See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/355188136

A comprehensive punch-press project for an undergraduate course on

Mechanical Systems Design

Preprint · August 2021

CITATIONS READS

0 2,599

2 authors:

Petru A. Simionescu Eric Constans

Texas A&M University – Corpus Christi Rose–Hulman Institute of Technology
118 PUBLICATIONS 832 CITATIONS 44 PUBLICATIONS 119 CITATIONS

SEE PROFILE SEE PROFILE

All content following this page was uploaded by Petru A. Simionescu on 12 October 2021.

The user has requested enhancement of the downloaded file.

 1

Accepted for publication in the International Journal of Student Project Reporting

www.inderscience.com/ijspr
A comprehensive punch-press project for an undergraduate course on
Mechanical Systems Design
P.A. Simionescu, Texas A&M University Corpus Christi, TX 78412, USA [email protected]
Eric W. Constans, Rose-Hulman Institute of Technology, Terre Haute, IN 47803, USA [email protected]

Abstract

In this paper, a semester-long project for an undergraduate mechanical-systems-design course is

presented. The project requires students to perform kinematic and load torque analysis of a crank -
driven punch press, choose a suitable electric motor, and calculate the moment of inertia of the
flywheel such that an imposed coefficient of speed fluctuation is ensured. Then students select a pair
of sheaves and the V-belt of the first stage of the press transmission, and size for endurance the
second stage consisting of a pinion-shaft and the mating gear. In the process, students perform
kinematic and energy balance calculations which they compare with Working Model 2D simulations
of the crank press. While collaboration is encouraged, students choose their own set of design
parameters, and present their work as individual written reports. This comprehensive project was very
well received by the undergraduate Mechanical Engineering students at Texas A&M University
Corpus Christi and can be adopted as is or with modifications at other universities.

Keywords: project-based learning; engineering calculations; computer simulation; crank press.

1. Introduction

The benefits of project-based learning to engineering education are well recognized. These include
heightened motivation, enhanced student participation in the learning process (active and self-
learning), promoting critical and proactive thinking etc. It also facilitates the development of soft
skills, such as communication, working effectively in teams, project and time management,
awareness of societal and ethical issues etc. (Frank et al. 2003, Gary 2015, and Kokotsaki et al.
2016).
In this paper, a project assignment for a senior level class on Mechanical Systems Design is
presented. As part of this semester-long project, students perform kinematic and load torque analysis
of a crank-driven punch press. The calculated average torque is then used in selecting an electric
motor and in calculating the moment of inertia flywheel of the press, such that a desired coefficient of
speed fluctuation is ensured. Finally, students choose the V-belt with sheaves, and size the pinion-
shaft and its mating gear and produce a detailed mechanical drawing of the pinion shaft. This is a
comprehensive project which combines subjects taught in classes such as Engineering Graphics,
Manufacturing Processes, Kinematics & Dynamics of Machinery and Machine Component Design.

2. Project Statement

A mechanical power press is a machine used in manufacturing industry to apply pressure by means of
slides or rams upon a pair of dies, for the purpose of shearing, punching, forming or assembling metal
or other material (Lange 1995, and Hosford and Caddell 2011). Of the known mechanical presses
(Lange 1995, Ham and Jang 2009 and Halicioglu 2015), the student project discussed in this paper
 2

refers to a crank-slider press driven from a motor via a belt, in series with a pinion-gear pair, as
shown in Figure 1 (Karakoulidis 2015 and Convergence Training 2021).

Figure 1: Main components of a crank press: 1-motor; 2-belt transmission; 3-clutch; 4-pinion; 5-large
gear/flywheel; 6-crankshaft; 7-slide-block.

Each student chooses their own specification for the press according to the recommendations in
Table 1, and perform the design and calculations steps listed in Appendix 1. While collaboration is
encouraged, students present their work individually in one midterm and one final written report.

