Journal of Modern Mechanical Systems and Machining

Volume 3 Issue 1

Design and Analysis of Sheet Metal Die Punch

Suvarna Babu. R, Mr. Bhojendra Naik M

Assistant Professor
Department of Mechanical Engineering
St. Martin’s Engineering College, Dhulapally, Secunderabad, Telangana State
Corresponding Author’s email id: [email protected], [email protected]

Abstract
The sheet metal working processes are widely used in almost all industries like
automotive, defense, medical and mechanical industries. The major advantage
for using metal working process is to improve production rate and to reduce
the cost per piece. Nowadays many people are working for developing die
punches with innovative ideas. This project is also based on new design for die
punch.

The project mainly focuses on different operations done on single setup of die
punch in a single stroke; presently these operations are done on three
separate setups which leading to reduce the production rate and increasing
cycle time. With cost as well. The 3D parts are modeled in solid works and
saved in .stp file format so that it can be imported from any of the analysis
software. As per the companies requirement cad drawings are drawn in solid
works software.

The various analyses like Von-Mises stress analysis are carried out on solid
works simulation analysis software. By observing the results for 15ton load
the punch and die are within the safe limits i.e., less than the material yield
strength. But for the 20tonn load the punch is within the safe limit where as
die has yielded more stresses than material yield strength. So 15ton load is
safe operated for punch and die.

Keywords: - Metal Die Punch, Von- Mises stress analysis, Punching, 3D Parts

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 Journal of Modern Mechanical Systems and Machining
Volume 3 Issue 1

INTRODUCTION metal operation in punching press is

In punching, press shearing is the divided into two parts—cutting operations
procedure of cutting metal plate without and forming operations. In cutting
producing the chip. The material is operations the metal work piece is stressed
stressed and force applied on a metal sheet up to ultimate strength point and the shear
can be done by the punch and die. stresses develops into the metal sheet
Shearing consist of three stages—plastic while forming operations are used to
deformation, penetration and fracture. In change the shape of metal sheet as per the
plastic deformation, force is applied by the requirement with the help of force applied
punch tool on the metal work piece, the on the metal due to which stress is
force tends to deform the metal into the die developed below the ultimate strength
opening then the elastic limit increases point; there is no cutting of metal in whole
with the increase in load. This stage starts operation only the surface profile of the
to transform the metal in a radius form on work piece is changed to get the product
the lower edge called plastic deformation shape. Cutting operations include process
of material. In penetration, load further such as blanking, punching, notching,
increases and the punch starts to penetrate perforating, trimming, shaving, slitting and
the material to a certain depth and starts to lancing. Forming in this operation includes
force the metal or material of sheet into the process such as bending, drawing and
die portion; this stage consists of a bright squeezing.
surface finish on both the strips and the
blank. This stage is called penetration
stage. In fracture stage, when load
increases on material beyond the plastic
limit the material starts fracturing from
both the upper and lower cutting edges and
the load on the punch increases
continuously, the fracture extends and
causes complete separation. Press can be
classified according to frame, delivering Fig 1: Punching press operation layout
power mechanism, working area size,
number of stations utilized for heavy
production and mass production. The sheet
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 Journal of Modern Mechanical Systems and Machining
Volume 3 Issue 1

