INTRODUCTION TO PRESS

WORKING
Module -1
APPLICATIONS OF PRESSED COMPONENTS
APPLICATIONS OF PRESSED COMPONENTS
APPLICATIONS OF PRESSED COMPONENTS
APPLICATIONS OF PRESSED COMPONENTS
APPLICATIONS OF PRESSED COMPONENTS
APPLICATIONS OF PRESSED COMPONENTS
APPLICATIONS OF PRESSED COMPONENTS
APPLICATIONS OF PRESSED COMPONENTS
APPLICATIONS OF PRESSED COMPONENTS
APPLICATIONS OF PRESSED COMPONENTS
APPLICATIONS OF PRESSED COMPONENTS
APPLICATIONS OF PRESSED COMPONENTS
APPLICATIONS OF PRESSED COMPONENTS
APPLICATIONS OF PRESSED COMPONENTS
APPLICATIONS OF PRESSED COMPONENTS
APPLICATIONS OF PRESSED COMPONENTS
APPLICATIONS OF PRESSED COMPONENTS
APPLICATIONS OF PRESSED COMPONENTS
APPLICATIONS OF PRESSED COMPONENTS
 ADVANTAGES OF SHEET METAL PARTS

• High strength

• Good dimensional accuracy

• Good surface finish

• Relatively low cost

• Economical in mass production

PRESS WORKING OPERATIONS
PRESS WORKING OPERATIONS
 PRESS WORKING OPERATIONS

• Blanking is the cutting of the complete outline of a work piece in

a single press stroke.

• Because a scrap skeleton is usually produced, blanking involves

some material waste.

• The skeleton left by blanking sometimes has only scrap metal

value .
 PRESS WORKING OPERATIONS

Piercing also called punching , is similar to blanking except that the

punched-out (blanked) slug is the waste and the surrounding metal
is the workpiece.
 PRESS WORKING OPERATIONS

• Trimming is defined as the cutting off of excess material from the

periphery of a work piece.
• It is usually done in dies and is similar to blanking.
• It is often the final operation on a formed or drawn part.
 PRESS WORKING OPERATIONS

• Trimming is an operation for removing excess metal (such as

deformed and uneven metal on drawn or formed parts) and
metal that was used in a previous operation (such as a blank
holding flange for a draw operation).

• Trimming is done in several ways, depending on the shape of

the work piece, the accuracy required, and the production
quantity.
PRESS WORKING OPERATIONS
PRESS WORKING OPERATIONS
 PRESS WORKING OPERATIONS
• Parting is the separation of blanks by cutting away a strip of
material between them.
• Like cutoff, it can be done after most of the part outline has
been developed by notching or lancing.
• It is used to make blanks that do not have mating adjacent
surfaces for cutoff or to make blanks that must be spaced for
ease of handling in order to avoid distortion or to allow room for
sturdy tools.
• Some scrap is produced in making blanks by parting; therefore,
this method is less efficient than cutoff in terms of material use.
PRESS WORKING OPERATIONS
 PRESS WORKING OPERATIONS

• This operation consists of

cutting along a line to
produce blanks without
generating any scrap in the
cutting operation.

• The cutoff line can take

almost any shape--straight,
broken, or curved.

• After being cut off, the

blanks fall onto a conveyor.
 PRESS WORKING OPERATIONS
• A cutoff die can be used to
cut the entire outline of
blanks whose shape permits
nesting in a layout that uses
all of the material (except
possibly at the ends of the
strip).
• Alternating positions can
sometimes be used in
nesting (middle, Fig.) to
avoid producing scrap except
at strip ends.
• Cutoff is also used to cut blanks from strip that has already been
notched to separate the blanks along part of their periphery.
PRESS WORKING OPERATIONS
PRESS WORKING OPERATIONS
 PRESS WORKING OPERATIONS

• Lancing is a press operation in which a single-line cut or slit is

made part way across the strip stock without removing any metal.

