Course Conducted for

Post Graduate Diploma in Tool Design and Cad

/cam

Topic
PRESS TOOL DESIGN

Presented by:
Shaikh Kamaloddin,
Engineer Design
Central Tool Room
A-5, Focal Point
Ludhiana
Tel.: 0161-670058, 59,

Books & Reference:-

• Press tool design and construction By P.H Joshi
• Sheet Metal Press Tools Design Making By Midhat Luqman
• Guide to Press Tool Design By William Francis Walker
• Cyril Donaldson, George H LeCain, V C Goold, Tool design 3rd edition, Tata McGraw-Hill Education,
New Delhi
• https://designtools.page.tl/Press-Tool-Operation.htm#ncutting

PRESS TOOL:-

A tool used to perform both cutting and non-cutting operation on a sheet of metal called Stock by
using a Press. Usually press tool are used where the production of a component is in large numbers.
A press tool comprises a punch and a die as its basic components.

Types of operations performed using press tool:-

Cutting operations:-
Piercing:- Piercing involves cutting of clean holes with a resulting scrap slug. The operation is
called die cutting and can also produce flat components where the die, the shaped tool, is pressed
into a sheet material employing a shearing action to cut holes. This method can be used to cut parts
of different sizes and shapes in sheet metal, leather and many other materials with proper cutting
clearances.

• Blanking:- When a component is produced with one single punch and die where the
entire outer profile is cut in a single stroke the tool is called a blanking tool.
• Blanking is the operation of cutting flat shapes from sheet metal.
• The outer area of metal remaining after a blanking operation is generally discarded as waste.
• Size of blank or product is the size of the die & clearance is given on punch.
• The size of the blank depends on the size of the die.
• So the size of the die opening is equal to the blank size.
• Clearance is given to the punch.

Notching:-This is an operation where a piece of scrap is removed by performing cutting action

on three sides of the punch.
Notching is a metal-cutting process used on sheetmetal or thin barstock, sometimes on angle
sections or tube. A shearing or punching process is used in a press, so as to cut vertically down and
perpendicular to the surface, working from the edge of a workpiece. Sometimes the goal is merely
the notch itself, but usually this is a precursor to some other process: such as bending a corner in
sheet or joining two tubes at a tee joint, notching one to fit closely to the other.

Lancing:- Lancing is a piercing operation in which the workpiece is sheared and bent with one
strike of the die. A key part of this process is that there is not reduction of material, only a
modification in its geometry. This operation is used to make tabs, vents, and louvers.
The cut made in lancing is not a closed cut, like in perforation even though a similar machine is
used, but a side is left connected to be bent sharply or in more of a rounded manner.
Lancing can be used to make partial contours and free up material for other operations further down
the production line. Along with these reasons lancing is also used to make tabs (where the material
is bent at a 90 degree angle to the material), vents (where the bend is around 45 degrees), and
louvers (where the piece is rounded or cupped).It also help to cut or slight shear of sheet on
cylindrical shape.
Normally lancing is done on a mechanical press, lancing requires the use of punches and dies to be
used. The different punches and dies determine the shape and angle (or curvature) of the newly
made section of the material. The dies and punches are needed to be made of tool steel to
withstand the repetitious nature of the procedure.[2]

Parting Off:- Partings are similar, in that a discrete part is cut from a sheet or strip of metal
along a desired geometric path. The difference between a cutoff and a parting is that a cutoff can be
nestled perfectly on the sheet metal, due to its geometry. With cutoffs, the cutting of sheet metal can
be done over one path at a time and there is practically no waste of material. With partings, the
shape cannot be nestled precisely. Parting involves cutting the sheet metal along two paths
simultaneously. Partings waste a certain amount of material that can be significant.

Cut-Off:- Cut off operations are those in which a strip of suitable width is cut to length in a
single operation. Cut-off tools can produce many parts. The required length of strip can be cut off for
bending and forming operations using this too.

Cropping:-Cropping is a process where metal strip is sheared of from the side in order to
maintain the movement of the strip in the tool. This operation is often used in progressive tool where
movement of the sheet with precision is required in order to produce component of higher accuracy.

Perforating:- Perforating is a piercing tooling that involves punching a large number of

closely spaced holes.

Nibbling:- The nibbling process cuts a contour by producing a series of overlapping slits or
notches. This allows for complex shapes to be formed in sheet metal up to 6 mm (0.25 in) thick using
simple tools. Punches are available in various shape and sizes; oblong and rectangular punches are
common because they minimize waste and allow for greater distances between strokes, as
compared to a round punch.

The process is often used on parts that do not have quantities that can justify a dedicated blanking
die. The edge smoothness is determined by the shape of the cutting die and the amount the cuts
overlap; naturally the more the cuts overlap, the cleaner the edge. For added accuracy and
smoothness most shapes created by nibbling undergo filing or grinding processes after completion.

Louvering:- It is a process where cutting is done on one edge and the remaining edges are
attached to the stock.

Trimming:- When cups and shells are drawn from flat sheet metal the edge is left wavy and
irregular, due to uneven flow of metal. Shown is flanged shell, as well as the trimmed ring removed
from around the edge. While a small amount of Material is removed from the side of a component in
trimming tool.

Shaving:- Shaving removes a small amount of material around the edges of a previously
blanked stampings or piercing. A straight, smooth edge is provided and therefore shaving is
frequently performed on instrument parts, watch and clock parts and the like. Shaving is
accomplished in shaving tools especially designed for the purpose.

Non-Cutting Operations:-
Bending:- Bending is a process where simple bends are performed on the stock. A simple
bend is done in which the line of the bend is straight. One or more bends may be involved, and
bending tools are a large important class of press tools.

