TOOL DESIGN

Tool design is a specialized phase of tool engineering.

The tool design functions may be performed by a tool
engineer in addition to his other duties in manufacturing
or they may be performed by a tool design specialist who
devotes his entire working time to tool design.

The word “tooling” refers to the hardware necessary to
produce particular product. A considerable amount of
tooling is the result of work performed by tool designer.

The type of production will determine to a larger extant

The type of tooling.
 TYPES OF TOOL DESIGN
The most common classification types of tool
design is as follow:
1. Cutting tools, such as drills, reamers, milling cutters,
broaches and taps etc.
2. Jigs and fixtures for guiding the tool and holding
the workpiece.
3. Gauges and comparators for inspection and checking
4. Press tools for all types of sheet metal
5. Moulds for all types of plastics
6. Die casting dies for metals like as zinc and Al alloys.
7. Forging dies for hot and cold working of metals.
 INTRODUCTION
The stamping has now replaced many components that
were earlier casted or machined.
Material economy and the result reduction in weight
and cost, High productivity and use of unskilled labour.
High degree of possible precision have rendered
PRESS-WORK indispensable for many mass produced
goods.
Such as electronic appliances, utensils and vehicles.
The entire top of a car can be finished to size from a
single metal sheet. There is no need for further
machining.
 PRESS TOOL Tool_Assly.exe

Press tool is an assembly of punch (male part) and die

(female part) and some other parts and accessories with
which we can produce a particular shape and size sheet
metal component in mass by applying a high pressure.

SHEET METAL
A sheet metal may be described as a thin film of a metal,
which has a thickness of at the most 6 mm where as
length and breadth have no limitations. Generally the
sheets are made up of malleable metals, which do not
shatter while subjected to load under drawing.
 REQUIREMENT OF TOOL

 ACCURACY AND FINISH

 PRODUCTIVITY
 PHYSICAL STRENGTH
1. TENSILE STRENGTH
2. COMPRESSIVE STENGTH
3. PLATE DEFLECTION

 WEAR RESISTANCE
 CORROSION RESISTANCE
 SAFETY IN OPERATION
 MAINTENANCE & INTERCHANGEBILITY

 EASE OF INSTALLATION IN PRESS M/C

 REASONABLE TOOL COST

PRESS WORKING OPERATIONS
The most important press working operations are:
SHEARING
Blanking :
Blanking is a punching operation in which entire periphery is
cut out and the cut out portion is required and is known as
stamp or blank.

SCRAP BLANK
PIERCING:
It is also a punching operation like as blanking but the cut
out material is waste and the hole in sheet is required.

Required Waste

PERFORATING:
It is an operation in which numbers of holes are pierced in a
given pattern in sheet or blank.
CUTTING OFF :

It is an operation in which the sheet or blank is cut in along a

straight line or curved line for separation. In this operation no
wastage of matl. Takes place

Before After

PARTING OFF :
It is an operation in which the sheet or blank is cut in along two
straight line or curved line for or any profile for separation. In
this operation wastage of matl. Takes place
 Before After Waste

NOTCHING :
It is an operation in which two or three side cutting takes place
on the edge of the sheet, for this operation heeled punch is
used.

Before After
 LANCING :
It is an operation in which two or three side cutting and one
side bending is done. For this type of operation a hybrid punch
is used ( shearing and non shearing both operation takes place).

Before After
LOUVERING :
It is an operation in which two or three side cutting and one
side bending is done. For this type of operation a hybrid punch
is used ( shearing and non shearing both operation takes place).

Before After
 TRIMMING :
It is an operation to remove the distorted and wavy surface of a
drawn shell, it is also used to remove the unwanted excess matl.
(flashes) from the forged component. Like as spanner etc.

Before After

SHAVING :

It is a secondary operation which is used to finish a pre pierced

hole for a closer tolerance and smooth surface of the hole. In
this operation the matl. is removed in chip form.
 NON SHEARING
BENDING :
It is an operation in which a flat sheet is bend at an angle along
a straight axis.

Before After
CURLING :
It is an operation in which a edge of drawn shell or of flat sheet
is curled.

Before After
PLUNGING OR HOLE FLANGING :
It is an operation in which a flange is made in a pre-pierced
hole.