• Lancing is usually done to free metal for forming.

• The cut does not have a closed contour and does not release a
blank or a piece of scrap.

• In addition to its use in freeing metal for subsequent forming,

lancing is also used to cut partial contours for blanked parts,
particularly in progressive dies.
PRESS WORKING OPERATIONS
 PRESS WORKING OPERATIONS
• Notching is an operation in which the individual punch removes a
piece of metal from the edge of the blank or strip.

• Notching is done for such reasons as the following:

• To free some metal for drawing and for forming while the
work piece remains attached to the strip.
• To remove excess metal before forming .
• To cut part of the outline of a blank that would be difficult to
cut otherwise.
 PRESS WORKING OPERATIONS

Notched work illustrating the use of notching for freeing metal

before drawing (a), and before forming (b), and for removing
excess metal before forming (c)
PRESS WORKING OPERATIONS
PRESS WORKING OPERATIONS
PRESS WORKING OPERATIONS
PRESS WORKING OPERATIONS
PRESS WORKING OPERATIONS
PRESS WORKING OPERATIONS
PRESS WORKING OPERATIONS
PRESS WORKING TERMINOLOGY
 PRESS WORKING TERMINOLOGY
Shank: (Material: MS or CI, IS: ST 42 )
• This is a projection from the upper shoe which enters the press
slide flange recess and is clamped to the slide or press ram.
• It is used to locate the press tool in press for alignment purpose.

Punch : (Material: HCHCr IS: T215Cr12 HRC: 60-62)

• It a an element which performs the actual shearing operation. It is
fastened to the press ram.

Punch plate: (Material: MS or CI)

• It is a plate that fits on the body of punch and holds it properly in
position.
 PRESS WORKING TERMINOLOGY
Back up Plate : (Material: MS or CI)
• This plate prevents the hardened punches penetrating into top
plate.
• It prevents the punch holder by not allowing the intensity of
pressure to exceed on it.
• The plate distributes the pressure evenly thus preventing the
punch from crushing.

Punch Holder: (Material: MS or CI)

• It is the upper part of the die set which contains guide post
bushings.

Die : (Material: HCHCr IS: T215Cr12 HRC: 58-60)

• It is an element which allows the part to be sheared by punch.
• The sheared part is allowed to move through the die.
 PRESS WORKING TERMINOLOGY

Die set (Material: MS or CI)

• It is an assembly which contains the upper and lower shoe, guide
post and bushings.

Die Block (Material: MS or CI)

• It is the block which contains the die cavity.

Die Holder (Material: MS or CI)

• This plate prevents the hardened Die inserts penetrating into the
bolster plate.
• It is mounted on the bolster plate.
• The die block and guide posts are mounted on it.
 PRESS WORKING TERMINOLOGY
Bolster plate (Material: MS or CI)
• Its main function is to provide a rigid foundation or base to the
assembly.
• It is also called as base plate.
• It is usually 12.5 mm thick.

Guide Pillar (Material: Case Hardened steel. IS: 17Mn1Cr95 HRC: 56-58 )
• These are cylindrical pins known as guide pins or guide pillars.
• These provide accurate alignment between top and bottom halves
of press tool.
• The contacting surface of pillars and guide bushes have h7/h6 fit
where as the press fitted portion of the bush with top plate have
h7/j5 tolerance and are ground.
• One end of pillar is press fitted in the base plate with h7/p6
tolerance. The other portion, which is sufficient long, provides
guide for top plate for easy sliding.
 PRESS WORKING TERMINOLOGY
Guide Bush (Material: Case Hardened steel. IS: 17Mn1Cr95 HRC: 56-58 )
• These are mounted on the top plates, which provide smooth
sliding contact between pillars and top plates.

Stripper plate (Material: MS or CI)

• It is used to strip off the component from punches.
• It may or may not guide the stock

Strip guides (Material: Gauge Steel HRC: 48-50)

• It is used to guide the strip into the press tool to perform the
operation.

