Professional Documents
Culture Documents
CUTTING FORCE
• “Cutting force is the force applied on the stock material in order
to cut out the blank or slug”.
• The capacity of a press is determined by the maximum cutting
force it can apply.
• The cutting force is determined by
• The length of cut
• Sheet thickness
• Material strength
• Formula for calculating the cutting force:
• Cutting force= L x S x T Max
• L = Length of periphery to be cut in ‘mm’.
• S = Sheet thickness in ‘mm’
• T max = Shear strength in N/mm2 (80 % of tensile
strength (σ max)
• Where the cutting surfaces become dull, the cutting force has to be
increased 15 to 30 percent.
CUTTING FORCE
Calculate the press force required to produce the following
component. Sheet thickness 2mm. Material is brass.
P= ( L x S x Tß ) / 10
P = Stripping force
S = Material thickness
L = Total cutting length
A = L x S = Shear area
Tß = Shear strength
METHODS OF REDUCING THE CUTTING FORCE
• The cutting force should be reduced for the life of punch and
die.
• This has an effect of reducing the area in shear at any one time
and maximum force is much less.
• This results in heavy cutting force and hence heavy load on the
punch.
• The force diagram shows the steep rise in the cutting force and
then sudden release of force as the cut in complete.
METHODS OF REDUCING THE CUTTING FORCE
• Cutting action will start at the leading edge of the punch and then it
will gradually spread to the rest of the punch.
• Thus the punch travel will be more for same energy but less force.
METHODS OF REDUCING THE CUTTING FORCE
• When the leading edge of the punch has travelled through the stock
thickness, the trailing edge of the punch will start making contact
with the material.
• The cutting force would be half of that when the shear is zero,
• The punch travel will be more for same energy but less force.
METHODS OF REDUCING THE CUTTING FORCE
METHODS OF REDUCING THE CUTTING FORCE
METHODS OF REDUCING THE CUTTING FORCE
• When shear is on the face of the punch, the blank cannot be flat
and when shear is on the face of the die, the hole (skeleton)
(piercing) cannot be flat.
• When the shear on punch is too big, say 2t or 3t, the cutting edge of
the tool becomes too acute and liable to break away easily.
• Shear that is = in depth or > than stock thickness is called full shear.
METHODS OF REDUCING THE CUTTING FORCE
Pitch (C)
• Distance between two consecutive operations on a strip.
Feed (S)
• It is the advancement in length of one
piece of stock needed to produce one
blank
STRIP LAYOUT FOR BLANKING TOOLS
TERMS USED IN STRIP LAYOUT
N = L-B / S
STRIP LAYOUT FOR BLANKING TOOLS
TERMS USED IN STRIP LAYOUT
Material Utilisation
• It is the number of blanks produced from one length of stock.
Percentage Utilisation
• It is the amount of material utilised from one length of stock.
• When blanks can be run either way, select the "wide run"
method for three reasons:
• 1. Fewer cuts will be necessary for producing the strips
• 2. The feed is shorter when running strips through the die, thus
reducing the time required
• 3. More blanks are produced per strip and fewer strips have to
be handled.
STRIP LAYOUT FOR BLANKING TOOLS
FACTORS INFLUENCING THE STOCK / STRIP LAYOUT
• Economy of material
• Direction of material grain or fibre
• Strip or coiled stock
• Direction of burr
• Press used
• Production required
• Die cost
STRIP LAYOUT FOR BLANKING TOOLS
FACTORS: ECONOMY OF MATERIAL
• If the strip is cut from the coil, the orientation of the grains
should be taken care of, if subsequent operations are to be
performed.
STRIP LAYOUT FOR BLANKING TOOLS
FACTORS: STRIP OR COILED STOCK
• The shape, height, and roughness of burrs must be controlled to some degree
in nearly all blanking operations.
• Complete elimination of burrs is not possible, but their formation can be
minimized by the use of proper clearance between punch
• and die and by good maintenance.
• Exposed burrs on the finished part can be unsafe and unsightly.
• Burrs on some blanked work can cause difficulties in forming and can increase
the rate of workpiece breakage and die wear.
• Burrs can be removed by grinding, which generally removes the burr and a
portion of the work-hardened edge.
• Tumbling in a barrel is a common method of deburring small parts.
• Other deburring methods include chemical and electrolytic deburring, belt
grinding, polishing and ultrasonic methods.