Drawing:- Drawing is a processin which transformation of flat sheets of metal into cups, shells
or other drawn shapes by subjecting the material to severe plastic deformation. Shown in fig is a
rather deep shell that has been drawn from a flat sheet.
Embossing:- Sheet metal embossing is a stamping process for producing raised or sunken
designs or relief in sheet metal.

Coining:- Coining is a form of precision stamping in which a workpiece is subjected to a

sufficiently high stress to induce plastic flow on the surface of the material. A beneficial feature is that
in some metals, the plastic flow reduces surface grainsize, and work hardens the surface, while the
material deeper in the part retains its toughness and ductility. The term comes from the initial use of
the process: manufacturing of coins.

Bulging:-It expands the Cups along a narrow band and simultaneously reduces the height of
the component.

Seaming:-This is the operation in which the material is pushed inside or streatched outside and
simultaneously reduces the height of the component.

Curling:-Curling is the operation in which the edges are turned inside in order to avoide the
human contact to the sharp edges.

Classification Of press tools:-

Press tools can be classified as

1.Progressive tool

2.Compound Tool

3.Combination Tool
 Progressive Tool:-
A progressive tool differs from a stage tool in the following respect: in a progressive tool the final
component is obtained by progressing the sheet metal or strip in more than one stage. At each stage
the tool will progressively shape the component towards its final shape, with the final stage normally
being cutting-off.

Compound tool
The compound tool differs from progressive and stage tools by the arrangement of the punch and
die. It is an inverted tool where blanking and piercing takes place in a single stage and also the
blanking punch will act as the piercing die.

Combination tool
In a combination tool two or more operations such as bending and trimming will be performed
simultaneously. 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 takes place- it can perform a cutting and non-cutting operations in a single tool.

Elements Of Press Tool

TYPICAL PRESS TOOL AND PARTS
INTRODUCTION

In typical press tool in order to produce a component a complete assembly is required which

consists of various elements and each element performs a specific function.

a) TYPICAL PRESS TOOL AND THEIR PARTS
A basic press tool for the purpose of cutting, non-cutting or integrated operations
consists of following parts:
• Punch
• Die or die plate
• Stripper plate
• Strip guides
• Punch plate
• Bottom plate
• Top plate
• Guide pillars
• Guide bush
• Shank
• Stops
12. Standard parts e.g. dowels, springs, screws etc.
 • Punch:
• It is the male cutting member of the press tool and is fixed mostly with the top half
of the tool.
• It determines the size of pierced profile.
• Its length should be as minimum as possible to avoid bucking/ bending and it is
determined by the following formula.
L = d/8 x Ed / Ft
Where d = dia of punch
E = Mod. of Elasticity
F = Shear force
t = Sheet thickness

iv. It can be fixed with the help of screw (s) or in punch plate by providing collar in the
punch
• Die:
It is the female cutting member of the tool.
It determines the blank size.
It can be made from solid plate by filing, milling, EDM, wirecut or in splits by grinding.
The die splits has to be nested in a plate called die plate.

• Stripper plate:
It strips the coil or strip from the punch.
It is of two types, fixed and spring loaded.
Some time it is guided in stripper to give strength to the punches.

• Punch Plate:
It is mostly fixed in the top plate.
Punch plates hold support, locate as well as straighten the punches.

• Stops:
Finger stops: Finger stops or primary stops (as they are also called) are used in dies
with two or more stations. They register the strip for performing operations prior to strip
engagement by the automatic stop or roll-feed.

Automatic stops: They are also known as trigger stops. They register the strip at the
final die station. They differ from finger stops in that they stop the strip automatically,
the operator simply keeping the strip pushed against the stop in its travel through die.

Strip guides or stock guides: Stock may be solidly guided by suitable slots in a
stripper by the stock rails or, by pins buttons or angle iron. Solid guides may or may not
required spring guides or spring pushers for optimum stock guiding.
They are not always mounted to the die shoe and some types are mounted on the
stripper plate.
 • Shanks: Shanks may be attached to or made as an integral part of the punch shoe. They
are available as an integral part of the punch shoe. They are available as integral cast,
welded or inserted (by screws). The shank diameter is determined by the press in which
the tool is to be used.
• Pilots: They are provided with a cone shape head which enters previously pierced holes
in the strip, the cone shaped causes the strip to shift to accurate register before blanking
occurs.
• Guide bush:
It is the provided in the top half of the die.
It is provided for proper alignment of die sets
10. Guide pillar:
It is press fitted in the bottom plate of the die.
It is also provided for correct alignment.

Its upper half slides in guide bush

11. Top Plate:

It is located on the upper half of the die.
It serves the function of holding the punch (punches) and the shank.
Guide bushes are fixed to it.
12. Bottom plate:
It is located in the lower half of the die.
It serves the function of holding the die.
Guide pillars are press fitted into it.
 DESIGN PARAMETERS FOR SHEARING
For making a press tool, design parameters are to considered, so that maximum production and
least maintenance with lowest feasible die life cost can be attained
SHEARING FORCE, STRIPPING FORCE
SHEARING FORCE: The force required to penetrate the stock material with the punch is
known as shearing force. For determining the shearing force take into account the
thickness of stock material, the perimeter of stock material & the shear strength of stock
material.
The shearing force formula is
F = Sxpxt
where F = Shear force
S = Shear strength of stock material.
p = perimeter or length of cutting force.
t = thickness of material.
STRIPPING FORCE: The force required to strip or remove the scrap or stock from the
punch is known as stripping force. This may be 5 to 8 percent of shearing force for normal
clearance & 10 to 20 percent (for narrow clearance & contours) of shearing force.
PRESS CAPACITY = (Shearing force + Stripping force) x Factor of safety
SIZES OF DIE ELEMENTS
1. Thickness of die plate ( Td ) = F 1/3
Where F = Shearing force
2. Thickness of bottom plate = (1.75 to 2) Td
3. Thickness of top plate = (1.25 to 1.5) Td
 4. Thickness of sticker plate = (0.5 to 0.75) Td
5. Thickness of punch holding plate = (0.5 to 0.75) Td
• Thickness of punch back plate = 8 to 12mm
• Length of punches = 65 to 80mm