Figure 1 shows the components of a that thickness of the machine can be

punching operation. It includes parts such reduced by 25%.
as, punch which applies the force and is in
motion, sheet on which load is being Punching is a forming process that uses a
applied, blank die which gives the shape to punch press to force a tool, called a punch,
the sheet and blank holder which holds the through the work piece to create a hole via
sheet in position. Naik and Mandavgade shearing. Punching is applicable to a wide
[1] in the year 2012 studied the effect of variety of materials that come in sheet
finite element analysis (FEA) form, including sheet metal, paper,
implementation in hydraulic cotton lint vulcanized fiber and some forms of plastic
bailing machine for optimization of top sheet. The punch often passes through the
and bottom frame. They targeted their work into a die. A scrap slug from the hole
study towards reducing the bending is deposited into the die in the process.
stresses, reducing the cost, increasing the Depending on the material being punched
safety and to design the process this slug may be recycled and reused or
successfully into a structural shape discarded.
optimization problem. They used topology
for optimization of the problem by taking Punching is often the cheapest method for
the weight as an objective function. creating holes in sheet materials in
Software ANSYS was used for this work medium to high production volumes.
and found 13% reduction in frame. When a specially shaped punch is used to
Chauhan and Bambhania [2] in the year create multiple usable parts from a sheet of
2013 designed and analyzed frame of a 63 material the process is knownas
tons power press machine using finite blanking.In metal forging applications the
element method of an industry. Material work is often punched while hot, and this
used by them were ST 42 W, which have a is called hot punching. Slugging is the
maximum tensile strength of 540MPa, operation of punching in which punch is
maximum allowable stress of 105Mpa, stopped as soon as the metal fracture is
Young’s modulus of 2100 GPA and complete and metal is not removed but
density of 7850 kg/m3 . They utilized held in hole.
CAD for modeling of the geometry and
imported it in the FEA software and found
PROCESS:
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 Journal of Modern Mechanical Systems and Machining
Volume 3 Issue 1

Punch tooling (punch and die) is often

made of hardened steel or tungsten GEOMETRY:
carbide. A die is located on the opposite The work piece is often the form of a sheet
side of the work piece and supports the or roll. Materials for the work piece can
material around the perimeter of the hole vary, commonly being metals and plastics.
and helps to localize the shearing forces The punch and die themselves can have a
for a cleaner edge. There is a small amount variety of shapes to create an array of
of clearance between the punch and the die different shaped holes in the work piece.
to prevent the punch from sticking in the Multiple punches may be used together to
die and so less force is needed to make the create a part in one step.
hole. The amount of clearance needed
depends on the thickness, with thicker
materials requiring more clearance, but the
clearance is always less than the thickness
of the work piece. The clearance is also
dependent on the hardness of the work
piece. The punch press forces the punch
through a work piece, producing a hole
that has a diameter equivalent to the punch
or slightly smaller after the punch is
Fig 2: Extruded Holes
removed. All ductile materials stretch to
some extent during punching which often
Usually, the punch and die are close to the
causes the punch to stick in the work
same dimensions, creating a sheared edge
piece. In this case, the punch must be
when they meet. A punch that is
physically pulled back out of the hole
significantly smaller than the die can be
while the work is supported from the
used to produce an extruded hole where
punch side, and this process is known as
the punch displaces the punched material
stripping. The whole walls will show
to the sides, forming a tube perpendicular
burnished area, rollover, and die break and
to the punched sheet.
must often be further processed. The slug
from the hole falls through the die into
DIE FORMING:
some sort of container to either dispose of
the slug or recycle it.
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Volume 3 Issue 1

Forming dies are typically made by tool securely clamps the work piece and
and die makers and put into production provides similar stretching bending, and/or
after mounting into a press. The die is a blanking operation. The work piece may
metal block that is used for forming pass through, several stages using different
materials like sheet metal and plastic. For tools or operations to obtain the final form.
the vacuum forming of plastic sheet only a In these case of an automotive components
single form is used typically to form are will usually be a shearing operation
transparent plastic containers (called after the main forming is done and then
blister packs) for merchandise. Vacuum additional crimping or rolling operations to
forming is considered a simple molding ensure that all sharp edges are hidden and
thermoforming process but uses the same to add rigidity to the panel.
principles as die forming. For the forming
of sheet metal, such as automobile body Design of Punch and Die:
parts, two parts may be used one, called The sheet metal punch and die consists of
the punch, performs the stretching, First step: Bending on right side Second
bending, and/or blanking operation, while step: Die in center with springs
another part that is called the die block

Fig 3: Punch
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 Journal of Modern Mechanical Systems and Machining
Volume 3 Issue 1

Fig 4: Different views of die

Fig 5: Thrust plate iso view

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 Journal of Modern Mechanical Systems and Machining
Volume 3 Issue 1

Fig 6: Push off pins

Fig 7: Punch holder iso view

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 Journal of Modern Mechanical Systems and Machining
Volume 3 Issue 1

Fig 8: Shank

Fig 9: Guide pins

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 Journal of Modern Mechanical Systems and Machining
Volume 3 Issue 1