Pilots
• Pilots are used to align the components accurately for secondary
operation.
 PRESS WORKING TERMINOLOGY

Fits in press tools

• Punch holder and Punches =H7/k6

• Punch and Stripper = H7/K6
• Guide Pillar and Guide bush = H7/g6
• Guide bush and Top plate = H7/p6
• Guide pillar and bottom plate = H7/p6
• Dowel and plate = H7/m6
• Dowel holes = H7/r6
 THEORY OF SHEARING

• Shearing is the method of cutting sheets or strips without

forming chip.

• Material is stressed in a section which lies parallel to the forces

applied.

• Forces are applied by means of shearing blades or punch and

die.

• Shearing is defined as a cutting operation used to remove a blank

(or slug) of required dimensions from a large sheet.
• Shearing in metal sheet is similar to that in turning or facing
operation.
 THEORY OF SHEARING
• Consider a metal being sheared between a punch and a die (Fig.1).

• Shearing starts as the punch presses against the sheet metal.

• At first, cracks form in the sheet on both the top and bottom edges
(marked T and T', in the figure 2).

Figure 1 Figure 2
 THEORY OF SHEARING
• As the punch descends further, these cracks grow and eventually
meet each other and the slug separates from the sheet. (fig.3)
• Cut edges are neither smooth nor perpendicular to the plane of
the sheet.
• Close look at the fractured surfaces, revel that these are quite
rough (a) and shiny (b)
(a) because of the cracks formed
(b) due to rubbing of sheared edge against the die walls.

Figure 1 Figure 3
THEORY OF SHEARING
Critical stages in
shearing
Initial Contact

Plastic deformation

Penetration

Fracture
 THEORY OF SHEARING
Plastic deformation
• The pressure applied by the punch on the stock material tends
to deform it into the die opening.
• When the elastic limit is exceeded by further loading, a portion of
the material will be forced into the die opening in the form of an
embossed pad on the lower face of the material
 THEORY OF SHEARING
Plastic deformation
• This will result in a corresponding depression on its upper face of
the material.
• This stage imparts a radius on the upper edge of the strip and the
lower edge of the punched out material.
• This is called the stage of “plastic deformation”.
 THEORY OF SHEARING
Penetration stage
• As the load is further increased, the punch will penetrate the
material to a certain depth
• This force an equally thick portion of metal into the die.
• This stage imparts a bright polished finish on both the strip and
the blank or slug.
• The cut band will be 1/3rd the sheet thickness.
• This is “PENETRATION STAGE”.
 THEORY OF SHEARING
Fracture stage
• In this stage, fracture will starts from both upper and lower
cutting edges.
• As the punch travels further, these fractures will extend towards
each other and eventually meet, causing complete separation.
• This stage imparts a dull fractured edge. This is the “fracture
stage”.
FIGURE Stresses in shear operation.
THEORY OF SHEARING
THEORY OF SHEARING
THEORY OF SHEARING
 THEORY OF SHEARING
Zones in Slug or Blank or Sheet
• Different zones may be exhibited by the flow of material, based
on the initial geometry of the sheet and the process parameters.

• The part edge typically includes three distinct zones:

• roll over,
• burnished zone (also called sheared zone)
• and fracture zone (including burr).

Formation of the different zones is

influenced by a number of
parameters such as: material
properties and thickness,
clearance, tool velocity and part
geometry. Cut edge profile on the sheared surface.
 THEORY OF SHEARING
Zones in Slug or Blank or Sheet

• The roll over and the burr are

results of elastic and plastic
deformations at the beginning
of the cutting process.