b) CUTTING CLEARANCE, ANGULAR CLEARANCE, LAND

CUTTING CLEARANCE
The intentional dimensional difference between the punch, cutting edge and the die cutting
edge. Clearance is always expressed as the amount of clearance per side. It ranges
normally between 2% to 8% depending on shear strength & thickness of sheet metal.
ANGULAR CLEARANCE: After the blank or the slug is cut it remains in most cases in the die &
is pushed down by next cutting & soon. Usually the die is many times thicker then the cut out
blank or slug. If too many cuttings are stacked together inside the die, unwanted side effects are
expected. The parts or slugs jam because of spring lack. To avoid stacking of too many blanks
or slugs, angular clearance is provided. It usually ground from ¼ to ¾ per side but occasionally
as high as 20 , depending mainly on stock thickness & frequency of sharpening.

LAND: A flat edge contiguous to the cutting edge of a die, its purpose being to reduce the area
to be ground & reground in maintaining a sharp edge.

CONCEPT OF APPLYING CUTTING CLEARANCE

The diameter of the blank or the pierced hole is determined by the measurement of the
burnished area. Since the walls of the die produce the burnished area or the blank, the
diameter of the blank will be the same as diameter of the die. The same principle applies to
the diameter of the pierced hole. The burnished area in the hole is caused by the punch, thus
the diameter of the pierced hole will be the same as the punch. Therefore, die clearance is
either placed on punch or die, depending upon whether the pierced hole or the blank will be
the desired workpiece. If the blank is to become the workpiece, the die diameter is made to
the workpiece size and the punch is reduced in size. An amount equal to die clearance. If the
pierced hole is to become part of the workpiece, the punch is made to the correct hole size
and the die opening is made oversize an amount equal to die clearance. In simple terms the
die controls blank size and the punch controls hole size.

CONCEPT OF DIE LIFE

One reference may recommend 6% of stock material thickness per side, while another way
 recommend 12% for the same material. The difference is probably end result each is striving
for. The designer should consider the application of blanked or pierced workpieces.

When the purpose is only to make the hole, as in case of structural steel, wide clearances
may be given to increase the die life. Blanked workpieces that assemble as an integral part of
a mechanism require tighter clearances for higher accuracy and hence have less die life. Die
life also depends upon the thickness of stock to be cut, lesser the thickness, lesser will be the
force required and lesser will be the load on die which increases its life and vice versa.

SHEAR ANGLE:
It sometimes becomes necessary to reduce cutting forces to prevent press overloading. To
overcome the problem the face of the punch and the die are grinded at small shear angle
with the horizontal. This has the effect of reducing the area of shear at any one time. Shear
also reduces shock to the press and also smoothes out the cutting operation. The shear
angle chosen should provide the change in the punch length from 1 to 1 ½ times the stock
thickness. Shear that is equal to or greater than the stock thickness is called full shear.
Cutting forces are approximately reduced to 30% when full shear is applied.
Double angled shear is preferred once single angle shear because it does not set up lateral
force components. Double shear angle on punches should be concave to prevent stretching
the material before it is cut. The shear angle is either applied to the punch face or the die
face, depending on whether the operation is blanking or piercing, because shear will distort
the work material. In other words, the shear angle for a blanking operation will be on the die
member, while in a piercing operation the shear angle will be on the punch member.

Shear Angle

PRINCIPLE OF DESIGN PARAMETERS SUCH AS CUTTING CLEARANCE, ANGULAR

CLEARANCE, LAND WITH RESPECT TO QUANTITY AND QUALITY REQUIREMENTS

CUTTING CLEARANCE: When the requirement is such that a very large number of
components are required cutting clearance should be maximum so as to increase the die life.
But when quantity is less cutting clearance can be minimum
When we require high quality product which has to assemble as an integral part, minimum
clearance should be provided. But when the purpose is only to make a hole, wide clearances
may be provided.

ANGULAR CLEARANCE: For large quantities and fine qualities less angular clearance is
required. For less quantities and poor qualities larger angular clearance is required.
Angular clearance varies from 1/40 to 2 depending on the requirement.
LAND: For large quantities & fine qualities maximum land is required. For less quantities &
poor qualities minimum land is required. Land varies from 2mm to 5mm depending upon
the requirement.