Fig 10: Assembly of Punch and Die

Fig 11: Diff views of punch and die

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 Journal of Modern Mechanical Systems and Machining
Volume 3 Issue 1

Fig 12: Punching and bending of sheet metal

Analysis of Punch and Die: The static analysis of punch is done by using stainless steel
material by applying a load of 15ton and 20ton load. Study Results:

Name Type Min Max

Stress1 VON: von Mises 0.678995 N/mm^2 40.3281 N/mm^2

Stress (MPa) (MPa)

Node: 3326 Node: 9261

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 Journal of Modern Mechanical Systems and Machining
Volume 3 Issue 1

Name Type Min Max

Displacement1 URES: Resultant Displacement 0 mm 0.00420312 mm

Node: 14 Node: 257

Fig 13: Analysis of Punch and Die

Static analysis of punch by applying 20tonn load using stain less steel material

By applying same boundary conditions and loading conditions the results are as follows:

Name Type Min Max

Stress1 VON: von Mises Stress 0.905327 N/mm^2 53.7708 N/mm^2

(MPa) (MPa)

Node: 3326 Node: 9261

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 Journal of Modern Mechanical Systems and Machining
Volume 3 Issue 1

Name Type Min Max

Displacement1 URES: Resultant 0 mm 0.00420312 mm

Displacement
Node: 14 Node: 257

Fig 14: Static Analysis of Punch

Static Analysis of Die by Applying 20Tonn Load Using Stain less Steel Material
Name Type Min Max
Stress1 VON: von Mises 0.0100668 N/mm^2 264.003 N/mm^2
Stress (MPa) (MPa)
Node: 10968 Node: 10393

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 Journal of Modern Mechanical Systems and Machining
Volume 3 Issue 1

Name Type Min Max

Displacement1 URES: Resultant 0 mm 0.187082 mm
Displacement Node: 1037 Node: 763

Fig 15: Static Analysis of Die

RESULTS AND DISCUSSIONS Comparison of results for punch and die

The structural analysis of the punch and load of 20 tonn:
die is done by applying stainless steel S.No Punch die
material 15 ton and 20ton loading Stresses developed
53.77 264.2
conditions. [Mpa]
Resultant
0.004 0.18
Comparison of results for punch and die displacement [mm]
load of 15 tonn:
S.No Punch die By observing the above results for 15 ton
Stresses developed load the punch and die are within the safe
40.3 148.1
[Mpa] limits i.e., less than the material yield
Resultant strength. But for the 20tonn load the punch
0.003 0.14
displacement [mm] is within the safe limit where as die has
yielded more stresses than material yield
strength. So 15ton load is safe operated for
punch and die.
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 Journal of Modern Mechanical Systems and Machining
Volume 3 Issue 1

CONCLUSION II. Donaldson, George H Lecain,

In this project work some significant Vcgoold, Tool Design, Third
aspects of press tool design for chain guide Edition.
mounting bottom brocket is discussed and
also detail study and analysis were carried III. K.R. Phaneesh, Material science &
out. Both in punch and die maximum Metallurgy, Sudha Publications,
stress developed was very less when Fifth Revised Edition [2007]
compared to the calculated value. Through
static analysis it confirms that the material IV. Jutz-Scharkus, Westermann
selected for both punch and die are safe. Tables, Revised Second Edition,
Punch and die designed is made New Age International Publisher
detachable so that only the damaged part is [2006] [1996]
replaced. By incorporating finite element
method overall production rate is V. TOOL DESIGN DATA BOOK,
optimized. The results reveal that by Directorate of Technical Education
integrating CAD/CAE will be highly Government of Tamil Nadu.
beneficial. By the implementation of
computer in design, accuracy of design is VI. Estimation of Cost For Tool & Die
improved and design process time is Making By Steve Thompson,
reduced drastically than by traditional Woodhed Publishing LTD. [1999]
method. Many design problems which are
complicated to eliminate by traditional
methods are eliminated by using CAD
system.

REFERENCES
I. Stephen A, Esther T,
“Microstructural Development
during Mechanical Forming of
steel sheets”, WCE 2013, UK
Proceedings of the world congress
on Engineering.

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