• The magnitude of roll over

depends upon the ductility of
the material.
• An ideal part edge would have
almost no roll over, burr or
fracture zone and consequently
would show almost 100% shear.
Cut edge profile on
the sheared surface.
• The plastic flow pulls
the material around
the punch, causing
the burnished area.
 THEORY OF SHEARING

Characteristics of a pierced hole. Curvature and angles are

exaggerated for emphasis.
 THEORY OF SHEARING
Zones in Slug
or Blank

Zones in Plate
CHARACTERISTICS OF BLANKED EDGE
Characteristics of Blanked Edges
The sheared edges of
a blank produced in a
conventional die are
not smooth and
vertical for the entire
thickness of the part,
but exhibit the
characteristics
represented in figure.

Curvature and angles

are exaggerated for
emphasis.
 CHARACTERISTICS OF BLANKED EDGE
• The angle of the fractured portion of the edge is identified as the
breakout angle.

• The burnish dimension of the hole in the scrap skeleton are

approximately equal to the corresponding punch dimension, and
the burnish dimension of the blank is very close to the
corresponding die dimension.

• Therefore, the punch determines the hole size, and the die governs
the blank size.

• Penetration depth, or the amount of penetration of the punch into

the work metal before fracture occurs, is shown on the edge of the
remaining stock or scrap skeleton.
 CHARACTERISTICS OF BLANKED EDGE
• This depth is approximately equal to the sum of the rollover
depth and the burnish depth on the blank, except when low die
clearance produces secondary burnish.

• The percentage of penetration (before fracture) depends on the

properties of the work metal.

• The percentage of penetration affects energy consumption and

cutting force in blanking.

• Rollover (plastic deformation) and burnish depths are greater in

thick material than in thin material and are greater in soft material
than in hard material
 THEORY OF SHEARING

Zones in Slug or
Blank or Sheet

SEM Photograph
THEORY OF SHEARING

Zones in Slug or
Blank or Sheet
 THEORY OF SHEARING

Zones in Plate
THEORY OF SHEARING
Progression in cutting
THEORY OF SHEARING
Progression in cutting
THEORY OF SHEARING
Progression in cutting
THEORY OF SHEARING
Progression in cutting
 THEORY OF SHEARING
Load Stroke curve- Phase I
• With the penetration of the punch into the sheet, the load
increases continuously and elastically.
 THEORY OF SHEARING
Load Stroke curve- Phase II
• Loading continues and yield strength of the material is reached.
• Material flows along the cutting edges in the direction of the punch
penetration and into the gap between the two tools.
• At this time, the cross-section is not reduced and the shearing has
not appeared.
 THEORY OF SHEARING
Load Stroke curve- Phase III
• Once the pressure at the cutting edges increases sufficiently, the
material stops deforming and shearing starts.
• Due to a decreasing cross section, the cutting force decreases.
 THEORY OF SHEARING
Load Stroke curve- Phase IV
• A fracture starts after the shear strength of the material is
exceeded.
• The incipient cracks run towards each other separating the sheet
and the sheared part.
• The shearing force decreases rapidly during this phase (as the
shearing strength of the material is overcome.)
PENETRATION
 EDGE TYPES
Edge Types
There are five types of edges that result from the use of different
clearances in piercing or blanking low-carbon steel at a maximum
hardness of 75 HRB.

Type 1
• This type of edge has a large rollover radius and a large burr that
consists of a normal tensile burr in addition to bending or
deformation at the edge.
• Burnish depth is minimal.
• Fracture depth is about three-fourths of stock thickness, and the
fractured surface has a large angle.
• This edge is satisfactory for noncritical applications in which edge
quality and part flatness are not important.
 EDGE TYPES
Edge Types
Type 2
• This edge, which has a moderate rollover radius, normal tensile
burr, and a small fracture angle, provides maximum die life and a
hole or blank that is acceptable for general work in which a large
burnish depth is not required.
• Burnish depth plus rollover depth is about one-third of stock
thickness; fracture depth, about two-thirds.
 EDGE TYPES

Type 3
• This edge has a small rollover radius, a normal tensile burr, and a
small fracture angle. It has low residual stress and is therefore
particularly desirable for use in parts made of work-hardenable
material that will undergo severe forming.