b) GEOMETRICAL RELATIONSHIP BETWEEN COMPONENT, PUNCH AND DIE

The diameter of the blank or pierced hole is determined by the measurement of the
burnished area. Since the burnished area on the blank is produced by the walls of the die,
the diameter of the blank will be the same as the diameter of the die. The same principle
applies to the diameter of the pierced hole. The burnished area jn the hole is caused by the
punch, thus the diameter of the pierced hole will be same as punch. Therefore, die
clearance is either placed on the punch or the die, depending upon whether the pierced
hole or the blank will be desired workpiece, if the blank is to become the workpiece. The
die diameter is made to the workpiece size and the punch is made to the correct hole size
and the die opening is made oversize an amount equal to the die clearance. In simple
terms, the die controls the blank size and the punch controls hole size.
 DESIGN STEPS FOR CUTTING DIES
• FIRST STEP :- In designing of cutting tools first step is a preparation of a sketch
incorporating all elements of die. This die is then given dimension in a systematic manner,
in which parts are assembled. There are few designs of cutting tool which design is
selected for making the sketch is also decided by the tool designer considering the size
and shape of the blank and also the restriction placed by press available.
• SECOND STEP: Determine punch & die opening diameters considering whether the
operation is of blanking or piercing.
• THIRD STEP: Design the die block as regard its overall dimension and surface area and
select a die set of the available for the particular die block dimensions and decide the
number, size, location of dowel pins and Allen screws length of the punch is determined
next after computing the thickness of the punch is block. Overall length of the punch is
equal to the shut height minus computed thickness.
• FORTH STEP: Provide arrangement for fixing the punch retainer. Special precaution are
always needed to fix and guide slender piercing punches.
• FIFTH STEP: Provide stock stops, sock guides and suitably designed stripper and
provide dimension to each part and also, its exact location on the die block or die shoe.
 Design, the springs of pressure pads if they are incorporated in the design.
• SIXTH STEP: Next prepare the dimensioned, assembly drawing which should show the
following views:
• Section elevation, similar to the sketch with punch in the position of just completing its
downward stroke.
• Plan of the lower portion showing die block, die shoe, stripper, stop pin, positions &
methods of securing punch, dowels and screws to the punch plate through the block
up plate and retainer.
• Side section elevation, of punch & die assembly.

• SEVENTH STEP: Indicate the press capacity and type of press where the job can be
handled, on the drawing. All above views are necessary for layout and assembling the die
elements in, the tool shop whereas detail drawings are also necessary for the sake of
process planning & manufacturing each elements by routing through various shops.

CLASSIFICATION OF DIE SET, SHUT HEIGHT AND CENTRE OF PRESSURE

• Classification of Die Set:
Die set is a pair of basis for mounting die component aligned to each other by
accurately aligned to each other by guide pins that ride in bushings die-sets are
classified as under:
• Back Post Design: In this design the die-set has two guide posts positioned in the
rear. This is the most frequently used design. This design leaves a clear space for
hand feeding second operation and there is no obstruction from guide posts.

Back post design

• Centre Post or Axial Post Design: In this design the two guide posts are positioned
along the transverse center–line of the die-set. This designs suitable when load is
two heavy and the strip feeding is from the front but this design prevent and feeding
end feeding either by hand or automatically.

Centre Post or Axial Post Design

• Diagonal post design: This design is used when the load is very heavy and end-
feeding is required. The guide post are along a diagonal line. Generally, the left guide
post is in front, but if we feed from left to right the guide post is in front.

Diagonal post design

 • Four Guide Post Design: In this design, a guide post is positioned at each corner of
the die set. For roll-feed operations, especially for progressive dies with several
stations this design should be used. This design provides maximum rigidity and
accuracy of alignment. The front guide posts are inconvenient for hand operation and
may even be dangerous unless proper guards are fitted to the press.

Four die post design

SHUT HEIGHT OF DIE SET:-

The shut height of the die set is the distance from the die shoe to the top of punch holder
when the die is in its closed position. The shut height is established by the length of guidepost,
which must be at least half inch shorter than the shut-height in order to allow for the reduced
shut height due to re-sharpening.
Centre of pressure:
When the shape of the blank to be cut is irregular, the summation of irregular shearing
forces on one side of the centre of ram may greatly exceed the forces on other side. This result
in bending moment in the press ram an undesirable deflection and misalignment. It is therefore
necessary in case of irregular shaped punches to find out the exact centre of pressure and
layout the punch position on the punch holder in such a way that centre of pressure and centre
of of ram hole or centre line of shank passes exactly to the same straight line. Summation of
shearing force must be symmetrical about the centre of pressure. It is the centre of gravity of the
line i.e. the parameter of the blank contour. It is not the centre of gravity of the area.
c) CLASSIFICATION OF ELEMENTS OF PRESS TOOLS

FUNCTIONAL ELEMENTS:- The functional elements are those which participate in the
actual shaping of the components e.g. punch, dies etc.

1. Punch:

• The male cutting member of the press tool is fixed mostly with top half of the tool.
• It determines the size of the pierced profile.
It length should be as minimum as minimum as possible to avoid bending or buckling. Mostly,
it is kept at 70mm length.

Die:

• It is the female cutting member of the tool.

• It determines the blank size.
 • It can be made from solid plate (one piece) by filing, milling, EDM, wirecut or in splits by
grinding. The die splits has to be nested in a plate called die plate.

GUIDING ELEMENTS: Guiding elements are those which ensure accurate alignment of the
upper ensure accurate alignment of the upper shoe with the die shoe in operation e.g.:
guide bushing and guide pillars.

• Guide bushing:- Guide bushings are mounted in the punch holder and slide over the
guide pins. Bushings are available in various lengths, removable or press-fitted, and of
plain or ball bearing type.
• Guide posts:- Guide posts are press fitted into the lower base. The length of the guide
pillars must be at least ½ inch shorter than the shut height so as to allow the
resharpening allowance to the die.
• Stock guide plates:- stock may be solidly guided by suitable slots in a stripper , by
stock rails or, by pins, buttons or angle iron. Solid guides may or may not require spring
guides or spring pushes for optimum stock guiding.

c) LOCATING ELEMENTS: Locating elements are those which provide for an accurate
positioning of the stock or the blank and fix it in the place while the operation is performed.
• Stock stops: It locates the work material at a suitable position in relation to previously
blanked surface in preparation to the next downward movement of the punch. Stock
stops are available in variety of designs, e.g finger stop & Automatic stop etc.
• Pilots:- The function of pilots is to position the stock strip accurately and bring it to
proper register for succeeding blanking & piercing operation. When the strip is fed by
hand, the stock stops allows a slight amount of overfeeding beyond the registry
position. A pilot than backs the strip into registry position in a direction away from the
stock stops. This prevents buckling the strip against the stop.