Before After
EMBOSSING :
It is an operation, which is used to make logos , emblem and
letters . In this operation thickness variation does not take place.

Before After
COINING :
It is an operation, which is used to make logos , emblem and
letters . In this operation thickness variation takes place.

Before After
BULGING :
It is an operation, which is used to increase the diameter of a
tube up to a particular portion.

Before After
 SWAGING OR NECKING : Press Tool.exe Progressive Tool.exe

It is an operation, which is used to decrease the diameter of a tube

up to a particular portion. This operation is just reverse to bulging

Before After
DRAWING :
It is an operation, where severe plastic deformation takes place.
This operation is used to make the round or rectangular shell.

Before After
 SHEAR THEORY
The name shear stands for the method of cutting sheets or stocks
with out forming chips. The metal is stressed between to cutting
edges to the point of fracture or beyond its ultimate tensile strength.
The metal is subjected to tensile and compressive stresses. The
stretching beyond the elastic limit causes the plastic deformation the
reduction in cross section finally fracture starts in reduced area.

CRITICALSTAGES OF SHEAR ACTION

1. PLASTIC DEFORMATION :
The pressure applied by the punch on the material tends to
deform in die opening.
When the elastic limit is exceeded by further loading a portion of
material will be forced into the die opening in the form of embossed
pad in the lower face of metal and depression on upper face.
This causes a radius top edge of opening in the strip and on the
lower edge of the punched out material (blank or slug) this is called
stage of plastic deformation.

PLASTIC DEFORMATION :
2. PENETRATION

As the load further increases the punch will penetrate the material
to a certain depth and an equally thick portion into the die. This
stage imparts a bright polished finish (cut band) on both strip and
the blank or slug. This called penetration stage.
3. FRACTURE

as the load further increases the fracture will start from both upper
and lower cutting edges. When the punch travels further these
fractures will extend towards each other causing complete
separation . This stage imparts a dull fractured edge.
4. SEPARATION
 CLEARANCE
It is the algebraic difference between punch and die dimensions.
It is used to intentionally given for performing shear operation.

TYPES OF CLEARANCE
1. OPTIMUM CLEARANCE
1. Small radius is the result of plastic deformation (Roll over) which is
first stage of shearing..

2. Highly smooth cut band occurs due to penetration, the second

stage of shear.
3. The width of the cut band is 1/3rd of sheet thickness.

4. The balance cut 2/3rd of sheet thickness is the break which

occur due to fracture, the third stage of shearing.

5. The break area contain the burrs. The degree of burr from
component will give indication whether the die and punch are
ready for resharpening.

6. The burr side of blank will be on the punch side .

 2. EXCESSIVE CLEARANCE

1. Large space between punch and die cutting edges allow the stock
matl. to react initial punch pressure in a manner approaching that
of forming other than cutting.
2. The edge radius becomes larger and does not blend properly into
cut band.
3. Cut band becomes smaller.
4. The break shows great irregularity ( more objectionable burr).
 3. INSUFFICIENT CLEARANCE

1. If the clearance is slightly small then greater width of cut band

and more irregularity will appear.
2. Smaller edge radius will occur
3. If the clearance is further decreased the blank will show two or
more cut bands
4. Cutting force will increase.
 IMPORTANCE OF CLEARANCE
The proper (optimum) clearance is necessary to increase the die life
and quality of the piece part.
Excessive clearance result in objectionable burr and insufficient
clearance causes undue stresses and wear on the cutting edges
because of the greater punching force required.

EXCEPTION
However round cutting edges can operate successfully with less
clearance as determined.
Reduced clearance is used in some cases to overcome the hazard of
slug pulling.
In other cases it is used where a wider cut band is required in the
piece part.
 DETERMINING CLEARANCE
Factors on which clearance depends:
1. Sheet thickness
2. Sheet Material
3. Shear strength of sheet material
The clearance should be expressed in terms of
percentage of sheet thickness per side the
percentage varies with the property of material

for soft material it varies from 3 -5 % of sheet thickness

for hard material it varies from 5 -7 % of sheet thickness
The clearance can be also calculated by following
formula:
c/2 = 0.01 X t X √shear strength
ANGULAR CLEARANCE ( Die relief )
The angular clearance is a draft or taper applied
on the side wall of the die opening.
It is provide to relief the internal pressure of the
blank or slug as it passes through the die.
angular clearance should be expressed in term of
the amount of clearance per side.
TYPES OF ANGULAR CLEARANCE ( Die relief )