• The clean stress-free edge reduces the possibility of edge cracking

during forming. Burnish depth plus rollover depth is one-third to
one-half of stock thickness.
 EDGE TYPES
Type 4

• This is a desirable edge for stampings used for mechanisms or

parts that must receive edge finishing such as shaving or
machining.
• The edge has a very small rollover radius, a medium tensile and
compressive burr, and a small fracture angle.
• Burnish depth plus rollover depth is about two-thirds of stock
thickness.
• This edge type can be recognized by the spotty appearance of
secondary shear on the fractured surface.
 EDGE TYPES
Type 5

• This edge has a minimum rollover radius and a large tensile and
compressive burr, and it can be recognized by the complete
secondary shear on the cut surface.
• It is useful in applications in which edges must have a maximum
of straight-wall depth without secondary operations.
• On steel and other hard metals, die life is extremely short.
• The edge can be useful on some of the softer metals, which allow
a reasonable die life.
EDGE TYPES
EDGE TYPES
EDGE TYPES
 EDGE TYPES

(a) Rollover plus burnish approximately equals punch penetration before fracture.
(b) Burnish on edge of slug or blank may be small and irregular or even absent.
(c) With spotty secondary shear.
(d) In two separate portions, alternating with fracture.
(e) With rough surface.
(f) In two separate portions, alternating with burnish.
(g) Amount of compressive burr depends on die sharpness.
 EFFECT OF TOOL DULLING
• The sharpness of punch and die edges has an important effect on
cut-edge characteristics in piercing and blanking.

• At the beginning of a run, with punch and die equally sharp, the
hole profile is the same as that of the slug or blank.

• As the run progresses, dulling of the punch increases the rollover

and the burnish depth on the hole wall and increases the burr
height on the slug or blank.

• Dulling of the die increases burnish depth and burr height on the
hole edge.

• The punch dulls faster than the die; therefore, the changes in
hole characteristics related to punch dulling proceed more rapidly
than those related to die dulling.
 EFFECT OF TOOL DULLING
• On average, the following differences between hole edge and
blank edge are observed in production work on sheet metal:

• Rollover is greater on hole edge than on slug or blank edge.

• Burnish depth is greater on hole edge than on slug or blank

edge.

• Fracture depth is smaller (and fracture angle greater) on hole

edge than on slug or blank edge.

• Burr height on hole edge is less than that on slug or blank

edge, and varies with tool sharpness.
 CLEARANCE
• Cutting clearance is the gap
between the side of the
punch and the corresponding
side of the die opening on
one side of the edge, when
the punch is entered into the
die opening.

• Clearance is the space

between the punch and the
sidewall of the die.

• It is an intentional difference required for shearing to happen.

• It is expressed as the amount of clearance per side.

 CLEARANCE

• Decided by burnishing area.

• Punch controls the hole size and die controls the blank size.
• soft material – less clearance and v v
• Expressed as percentage of stock thickness
• Depends upon material.
 CLEARANCE
• Clearance is provided on die in punching operation. The punch is of
exact size. The die opening is then equal to the punch size plus
twice the specified clearance per side.

• Clearance is provided on punch in blanking operation. The die is of

exact size. The punch size is then equal to the die opening minus
twice the specified clearance per side.

Punching Blanking
 SELECTION OF DIE CLEARANCE
• Clearance affects the reliability of operation of piercing
equipment, the characteristics of the cut edges, and the life of
the punch and die.

• Published papers suggest a clearance per side of 3 to 12.5% of the

stock thickness for steel.

• Larger clearances prolong tool life.

• Because of differences in cut-edge requirements and in the effect

of tool life on overall cost, clearance practices vary among plants
and for different applications.
 SELECTION OF DIE CLEARANCE

• Clearance should vary directly with material thickness and

hardness and inversely with ductility.

• Amount of clearance is influenced by the required characteristics

of the cut edge of the hole or blank and by the thickness and the
properties of the work metal.