SUPPORTING AND CLAMPING ELEMENTS: Supporting and clamping elements are those
which join and hold together all parts and units of press tools.
Punch plate or punch holding plate: The main purpose of the punch plate is to locate
and support the punch. No dowels are used and screws serve to prevent the punch from
pulling from the punch plate. A light interference fit is used between punch & punch holder
to ensure accurate location. No screws or dowels are used if the head of the punch is
stepped that prevents the punch from pulling from the punch plate.
• Die plate: Just like punch plate, the die plate also locates and support the die block at
proper position with respect to punch. The plate is mounted on the die shoe or holder.
 In certain design die shoe itself serves as a retainer for the die block. The die block is
then mounted directly on the die shoe.
• Screws and dowels: The components or dies are clamped together by socket head cap
screw and held in alignment by dowel pin. The head on the cap screw is almost always
recessed in a contour bored hole to eliminate projecting screw heads. Cap screws
used to secure the die block are generally counter bored 1 ½ inch deeper then cap
screw head to allow additional material for die sharpening.
e) EJECTING ELEMENTS: Ejecting elements are those which ejects and removes the blank
and scrap from the working elements after the operation is over.
Stripper:-The purpose of the stripper is to remove the stock from the punch after blanking
the operation. Strippers are classed as fixed or spring operated.

• Fixed Stripper: It is also known as channel stripper. The most common channel
stripper consists of solid plate mounted on top of the die block. The channel or groove
is milled, through which the strip is passed. The height of the channel should be one
and a half times the stock thickness unless the strip must be lifted over the fixed pin
stop. The width must be equal to the strip width plus adequate clearance around the
punch should be adequate to clear the punch and should not be over one half the
thickness of strip material.

• Spring operated stripper: It is sometimes referred to as pressure pad strippers,

employ springs to apply pressure to the stock strip. An advantage of this type is that it
intends to hold the strip flat during the press cycle. It is always mounted on the upper
half of the die.

ii) Knockout pin: A mechanism for ejecting blanks or other work from the die commonly
located on the slide but may be located under the bolster. Knock out are of two types
positive knock out and indirect knock out. A knock out assembly consists of a plate, push
rod and a retaining collar. It is generally of lower cost than strippers.

CONCEPT OF MATERIAL SELECTION:-

The material selection for the different elements depends upon the following factors:
• The function of each element.
• No. of components to be produced.
 • Economy Produced.
• Properties of the material.
• Thickness & material of sheet.
• PUNCH: It is made up of high carbon steel for short runs, O.H.N.S, EN31 for medium
run, High carbon high chromium and HSS for large runs and carbide for highly mass
production. Eg: Blade die and laminations. The hardness is kept 60-62 HRC.
• DIE: It is made up of O.H.N.S, EN-31, HCHCr, H.S.S, carbide depending upon the
volume of production. The die hardness is kept at 60-62 HRC.
• GUIDE BUSHINGS: It made up of EN-353 and case hardened upto 55-58 HRC to 1.0
to 1.2mm depth.
• GUIDE PILLARS: It is also made up of EN-353 and case hardened upto 55-58 HRC to
1.0 to 1.22mm depth.
• STOCK GUIDE PLATES: It is made up of Mild steel with hard inserts. Inserts are made
up of EN-31 case hardened to 60-62 HRC.
• STOCK STOPS: They are made up of EN-31 hardened to 55-58 HRC.
• PILOTS: Pilots are made up of HcHcr, O.H.N.S or EN-31 hardened to 58-60 HRC.
• PUNCH PLATE: It is made up of mild steel and kept soft.
• DIE PLATE: It is also made up of mild steel & kept soft.
STRIPPER PLATE: It is made up of mild steel and kept soft. In some special cases it
is hardened and made up of EN-31.

PRINCIPLE OF CONSTRUCTION OF PRESS TOOL:

While constructing the press tool the following principles should be considered.
1) DESIGN FACTORS:
• Shapes are limited to those which may be produced by cutting, bending, forming or drawing
of a piece of sheet metal or compressed operations.
• Maximum sizes are limited chiefly by the types & sizes of available presses.
• Good tolerances can be obtained within + 0.050mm is common, and closer limits are
possible on small and thin parts.
• The weight factor is highly advantageous points formed from sheet metal are lowest in
weight, (in kgs/mm2) of surface.
• Surface smoothness is very good since surface condition usually is not affected by forming
operation.
• A wide choice of materials are available including any in sheet form and not so brittle as
to break.
II) PRODUCTION FACTOR
• Tooling time, compared with some other production methods, is adverse except for
temporary or low production tooling. Die design tryout and development may take months.
• Production time is favorably low, since the rate of output is very high as many as 3000
pieces/ hour have been produced.
III) ECONOMIC FACTORS
• Stamping materials costs should be considered low, a favorable cost factor is minimum
scrap lost achieved through careful selection of stock and skilled strip layout.
• Tool & die costs are high, usually higher than for tooling for comparable parts that are to be
die cast. Cost are more favorable where large production is in view.
• Direct labour costs depends upon the part size and shape; under normal conditions, they
are characteristically very low.
Finishing cost are low as no other finishing is required than normal painting or plating.