STRAIGHT ANGULAR CLEARANCE

This type of clearance is used for less precise component

like as electrical stamping.
LAND &TAPER CLEARANCE

This type of clearance is used for precise component

like as surgical blades etc.
CYLINDRICAL CLEARANCE

This type of clearance is used when sheet thickness is

more than 3mm.
MAIN PARTS OF PRESS TOOL

1. DIE PLATE

It is the main female part of a press tool, it consist the

profile of the component which is required

The material should be HCHCr and hardened upto 60-62

HRC. HSS also can be used
2. PUNCH

It is the main male part of a press tool, it consist the

profile of the component which is required.
The matl. and hardness should be as of die plate.
3. STRIPPER PLATE

It is the part of a press tool, which is used to eject the strip

from the punch on return stroke of press ram.
The material should be OHNS die steel and hardened up
to 40-45 HRC .
The stripper are of two type :

1. Fixed stripper : It used to be fixed on the top of the die

plate and remains stationery during operation it is
used for heavy gage material. Where the thickness of
sheet is more than 2 mm.

2. Floating or moving stripper : It used to be fixed on the

top half of the tool and moves up and down with ram
used for light gage material. Where the thickness of
sheet is less than 2 mm.
4. PUNCH HOLDER PLATE

It is used to hold the punches, the material for it may

be any material like as MS, En-8, En-9 etc. with out
hardening.
5. THRUST PLATE

It is used to absorb the upward thrust of the punches

which generated during the operation, any hardenable
material can be used with 50 - 55 HRC like as En-31 etc.
6. TOP PLATE

It is used to hold the punch plate and it will be fixed in

press ram with the help of shank.
The material should be Cast Iron / Mild steel
7. BOTTOM PLATE

It is used to hold the die plate, stripper plate etc. it will

be fixed on press bed with the help of clamps.
The material should be Cast Iron / Mild steel
8. GUIDE PILLAR

Generally it is used to be fixed with bottom plate for

aligning both the halves i.e top half and bottom half.
The material for this should be En-36/En-31 with
60 – 62 HRC.
8. GUIDE BUSH

Generally it is used to be fixed with top plate for

aligning both the halves i.e. top half and bottom half
and material and hardness as of guide pillar.
9. SHANK

It is used to hold the top half of the tool with press m/c
ram. The material for this may be mild steel.
SECTIONAL VIEW OF PRESS TOOL ASSEMBLY
Tool_Assly.exe
CUTTING FORCE
The force required to drive the punch through the stock
material is the cutting force for the particular punch.

If the tool has more than on punch acting simultaneously

then total cutting forces of all the punches will be added
for considering press tonnage.

Factors on which cutting force depends:

1. Sheet thickness
2. Shear strength of material
3. Cutting length ( periphery of profile)
COMPUTING CUTTING FORCE :

CUTTING FORCE = L x s x t

Where L is cutting length in mm

s is shear strength in kg/mm2 or N/mm2
t is sheet thick ness in mm

It should be expressed in tonnes, 10 KN = 1 ton

STRIPPING FORCE = (L x s x t)/ 5

TYPES OF TOOLS :

The press tools are classified to different categories

depending upon the type of construction of the tool.
Generally the PRESS TOOLS are classified as:

1. SIMPLE TOOL (BLANK THRUGH)

In a simple tool only one operation is performed at each
stroke of the ram.
In a simple tool category , blanking tool produces a
blank by cutting the entire periphery in the operation.
The blank fall below the press bed. In this type of tool
components are not fully flat.
2. INVERTED TOOL

This type of tool is used for getting fully flat component

and big size component which can not be fall through
the die due limitation of press bed hole.
In this type of tool the punch will be fixed with the
bottom half and will remain stationary while die will be
moving up and down.
In this type of tool the moving stripper is used with
bottom half.

