Introduction to

Press Working
MODULE 1
MEDLO6021
PRESS TOOL DESIGN

PRESS TOOL DESIGN 1

Syllabus
• 1.1 Classification of common Press working operations. Benefits and
limitations of using Press tools. Applications of pressed parts/components.
• 1.2 Theory of Shearing in Press Working. Optimum Cutting clearance & its
effect on tolerances of pressed components. Press working terminology,
Functions of different elements of a press tool. Material handling equipment,
Methods of feeding the strip/coil material.

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Sheet Metal Basics
• Sheet metal is metal formed by an industrial process into thin, flat pieces.
• Sheet metal is one of the fundamental forms used in metalworking, and it can
be cut and bent into a variety of shapes.
• One of the cheapest and fastest ways of complete manufacturing of a
component.
• Generally considered to be a sheet with thickness less than 6 mm.
• Sheet metal operations are cold working operations producing low cost
products, having high production volume and components created at a fast
rate.

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Sheet Metal Basics
• Sheet: 0.5 to 6 mm thickness
• Plate: above 6 mm thickness
• Foil: less than 0.2 mm thickness
• Sheet metal is available in flat pieces or coiled strips. The coils are formed by
running a continuous sheet of metal through a roll slitter.
• In most of the world, sheet metal thickness is consistently specified in
millimeters. In the U.S., the thickness of sheet metal is commonly specified by
a traditional, non-linear measure known as its gauge. The larger the gauge
number, the thinner the metal.

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Sheet Metal Basics
• There are many different metals that can be made into sheet metal, such as
aluminium, brass, copper, steel, tin, nickel and titanium.
• For decorative uses, some important sheet metals include silver, gold, and
platinum.
• Sheet metal is used in automobile and truck (lorry) bodies, airplane fuselages
and wings, medical tables, roofs for buildings (architecture), Kitchen Utensils
and many other applications.

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Classification of Sheet Metal Operations
Stresses induced Operations
Shearing Blanking, Piercing, Trimming, Shaving, Notching,
Nibbling, Lancing, Perforating, Slitting, Slotting
Tension Stretch forming
Compression Coining, Sizing, Ironing, Hobbing
Tension and Compression Drawing, Spinning, Bending, Forming, Embossing

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Real Life Examples

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Shearing
Sheet Metal Shearing
processes are those in
which a piece of
sheet metal is
separated by applying
a great enough force
to cause the material
to fail.

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Tension
Stretch forming is a metal
forming process in which a
piece of sheet metal is
stretched and bent
simultaneously over a die
in order to form large
contoured parts.
Stretch forming is
performed on a stretch
press, in which a piece of
sheet metal is securely
gripped along its edges by
gripping jaws.
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Compression
Sheet metal Coining is a
process of pressing metal in a
die so that it flows into the die
space. For example Medals,
Coins, and Jewelry.

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Tension &
Compression
Sheet Metal Bending
occurs when forces are
applied to localized
areas.
Here the metal flow is
uniform along the
bend axis (neutral
axis) with the inner
surface in compression
and outer surface in
tension.

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 Classification of Presses
I. According to the connecting rod a) Punching
source of power mechanism b) Blanking
a) Manual b) Cam c) Drawing
b) Mechanical c) Eccentric d) Forming
c) Hydraulic d) Toggle joint e) Coining
d) Pneumatic e) Knuckle joint f) Embossing
f) Rack and pinion /
II. According to the screw arrangement VI. According to the
number of rams and g) Gears design of the frame
slides a) Straight Side Frame
a) Single Action Type IV. According to the b) Arch Type Frame
b) Double Action Type position of the ram c) Gap Type Frame
c) Triple Action Type a) Vertical
b) Horizontal VII. According to
III. According to the c) Inclined Capacity
mechanism a) Rated Tonnage
a) Crank shaft and V. According to its use

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