PRINCIPLE OF MATERIAL PROPERTIES

1. The principle material used for different elements should passes the following
properties:
2. High strength, since the tool carries heavy pressure and is subjected to impact loads.
3. High hardness, since the cutting process can not be carried out unless the punch and
the die material is notably harder than workpiece material.
4. Adequate wear resistance, since long service life of the cutting tool depends upn the
degree of abrasive of its cutting edges.
5. High toughness so as to prevent crushing of the cutting edges likely to occur due to
frequent and heavy impacts.
6. Good harden ability, yielding crack free material after hardening and an adequate depth
of the hardened layer, which allows repeated grinding of the punch and die.
 DESIGN PARAMETERS FOR PROGRESSIVE DIE

For an economical utilization of the stock, it is necessary to make a layout to show how the
blanks can be best produced from the stock strip. This layout should show the relative
position of the areas to be blanked out, so arranged as to assure maximum utilization of the
material. The aim should be at least 75% utilization. The layout can be facilated by making
several templates from strip paper, cardboard or even the actual work material cut to scale in
the shape and size of desired blank.

STRIP LAYOUT
The strips are usually available in rolls and coils. If not, these strips have to be cut from the
sheets. The first step in the preparation of the blank is to layout the position of work piece in
the strip and their orientation with respect to one another. The main consideration in the strip
layout are as under:
• The best location of the blanks to save material.
• The best location of blanks to serve good bending where it is required i.e. consideration
of grain direction.

TERMS RELATED TO STRIP LAYOUT:

• STRIP (COIL): It is the material ready to be processed, it is sold by weight and
supplied within certain tolerances in width and thickness. Occasionally, strips are
sheared from sheets.
• LEAD END: It is the forward end in the sense of feeding direction.
• TAIL END: It is the other end of the coil or strip.
• FRONT SCRAP: It is the scrap portion remaining on the front side of the strip while
working.
• BACK SCRAP: It is the remaining scrap portion of the back side of the strip while
working.
• BRIDGE SCRAP: It is the remaining scrap portion between two punched openings.
Bridge Scrap= 1/1.5 times sheet thickness
ADVANCE: It is the width or the length of the component plus the width of the bridge
scrap. The distance between the two cutting steps (progression).
Advance = Width of component + Bridge scrap
The best strip layout is not always the one with best utilization of material. For example,
the layout with best utilization of material may require the construction of a more
complex die, which would off set the savings unless a large number of parts are
necessary.

It is always necessary to consider the spacing between the blanks when laying out the strip.
Blanks located too close or too close to the edge of the strip tend to allow the metal to slip by
the cutting edges of the punch and the die. The web between the blanks that forms the
scrap skeleton must be strong enough to withstand feeding forces, especially on a
progressive die. A general rule of thumb from strip layout is to make the web between the
blanks and edges of the strip at least 1 ½ times the sheet thickness. However, other factors
may allow the web to be thinner, including the thickness of the strip, the hardness of the
material, the length of the scrap web, the shape of workpiece and type of operation.
Progressive and two pass die requires wider web thickness i.e. 50 % wider.

To find the percentage scrap or material utilization the formulae are applied: -
Percent scrap = A-B X 100
A
Percent utilization = B X 100
A
where, A = area of uncut strip
B= total area of blank cut.

FACTORS INFLUENCING THE STRIP LAYOUT: -

GRAIN DIRECTION: The strip should be processed in this direction.
 ECONOMY OF MATERIAL: The bigger the requirement i.e. the total components required is
well worthwhile to spend some time and to do a few alternatives to save a few grams of
material per component. The minimum stock requirement can only be determined if the layout
is properly and carefully planned.

• TOOL CONSTRUCTION COST: It is an important factor finalizing the layout. If the funds
to built the tool is limited, the possibilities for an optimum tool layout are decreased. It is
quite common that a compromise between a reasonable tool costs and optimum layout
is aimed. For very high production tool cost should be secondary only and most attention
should be given to the economy of material and operation case.
• OPERATION CASE: The strip should be planned in such a way that the actual feeding
in to the tool is as simple as possible and the strip does not get jammed inside due to
projecting contours.
• AVAILABILITY OF STANDARD STRIPS: If possible common strip sizes should be
proposed. The advantage is that they are easily and quickly available. Uncommon sizes
have to be ordered especially and this is comparatively more expensive and longer
delivery times have to be accepted.
• BURR SIDE: It is a minor factor but some times for some reasons it is desirable to have
them on a particular side.

CLASSIFICATION OF STRIP LAYOUT

As soon as the component is longer than width, we are left with two possibilities, the smaller
(narrow) or the bigger (wide) sides are oriented towards the feeding direction.

• NARROW RUN: When the narrow side (smaller side) of the component is towards the
feeding direction, we call it as narrow run.

• WIDE RUN: When the wide side of the component in the strip is towards the feeding
direction. We call it as run.

In general the wide-run is preferred over wide run the narrow run for the following
factors:
The advance is shorter, therefore feeding is easier.
In many cases scrap wastage is small.
 For the same number of components the number of strips or coils are reduced, hence it
is cheaper because less strips or coils have to be prepared and less time is wasted in
starting feeding new strips into the tool.
• TWO PASS TOOL: In two pass tool, the scrap is fed twice, after the first pass, it is either
turned over or rotated endwise. The economy is in solving tool cost. For low or medium
production this why is recommended.

• GANG TOOL:- For higher production a gang tool or single pass tool should be made.
The initial higher investment costs are recovered during production. Using a single pass
tool the press is occupied for a shorter period for a particular production.

Gang tool

c) PILOTING AND STOPPING

PILOTING: The function of the pilot is to position the stock strip accurately and bring it to
proper register for succeeding blanking and piercing operations. When the strip is fed by
hand, the strip stop allows a small amount of overfeeding beyond the registry position in a
direction away from the strip stop. This prevents buckling the strip against the stop.
Mechanically fed strips are normally underfed and pulled forward in the same direction as the
feeding motions by the pilots because many mechanical feeding mechanisms utilize a
unidirectional locking device which prevents any back feeding of the strip.

