted to this plate.
24
Thickness of bottom bolster = 1.75 * Td

= 1.75 * 27

= 47.25 mm ( calculated)

= 50 mm ( standard)

Where, Td = Thickness of die block

Fig.5.13 3D View of Bottom Bolster

Length of bottom bolster = 2*(1.5*Dgp) + Ld + 2*(1.5*Dgp)

= 2*(1.5*25) + 141 + 2*(1.5*25)

= 75+141+75 = 291 mm ( calculated)

= 315 mm ( standard)

where, Dgp = Diameter of guide pillar

Ld = Length of die block

Width of bottom bolster = 315 mm

iii). Guide Rails:- Guide Rails are used to guide the strip or sheet.

Thickness of guide rail = stopper height + sheet thickness + 1

= 3+2+1 = 6 mm ( calculated)

25
 = 8.5 mm ( standard)

Fig. 5.14 3D View of Guide Rails

Fig.5.15 Front & Top View of Guide Rail

Length of the guide rails = Length of the die block = 145 mm
26
Width of the left guide rail = 39 mm
Width of the right guide rail = 40 mm
iv). Stripper Plate:- Its main function is to strip the stock scrap off the punch and to guide
the punch into the die.

Fig.5.16 3D View of Stripper Plate

Fig. 5.17 Front & Top View of Stripper Plate

27
Thickness of stripper plate = 0.5 * Td ( For fixed punch )

= 0.75 * Td ( For stripper guided punch )

Here, we are using fixed punch

Therefore, thickness of stripper plate = 0.5 * Td

= 0.5 * 27 = 13.5 mm ( calculated )

= 20 mm ( standard )

Length of the stripper plate = Length of the die block = 145 mm

Width of the stripper plate = Width of the die block = 145 mm

v) Guide Pillars:- Guide pillars are precision ground pins which are press fitted into
accurately bored holes in the bottom plate. Guide pillars are assembled into corresponding
guide bushes to align punch and die components with a high degree of accuracy. The guide
pillar shown below is press fitted type guide pillar.

Fig.5.18 3D View of Guide Pillars

Diameter of the Guide pillar = 25 mm ( standard )

Height of the guide pillar depends upon the shut height. The height of the pillars must be less
than the shut height in order to ensure that the press ram will not strike against the ends of the
pillars.

28
Shut height is the distance from the bottom plate to the top of the top plate when the tool is in
closed position.

vi). Stopper:- Stopper is used to avoid overfeeding and underfeeding of the strip. It is fixed
on the die block.

Fig.5.19 3D View of Stopper

Thickness of the stopper head = Thickness of the strip + 1

5.5.2 Upper Half Assembly: The upper half assembly is attached to the hub of the power
press machine. It contains

i). Punch

ii). Top Bolster

iii). Punch Holder

iv). Thrust Plate

v). Guide Bush

29
 Fig. 5.20 3D View of Complete Upper Half Assembly

i). Punch:- It is the cutting element of the tool. It is made of high carbon high chromium steel
(HCHCr). Punch is fitted in the punch holder plate. The main function of the punch is to
strike the sheet metal. Clearance should be there between punch and die block, otherwise we
cannot perform the operation. The punch is clamped inside the punch holder with the help of
punch head.

Height of the Punch is between 60 to 85 mm depending upon the shut height and the land.

Some negative clearance per side ( 0.097mm) is given to the punch, otherwise it wont be
able to enter the die block.

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
the land.

30
 Fig.21 Front & Top View of Punch Fig. 5.22 3D View of Punch

ii). Top Bolster:- This is the plate on which the punch holder is fixed. The top plate also
holds the shank and the bushes. Top plate absorbs the shock resulting due to the cutting
action.

Thickness of the top bolster = 1.25 * Td

= 1.25 * 27 = 33.75 mm (calculated)

= 50 mm ( standard )

Length of the top bolster = Length of the bottom bolster = 315 mm

Width of the top bolster = Width of the bottom bolster = 315 m

31
 Fig.5.23 3D View of Top Bolster

iii). Punch Holder:- Punch is fitted to the punch holder with a light press fit.

Fig. 5.24 3D View of Punch Holder Plate

Thickness of the Punch Holder = 0.5 * Td ( For stripper guided punch )

= 0.75 * Td ( For fixed punch )

Here, we used fixed punch

32
Therefore, thickness of the punch holder = 0.75 * Td

= 0.75 * 27 = 20.25 mm ( calculated )

= 27 mm ( standard )

Length of the Punch holder = Length of the die block = 145 mm

Width of the Punch holder = Width of the die block = 145 mm

Fig.5.25 Front & Top View of Punch Holder Plate

iv). Thrust Plate or Back Plate:- While performing the cutting the punch will exert an
upward thrust. So the punch should be backed by a hardened (45-50 HRC) plate to avoid
digging on the top plate. For this purpose the thrust plate is used.

33
 Fig.5.26 3D View of Thrust Plate

Fig.5.27 Front & Top View of Thrust Plate

34
Length of the thrust plate = Length of the die block = 145 mm

Width of the thrust plate = Width of the die block = 145 mm

There is no specific formula for the thickness of the thrust plate.

v). Guide Bush:- Guide bushes are precision ground bushes which are press fitted into
accurately bored holes in the top plate. Guide pillars & guide bushes are used to achieve a
well guided movement of the moving part with respect to the fixed part.

Fig.5.28 Front & Top View of Guide Bush Fig.5.29 3D View of Guide Bush

All the dimensions of Guide Bush are standard.

5.5.3 Fasteners & Dowels

Fasteners & Dowels are used to connect the different plates both in upper and lower half
assembly. Here, we have used fasteners & dowels of M6 size.

35
 Fig.5.30 3D View of Dowel

Diameter of the dowel = 6 mm

Fig.5.31 3D View of Fastener

36
5.5.4 Complete Assembly

Fig.5.32 Side View of Complete Assembly

Fig.5.33 3D Views of Complete Assembly

After finishing the design, CAM is used. CAM, Computer Aided Manufacturing is the use of
software to control machine tools and related ones in the manufacturing of work pieces.
CAM is a subsequent computer aided process after computer aided design and sometimes
after computer aided engineering (CAE), as the model generated in CAD and verified in
CAE can be input into CAM, which then controls the machine tool.

37
Computer Aided Engineering (CAE) is the broad usage of computer software to aid in
engineering analysis tasks. It includes Thermal and fluid flow analysis, Stress Analysis on
components and assemblies using Finite Element Analysis (FEA), Computational Fluid
Dynamics (CFD), Multi body Dynamics (MBD), and Optimization.

38
Conclusion

In 28 days training, I have studied the following things:

i). Introduction to the press tool, types of the press tool, and the press tool operations.

i). Studied various parameters, design considerations, & calculations involved in press tool
design.

iii). Designed and constructed the press tool using Siemens NX Software.

39
References

1. INDO GERMAN TOOL ROOM

40