The ejection of blank from die done by the spring

actuated shedder or by knock out bar of the press m/c.
SECTION VIEW ASSEMBLYOF INVERTED TOOL
(COMPOUND TOOL)
3. COMPOUND TOOL Asssly_CompoundTool.exe

The compound tool is also called as inverted tool the

only difference is that here blanking and piercing both
takes place at same stage in a single press stroke.
In order to do this both upper and lower of the tool
blanking and piercing elements which are directly
opposite to each other.
In other words the piercing punch act in opposite
direction of blanking punch.
The blanking punch also serves as the piercing die.
The side wall of adjacent to the cutting edges of the
blanking die opening are straight because the blank
does not pass through the die
The blank is return ejected from the die by the knock
out mechanism of press m/c. or by spring actuated
spring . The knockout bar is built into the m/c ram for
this purpose only.
Advantages :
1. Close tolerance & flat components.
2. Large components.
3. Long strip does not required.
4. No need of skilled operator.
Disadvantages :
1. Difficult in mfg. and assembly.
2. High cost of maintenance and slower in operation.
4. PROGRESSIVE TOOL
Progressive tool performs two or more operations at
difference stages at each stroke of press ram.

The strip is advanced through a series of station .

The strip must move forward after each stroke to
produce the complete component.
The distance from one station must be same , the
distance from one to next station is called advance
(pitch).
When placing the sequence of operation, the piercing
if any then it should be done first for piloting purpose.

The blanking must be done in the last station.

 Advantages :
1. More nos. of operations in a single press stroke.
2. Any intricate shape can be produced.
3. High rate of production.
4. piercing, notching, bending , forming and lancing etc.
Can be done in the same tool.
5. Easy in manufacturing.

Disadvantages :
1. More nos. of forms.
2. Big size component.
3. High press tonnage which a press can not give.
4. High tool cost.
SECTIONAL VIEW PROGRESSIVE TOOL Assem1.exe
5. COMBINATION TOOL

A tool in which shearing operation is combined with

non shearing operation.

The component can be made in singe station in same

stoke.

The shallow drawn component can be made by it.

The blanking punch serves as forming die.

SECTIONAL VIEW PROGRESSIVE TOOL
GENERAL PRESS INFORMATION
PRESS TONNAGE: - It indicates the amount of
pressure in tonnes that press exerts on the work safely
and is used for rating a press.
PRESS STROKE: - it is the reciprocating motion of a
slide and is usually specified as the no. of spm. It is
adjustable on a hydraulic press.
SHUT HEIGHT: -It is the distance from the top of the
bed to the bed to the bottom of the slide with the strike
down and the adjustment up. The shut height of the
die must be equal than the shut height of the press.

DIA AREA: - It is available surface for mounting

punch and die component (press tool) in the press.
 DIE BLOCK CONSTRUCTION

Factors which influence of die block design:

1. Piece part size
2. Stock thickness
3. Shear strength
4. Type of tool
5. Machinability
6. Hardenability
7. Ease in handling
Calculation for die block dimensions

The die block thickness can be calculated by shear

force acting on it.

Td= 3√ shear force , in cms.

The die block thickness should not be less than 16
mm in any case.
Length and width can be calculated by setting the
margin
General construction of die block.

Small tools used for producing accurate have a

solid die block made by WIRE EDM.
The die block for medium size simple shape and
less precise piece part can also made in solid die
block if the die opening can be easily machined.
For intricate contour die should be split for easy
machining, hardening and grinding etc.
The die block serves as yoke containing inserts
sections into the housing.
ONE PIECE DIE RING assly_ring.exe

Among the simplest of die block construction is

the one piece ring.
Dowel pins are used to locate and position and
screws for holding.
When should go for sectional die block.
1. Large die block :
As the size of the required die block increases
accordingly do sectioning for better advantage.
2. Small die opening :
When the size of die opening is too small to
permit efficient internal working, the should go
for sectioning.
3. Complexity :
The die block construction can be simplify by
making and replacing complexity in simple
portion of die.
4. Ground die opening : when internal grinding
required for better surface finish.
Stability and strength in sectional construction.
During the operation of tool the punching force
is transmitted to the die assembly.
A proportionate part of force is transmitted to
individual die sections.
High impact conditions are repeatedly and
continuously involved as a result.
During the total life the sections may be subjected
to several millions impacts.
We should make the sections with steel which is
high impact resistance.
View of sectional construction in housing.
Assem2.exe
 PUNCHES
Punch categories:
The punch categories can be defined by their
function which are as follows
1. Cutting Punches
In this category are the punches which blank,
pierce, notch shave etc. otherwise cutting stock
material.
2. Non Cutting Punches
In this category are the punches which bend,
emboss, swage, draw otherwise form the material
3. Hybrid Punches
Both cutting and non cutting functions are
combined in the same punch.
These punches are used for lancing and louvering
operations