PILOTS ARE USUALLY OF TWO TYPES:-

• Direct Pilots:- They are also known as punch pilots, are mounted on the face of the
punch. Some method of positive retention should be used to prevent the pilot from
dropping out of the punch. Press-fit pilots should be avoided for the same reason.

Methods of attaching pilots to punches

• Indirect Pilots:- They are designed to enter previously pierced roles in the strip some
distance away from the blanking punches. This practice provides more support under
the strip and helps prevent distortion. Spring loaded pilots are used in some cases
which retracts in case of misfeed. Spring loaded pilots are not necessary for thinner
materials because the pilot will pierce the strip rather than break in case of misfeed.

The use of indirect pilot: 1) Standard pilots and punches 2) indirect pilot
Stopping:- Some method must be used to locate the strip within the die-set when hand
feeding. Automatic feeding mechanisms usually do not require a stop within the die-set
because they can be adjusted to advance the strip quite accurately.

Stops are available as per the requirement and they are listed below:

• PIN STOP:- The simplest form of stock stop is probably a dowel pin against which an
edge of previously blanked opening is pushed after each stroke of the press. Enough
clearance is provided in the strip channel to allow the stock to be lifted above the pin on
the return stroke of the press and thus release the strip from the pin. It has the
disadvantage of demanding considerable skill on the part of the operator.

Pin stop
• TRIP STOP: - In it, as the stock is fed forward, the pawl rises on the ratchet principle, but
when the operator pulls the stock back, the pawl drops and locates the stock exactly
against the vertical surface of the pawl.

Trip Stop

• SHOULDER STOP:- When the workpiece is same width as the stock and the feed is
from one side with no skeleton of scrap material passing out the order side, this stop is
simplest and most effective. It is mostly used in progressive dies.

• PRIMARY STOP:- It is used to position the stock as it is initially fed into the die and is
generally mounted on the stripper plate. In use it is pushed inward by the operator with
one hand and stock strip is fed against it with the other. The first hit is completed & stop
released. Thereafter indexing of the strip is accomplished by automatic stops.

• AUTOMATIC DIE STOP:- In this the pin and finger is raised by the trip screw as the
punch descends and cuts the blank on return the pin end of the finger drops, and the pin
would drop into its former position if it were not for the end wise action of the finger which
causes the pin to drop onto top surface of the stock instead of into the blank space. The
mounting of the finger on the pivot is loose enough to allow for this endwise movement.
As the stock moves forward the pin drops into the next blank, enabling the operator to
locate the strip exactly.
 Automatic die stop

STRIP GUIDING
It is the space provided in the die block through which the stock strip is guided as it fed
into the die. The design of the stock guide will depend upon the type of stripper. For fixed
strippers (channel strippers), for the channel for guiding the stock is shown in figure and
its design is given under ‘fixed stripper’. For spring operated strippers, the various design
for guiding the stock are shown in figure. In this the guide rails are mounted on the die
block for guiding the stock. Some stripper acts as a pressure pad and presses directly
against the stock strip. The stripper does not contact the guide rails. Sometimes hooks
are provided on the guide rails in order to improve the guiding effect. When mere is
space limitations button stock strip guides may be used. At least three button guides
should be used on each side of the stock strip. The guiding is comparatively not as
efficient as with guide rails.

Strip Guiding
ECONOMY FACTOR
The bigger the requirement i.e. the total components required is more, it is well worthwhile to
spend sometime and to do a few alternatives to save few grams of material per component. The
minimum stock can only be determined if the layout is properly and carefully planned. But
sometimes the strip layout with maximum material saving may not be the best strip layout as the
die construction may become more complex which would offset the savings due to material
economy unless a large number of parts are to be produced.

PRINCIPLE OF GRAIN DIRECTION

The grain direction of the strip may be a consideration in the location of the workpiece,
especially if a bending operation is required when sheet metal is rolled in the steel mill, a fibre,
or grain, is produced in the direction of rolling. To obtain maximum strength from bent parts, the
bends should be made at an angle 900 to the grain direction. The normal grain of a coil strip is
parallel with the edge of the strip. When workpieces are shared from sheet stock, it is possible
that grain direction may be 900 to the edge of the strip, depending upon how the strip is shared
from the sheet.

PRINCIPLE OF MATERIAL UTILIZATION

Using workpiece templates may immediately show the best strip layout with regard to
 material utilization; however in two or three layouts the maximum utilization may not be
apparent. To find the percent of scrap o material utilization, the following formulas may be
used
Percent scrap = (A-B)/A*100
Percent utilization = B/A*100
where A = area of uncut strip
B = total area of blank cut .
The area of uncut strip would be width of strip multiply by the length of the component,
while the area of the blank would be the area of the actual blank itself. In use, the percent
scrap or material utilization is determined for each layout and compared for maximum
material utilization.

PRINCIPLE OF PRODUCTIVITY
If the production is high i.e. the total components required is more, it is well worthwhile to
spend some time and to do a few alternatives to save few grains of material per
component. The maximum stock required if the layout is properly and carefully planned.
RELATIONSHIP OF PIECE WORK AND STOCK
The advance multiplied by the width of the strip gives the required area per components. If
two or more components are obtained the result is divided accordingly. For comparison of
economy we work with area only.

The number of blanks which can be produced from one length of stock can be found as:
N=(L-b)/s
where N = number of blanks
L= length of strip
b = bridge scrap
s = advance.
e) PRINCIPLE OF STOPPER AND BURR SIDE CONSIDERATION
The burr produced during the piercing or blanking operation may determine the position of
workpieces in some instances. In some workpieces it may be desirable to have the burr on one
side. An example would be to locate the burr on a surface and during operation. Remember that
inverting the blank position will also invert the burr side with respect to the workpieces contain.

f) PRINCIPLE OF FEEDING

After uncoiling and straightening, the final step of stock handling is feeding the strip into the
press; the most exacting and critical step in the process. Numerous strip feeding method
 depends upon the factors such as width ,thickness, and surface condition of the material,
press speed, feeding interval, feeding length and feeding speed.