• Hand scrapers can be used to remove burrs from irregular shapes or soft
metal parts.
STRIP LAYOUT FOR BLANKING TOOLS
FACTORS: PRESS USED
• Also the bed area of the press should be kept in mind while
designing the layout.
• The size of slug or blank falling down is limited by the size of the
bed.
STRIP LAYOUT FOR BLANKING TOOLS
FACTORS: PRODUCTION REQUIRED
Case - I
• The minimum thickness of die block depends upon the strength
required to resist the cutting force.
• It depends upon the type and thickness of the material being cut.
• Thumb rule for tool steel die block is given below.
Case – III
If force is considered then thickness is considered as cube root of
force.
CONSTRUCTION OF DIE DETAILS
DIE OPENING
• The side walls of the die block opening should be provided with
sufficient relief.
• The taper can either start from the top or a straight land is
provided.
• The advantage of straight land is that the original dimensions of
the die are retained after repeated regrinding.
• With fully tapered die
cavity, the die opening
size increases after each
regrinding. This increase is
however very negligible to
cause any appreciable
effect on blank
dimensions.
CONSTRUCTION OF DIE DETAILS
DIE OPENING
• Die wall thickness from the edge of
die opening to the die block border,
distance A should be at least,
200 3.25
500 6.50
750 9.75
1000 13.00
• The die block is secured either to the die shoe or bolster plate.
• The size of screws and bolts employed are not usually
calculated.
• Along with screws, dowel pins are also used for alignment.
• They are located near diagonally opposite corners of the die
block.
• For maximum locating effect, the diameter of the dowel pins is
taken equal to the outside diameter of the fastening screw.
• Two and only two dowel pins are used for locating the die
block.
CONSTRUCTION OF DIE DETAILS
DOWEL PINS
• If the die opening is small and its contour is simple, a solid die
block is the choice.
• If the bed and press slide are not parallel, proper alignment
between two halves will be difficult.
PUNCH DETAILS
• The punch must be a perfect mate to the die block opening.
• The minimum length of punch should be such that, it extends far
enough into the die block opening.
• The length should ensure complete shearing of the blank.
• The punch length must also provide for anticipated number of
regrinds.
• The maximum punch length can be calculated from the formula
• The punch plate fits closely over the body of the punch and it holds
the punch in proper position.
• The back up plate is provided to
• take the cutting force of the punch
head
• provide a base to the punch
• ensure the punch against the deflection
when the punch does not have a flange.
• prevents the harder punch from being
pushed into the softer punch holder,
thus becoming loose.
BACK UP PLATE
• Criteria for Back up Plate
• It is the unit of compressive stress on the punch
• It is given by p = F/A
• After a blank has been cut by the punch on its downwards stroke,
the scrap strip has a tendency to expand.
• On the return stroke of the punch. The scrap strip has the tendency
to adhere to the punch and be lifted by it.
• This action interferes the feeding action of the stock through the
die.
• Some device needs to be used to strip the scrap material from the
punch as it clears up the die block.
• Such a device is called as stripper or stripper plate.
• It is basically a plate parallel to and above the die surface.
• An opening is cut through the stripper plate for free passage of the
punch.
• It should be 1.6 mm larger than the blank size on all sides.
STRIPPING FORCE
• Frictional forces originating within the skeleton prevents the
punch to move up.
• Considerable force is needed to overcome this influence.
• Stripping force is the force needed when the skeleton stick or jam
because of spring back.
• A properly designed tool needs to have a method for holding the
work while the punch is pulled back through the material.
• This stripping procedure can be either by a fixed-bridge or spring-
loaded stripper.
• Thinner material deforms easily when punch is withdrawn from a
hole, so the spring loaded stripper should be used.
STRIPPING FORCE
Stripping force can be calculated using:
Fst = S A t in KN
S is a stripping constant
A is the perimeter of the cut surface
t = stock thickness
F = 1.5 L t;
L and t are in mm and F in KN.
TYPES OF STRIPPER
• Fixed Stripper (Solid Stripper)
(Channel Stripper) MS
• As fixed stripper does not apply force on strip, thin sheets may
buckle or jam in stripper. So mainly used for thick sheets.
• Fixed mostly used for hand feed. Spring stripper for coiled feed.
• Press Tonnage
• Any other spring forces for forming, draw pads, etc. will have to
be added.