Punch groups:
The two major groups are distinguished by the
manner in which the punches are mounted
Segregated punches
These punches are self mounted in the sense that
they are positioned and retained by means of self
contained screws and dowels.
Mechanical integration with other elements such
as punch plates is not necessary.
As far as mounting is concerned, these punches
are self-sufficient for positioning and retention.
This tends to simplify mounting procedure and
to minimize the amount of work required for
mounting a given punch.
Integrated punches
The punches in this group depends upon some
other components. Such as a punch plate to
locate and position them.
In most cases, they depend upon the punch plate
to retain them.
When assembled, these punches are in effect, an
integral unit with their locating and retaining
components.
Punches belonging to either of these groups
requires additional guiding which can be made by
stripper plate.
PLAIN PUNCH
 TYPES OF SEGREGATED PUNCH

Plain punches
1. Rectangular in cross section.
2. Cutting contour is determined by work
requirement
3. Side wall of these punches follow the cutting
profile, originating at cutting edge and
extending to base surface.
4. A plain punch is actually a self mounting
straight punch.
Advantages :
1. Economic in tool construction .
2. Used in low production dies.
3. Machining time is saved

4. A minimum stock is removed in process.

5. A minimum stock is removed in process.
6. Absence of flanges and shoulder simplifies
setting of the punch for required machining or
grinding.
PEDESTAL PUNCH
Pedestal punches
1. Pedestal configuration.
2. Area of base surface is larger than the area of
cutting surface by an equal amount to the area
of flanged surface.
3. The flanged portion is an integral part of the
punch thus a pedestal punch is a unit which
has a larger base than the cutting area.
4. Inherent stability due to larger base and solid
configuration makes an ideal foundation
surface for the punch.
4. cutting forces are dispersed through the large
base which help for heavy cutting load.
BOSSED PUNCH
Bossed punches
1. This type of punches are made with an integral
positioning boss.
2. The boss diameter “d” should be made
standard (nominal size).
3. The boss diameter should be made too small
for a given set of circumference.
4. The boss height be restricted as a rule h= d/2.
5. The boss diameter should be made with wring
fit to its mounting hole.
6. If the work contour is irregular the punch must
be keyed to prevent rotation.
HEELED PUNCH
Heeled Punches

1. It is also known as notching or pitch punch.

2. A heel is an integral boss extended beyond the
working face of the punch commonly used in
progressive tools.
3. The heel is provided to support the punch by
resisting the lateral displacement
4. The nature of notching operation is such that
cutting force at the front of the punch is
unopposed and thus tends to displace the punch
away from the front edge.
Types of Integrated Punches
Punch mounted in the punch plate
HEADLESS PUNCH
1. These are the punches just like plain punches
except that they do not contain dowel holes.
2. The punch is positioned in opening of punch
holder plate.
3. The punch is fastened to the top plate by means
of screws.
4. A light interference fit is used between punch
and punch plate to ensure accurate location.
HEADLESS PUNCH
STEP HEAD PUNCH
1. These punches are fitted with out any screws
and dowels.
2. Step head prevents the punch for pulling from
punch plate.

3. An interference fit is used between punch profile

and punch plate opening to ensure adequate
location.
STEP HEAD PUNCH
BEVEL HEAD PUNCH
1. These punches are just like step head punches.
The only difference is that the sitting position
is at an angle ( head is angular ).
CLAMPED PUNCH

1. A suitable open slot is machined in the punch

plate to receive the punch.
2. The punch is held in the opening by pressure
from the side screws acting on the clamp.
3. The clamped type punches are sometimes
employed in order to make it possible to remove
the punch while the tool is mounted on the press.
CLAMPED PUNCH
FLOATING PUNCH

1. These punches are generally made loose in

punch holder plate and guided by the stripper.
2. The alignment of the stripper opening to die
opening is made perfectly.