• Typical values range between 4% and 8% of stock thickness

• If too small, fracture lines pass each other, causing double
burnishing and larger force
• If too large, metal is pinched (strained) between cutting edges
and excessive burr results
CLEARANCE
 CLEARANCE
ANGULAR CLEARANCE
• 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 buildup.
• Relief to enable the slug or blank to clear the die.
• Generally, soft materials require greater angular clearance than
hard materials. Soft thicker materials above 3mm require more
angular clearance.
• An angular Clearance of 1.5° per side will meet the usual
requirements.
 CLEARANCE
ANGULAR CLEARANCE

Dies employing an ejector to clear the blanks will have straight

walls without any angular clearance, as the blanks do not get
accumulated in the die.
 CLEARANCE

• Land: It a flat surface contiguous to the cutting edge of a die.

• Straight : Surface between beginning of angular clearance and

cutting edge.
• At least 3 mm for strip thickness less than 2 mm.
• Others - = to strip thickness
 CLEARANCE

IMPORTANCE OF CUTTING CLEARANCE:

Proper cutting clearance is necessary to:

• Aid the life of the die.

• Increase the quality of the piece part.
• Improve the characteristics of piece part.
• Reduces undue stress and wear on the cutting edges of the tool.
 CLEARANCE
EXCESSIVE CUTTING CLEARANCE

• In this the large gap between the

punch and die cutting edges allows
the stock material to react to the
initial pressure on a manner
approaching that of forming rather
than cutting.

• Therefore the edge

radius becomes larger and the cut
band becomes smaller.

• In case of excessive clearance the

burr results from dragging of the
material.
 CLEARANCE
INSUFFICIENT CUTTING CLEARANCE

• When the cutting clearance is slightly

less the condition can be identified by
greater width of the cut band.

• Because of steeper angle between the

punch and die cut edges the resistance
of the stock material to fracture is
increased.

• While insufficient clearance

compressive forces cause the burr.
 CLEARANCE
DETERMINATION OF PUNCH AND DIE SIZE:
For Punching: For Punching: Die size is bigger

Punch size = Exact size

Die = Punch size + 2 clearance.

For Blanking:

Die size = Exact size

Punch size = Die size - 2 clearance.

For Blanking: Punch size is smaller

 CLEARANCE
1. When clearance is applied to the punch:
• Subtract clearance from all radii with centers inside the punch.
• Add clearance to all radii with centers outside .
• Subtract from all dimensions between parallel lines
• Angles and dimensions between centers remain constant.

2. When clearance is applied to the die:

• Add clearance from all radii with centers inside the punch.
• Subtract clearance to all radii with centers outside .
• Add from all dimensions between parallel lines
• Angles and dimensions between centers remain constant.
CLEARANCE
 CLEARANCE

Clearance = c X s X √ (Tmax/10)

Where ,

s = sheet thickness in mm

c = constant= 0.005

T max = shear strength = 80% Ultimate tensile strength in N/mm2

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

cleanest work piece but required a higher cutting force and
considerably more energy. If we take c as 0.01 cutting force energy
as its minimum but finish will be bad. The usual practice however
is to take c as 0.01
 CLEARANCE
1. Calculating the clearance for punching a 2mm sheet. Tmax to be assumed to
be 300 N/mm2.

Clearance = c X s X √ (Tmax/10)
= 0.01 X 2 X√ (Tmax/10)
= 0.12 mm/side
Therefore clearance on one side = 0.12 mm

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

Clearance = c X s X√ (Tmax/10)
= 0.01 X 0.5 X√ (400/10)

= 0.03 mm/side
 CLEARANCE
For Blanking: Punch size is small : And Clearance is subtracted from punc

• Blanking die dimension is

the same as that of
component dimension.
• Piercing punch size is the
size of the pierced hole.
 CLEARANCE
For Punching: Die size is more : And Clearance is added to die
 BURR

Burr (exaggerated) produced along the edges

of
a blanked lamination.