BENDING DIES

PRINCIPLE OF BENDING

Bending: In bending, the material is formed around a straight axis which extends
completely across the material at the bend lines. It produces a plane surface which is at an
angle to the original surface.

Bending die
BENDING TOOL ELEMENTS
Like any other conventional press tool, we have in our bending tool the following elements
:

• Die set
• Punch
• Die
• Pressure pad
• Nest plate
• Stripper
• Shoulder plate
• Ejecting system

1. Die set: A die set means the arrangement which holds punch, die, stripping and ejection
arrangements and help them work more efficiently and accurately giving the repeatability in
stroke. The die set consist of top plate, bottom plate, guide pillars guide bushes and also
sometime the shank.
• Top plate: Top plate takes the punch, support them either independently or in a punch
holding plate. This also adopts the guide bushes and shank.
• Bottom plate :- Bottom plate holds the die on to it and also takes pillar. ejection system if
given from bottom is also held on bottom plate.
• Pillars:- Pillars help top and bottom plate to move in parallel plane and also check the
degrees of freedom in other planes except for vertical movements, pillar are normally
fixed in bottom plate.
• Guide bushes :- Guide bushes normally increases the guiding length and with their oil
groove in them help the die set move freely. Also if they are not provided by very frequent
use of top plate the holes of top plate get enlarged and make the top plate useless after
sometime.
• Shank :- This holds the top assembly in the press ram.
• Punch : This is male part of the press tool, bending tool which provide the inner shape to
 the component, this normally struck to top plate in case of bending. It is made of tool steel
and of EN-31 in case of bending tool. If the accuracy involvement are of very high nature
the punch is made HCHCr to avoid shrinkage in Heat Treatment processes.
• Die: This is either a solid block or a built-up type. Contrary to punch this s a female part of
the press tool/ bending tool. Die has the cavity of the outside shape of the component.
The blank is pressed b the punch and get deformed to the shape of die. The die gives the
component outer profile. The die sits on the bottom plate and also hold the stripping
arrangement on it.
• Pressure pad: The shouldered pressure pads are required where the stamping need
accuracy in forming. The pressure pad helps to hold the stock/ blanks securely during the
forming operation and also check any shift of component during working. The pressure is
generally provided by rubber or springs either directly or though pins. Air operated
pressure pads are also give when accuracy in pressure is needed. The pressure pads are
normally given light gauge or materials.

• Nest plate: The nest plate form a nest for the blank. This help in proper positioning of
blank before being actually operated upon. This can be either a single plate or two plate
as per designer requirement. The nest plate sits on die having the outer dimensions of
the blank.
• Stripper: This is an arrangement to strip the component. This is generally needed in U-
bending operations. To know it is only a plate held at such a position which strip the bent
component.
• Locater / pilot: Locaters are normally provided when the parts/ components need very
high accuracy in location. This is a pin generally made of tool steel, hardened and
ground.

 Bending force for V-bending

The bending force for V-bending is obtained using the following equation.

P=C1× B × t2 ×ts
L
　　P: Bending force (kgf)
C1: Coefficient
　　B: Bending line length (mm)
t: Plate thickness (mm)
2
　　 Ts: Tensile strength（Kgf/mm ）
The coefficient (C1) is 1.33 when the die shoulder width (L) is 8 times the material plate thickness
(t), 1.5 when the die shoulder width is about 5 times the plate thickness, and about 1.2 when it is
about 16 times the plate thickness.

Bending force for L-bending:-

The bending force for L-bending is obtained using the following equation.

P=C/3 * B * t * Ts（Kgf）
　　P: Bending force (kgf)
　　C: Coefficient ... 1.0 to 2.0
　　　(Select a larger coefficient when the punch R and the Die R are small.)
　　B: Bending line length (mm)
　　t: Plate thickness (mm)
2
　　Ts: Tensile strength（Kgf/mm ）

This shape is taken as the basis for the

bending force for pad-pressed bending.
In the case of U-bending such as shown in
Fig. since the bending line (B) is present at  
two locations, the above calculation is made
by doubling the value of the bending line
length (B) in the above equation.
In this manner, when bending is done in several locations at the same time, the total length of the
bending lines is taken as the value of B.

Bend Allowance:-
For close work the exact length of material required to make a bend is often determined by trial
and error. The assumed neutral axis varies depending upon the bending method used, the
location in the bend, and the type of stock being bent.
Direction of grain in a steel strip relative to bend also has a slight effect on the length of material
required to make a bend. Bending with grain allows the metal to stretch more easily than
bending against the grain, however this results in a weaker stamping
Bend allowance depends more upon the physical properties of the material such as tensile
strength, yield strength and ductility than on the metal from which it is made.

Blank Length:-
Blank Length = L1 + +L2

Where Bend angle in degrees

Value of C
For R < 2t, c=0.33t
R=2 to 4t, c=0.4t
R>4t, c=0.5t

Spring Back Compensation

Because all materials have a finite modulus of elasticity, plastic deformation is follow' by elastic
recovery upon removal of the load; in bending, this recovery is known as spring back. As shown
in Fig.

The final bend angle after spring back is smaller and the final bend radius is larger than before.
This phenomenon can easily be observed by bending a piece of wire or a short strip metal.
Spring back occurs not sheets or plate, but also in bending bars, rod, and wire of any cross-
section. A quantity characterizing springback is the springback factor Ks, which is defined as
follows. Because the bend allowance is the same before and after bending Shown here the
relationship obtained for pure bending is