3. These punches should not be withdrawn

completely from the stripper plate.
FLOATING PUNCH
 PERFORATOR PUNCHES
1. A perforator punch can be described as a cutting
punch 25 mm or less in diameter.
2. If not round in then its contour may be .
circumscribed whose diameter is 25 mm or less.
3. Commonly these punches are called perforators
for sake of convenience, whether or not their
function is strictly perforating.
4. Perforators whose working contours are not round
are often made with round shank and mush be
secured against rotation, i.e keyed in punch plate.
 TYPES OF PERFORATOR
1. The differences and variations in perforator
design may not be endless, but they are numerous.
2. However, a study of the features of some basic
types should enable the tool designer to cope with
any perforator construction by extrapolation.

STEP HEAD PERFORATOR

1. These are the commonly used perforators, they

have a step head and point diameter.
A TIPYCAL STEP HEAD PERFORATOR
 SHANKLESS STEP HEAD PERFORATOR
1. These are similar to step head perforators
except the shank diameter is more by 0.025
mm than the point diameter
 BEVEL HEAD PERFORATOR
1. On these types of perforators a beveled seating is
machined or peened.
HEADLESS PERFORATOR
These punches do not have shoulders, a whistle
notch is milled on the shank of the perforator
and a screw from the side will fasten the punch
in position.
 PYRAMID PERFORATOR
1. These types of perforators is used when there is
considerable disparity between point diameter
and shank diameter.

2. It is particularly well suited to relatively long

perforators with small point diameter

3. It is favorable for heat treating as well as

providing a generally strong physical construction
QUILLED PERFORATOR
1. The purpose of quills is to provide support for
relatively long, slender (delicate) punches.
2. Construction wise the quill is a hollow step head
punch which contains and supports the actual
perforator.
3. The inside diameter of the quill should provide
a close slip fit (no shake) for the perforator.
4. hardened thrust plate is required behind quilled
punches because most quilled perforators can be
considered heavy duty punches.
QUILLED PERFORATOR
PILOTS
1. The function of pilot is to position the stock strip
in relation to the die opening this term is called
as registering.
2. The strip is normally overfed more than the pitch
3. When the press is tripped the pilot comes down
and engages the pre-pierced hole. The strip is
dragged back into the registry position.

4. When mechanical feeding is employed the strip

is underfed the pilot pulls the strip into registry
position.
SIZE OF PILOT
1. The accuracy with which the strip can be
registered depends upon the proper location
and diameter of pilot
2. For average work
pilot dia. = pierced hole dia. – 0.05 to 0.1mm
3. For close work
pilot dia. = pierced hole dia. – 0.03 to 0.05mm
4. For accurate work
pilot dia. = pierced hole dia. – 0.01 to 0.02mm
5. Thick material an copper, Aluminium require
more clearance.
LENGTH OF PILOT

1. Registering of the strip must be completed before

the cutting punches comes and engages the sheet
2. Therefore the pilot must be larger than cutting
punch if the pilots are too short then can not
function properly.
3. In many cases the pilot length must be extended
beyond the punch face ( sheet thickness +1mm).
4. Some times it can be extended equal to sheet
thickness.
PILOT OPENING IN DIE BLOCK

1. The opening for pilot in die block should not be

too large, the strip may tends to draw in opening.

2. The opening for pilot in die block should be as:

3. Die opening = pilot dia + twice cutting clearance

PILOT OPENING IN BOTTOM PLATE
A through hole should be provided in bottom plate
for the following reasons.

1. Slugs produced during misfeeding can be cleared

2. Accumulated burrs dislodged from the pierced

hole is cleared.

3. During piercing operation burr is formed on the

pierced hole. The pilot while entering the pierced
hole will dislodge the burr
PILOT NOSE PROFILE
1. The most common pilot nose profile is bullet nose
2. The bullet shape is formed by radius ‘R’ which is
equal to the pilot diameter.

3. For piloting the holes less than 6mm dia the length
of radius R can be increased to reduce the lateral
force due to piloting.
4. The bullet nose is strong, simple to make and
smooth in function.