Table 1: Project specifications with recommended value ranges (see Figure 1)

The press punches holes in aluminum sheets of one of the following grades (choose one):
I
1100-H12; 1100-H18; 3003-0; 3003-H12; 3003-H18; 6061-0
II The hole diameter is between 40 and 160 mm;
III The stock thickness h is between 10 and 25 mm;
The punch stroke S max-S min is 15 to 25 times the stock thickness (bigger value for thinner
IV material). Note that for negligible slider eccentricity, the crank length is half the punch
stroke i.e. r2 = 0.5(S max - S min).
V Slider eccentricity r1 is between 0.5 and 1.25 times the workpiece thickness;
VI Connecting-rod length r3 is 2.5 to 4 times the punch stroke;
After penetrating the workpiece, the punch continues to travel at least 3 times the workpiece
VII
thickness;
The number of punches performed (equal to the average crank rotational speed n p) should be
VIII
between 80 and 120 holes per minute;
IX Belt angle  is between 50 and 80 degrees;
 3

Y Y
A T A
r2
O X O 2 X


gear/
flywheel
r3
motor
S S
Ss 3
B B
punch Sf
C

F
D r1 C

h stock

(a) (b)
Figure 2: Schematics of the crank-slider punch press and of its main kinematic parameters

To simplify the analyses in this project, the following assumptions are made:
• The material to be punched has an ideal plastic behavior.
• The friction in the joints of the crank-slider mechanism and between the punch and the
workpiece are neglected.
• The motor torque is constant and independent of the rotor speed.
• The motor power is transmitted to the punch without losses.
• The V-belt does not slip on its sheaves.
• All inertias, other than that of the flywheel, are neglected.
The press (Figure 2) employs a crank-slider mechanism of crank length OA=r2, connecting-rod
length AB=r3, eccentricity CD=r1, and punch length BC=Lp. The press punches holes of diameter d
into aluminum stock of thickness h and shear strength max, at a rate of n p holes per minute. The
actual punch begins when the displacement S equals S s and ends when S equals S f. According to the
simplifying assumptions listed above, force F acts only when the punch is moving down and
S s < S < S f . Assuming the workpiece shear-stress  versus punch penetration S as shown in Figure 3-a
with negligible elastic range, the punch force F will peak right when the punch makes contact with
the stock (i.e. for S = S s), and will decreases linearly as the penetration progresses, reaching zero
 4

when S = S f. The maximum punch force Fmax depends on the shear strength of the material and on the
shear area Ashear (equal to the side area of the hole) according to the equation:
𝐹max = max ∙ 𝐴shear = max ∙ (π ∙ 𝑑 ∙ ℎ) (1)
The punch force F versus punch displacement S will therefore be:
Sf −S d𝑆
∙ 𝐹max for 𝑆s ≤ 𝑆 ≤ 𝑆f and <0
𝐹(𝑆) = { Sf−Ss d𝑡 (2)
0 otherwise
 F
h
elastic
range

Fmax
 max

S
0 h 0 Ss Sf
(a) (b)
Figure 3: Shear stress  vs. punch penetration (a), and punch force F vs. punch displacement for an ideally
plastic material with negligible elastic range (b).

3. Punch Press Linkage Kinematics and Inverse Dynamics

The loop-closure equation of the crank-slider mechanism in Figure 2-b is:

→ → → → →
𝑂𝐴 − 𝐵𝐴 + 𝐵𝐶 − 𝐷𝐶 − 𝑂𝐷 = 0 (3)
and projects on the X and Y axes as:
𝑟 ⋅ 𝑐𝑜𝑠 𝜃2 − 𝑟3 ⋅ 𝑐𝑜𝑠 𝜃3 + 𝑟1 = 0
{2 (4)
𝑟2 ⋅ 𝑠𝑖𝑛 𝜃2 − 𝑟3 ⋅ 𝑠𝑖𝑛 𝜃3 − 𝐿𝑃 − 𝑆 = 0
The unknowns in scalar equations (4) are the punch displacement S and transmission angle θ3. To
solve for displacement S for any crank angle 2, equations (4) are rearranged as
𝑟 ⋅ 𝑐𝑜𝑠 𝜃2 + 𝑟1 = 𝑟3 ⋅ 𝑐𝑜𝑠 𝜃3
{2 (5)
𝑟2 ⋅ 𝑠𝑖𝑛 𝜃2 − 𝐿𝑃 − 𝑆 = 𝑟3 ⋅ 𝑠𝑖𝑛 𝜃3
and after squaring and adding them, a quadratic equation in the unknown S is obtained:
𝑆2 − 2 ⋅ 𝑏 ⋅ 𝑆 + 𝑐 = 0 (6)
For a given crank angle 2, the two solutions of this quadratic correspond to the two possible
assembly configurations of the mechanism (Uicker et al. 2016, Constans and Dyer 2018).
 5

Figure 4: Sample plots of punch displacement S and transmission angle 3 and their first- and second-time
derivatives.
Once slider displacement S is determined, the preferred way of calculating the unknown transmission
angle 3 is by applying the arctangent function of two arguments to the ratio of equations (5) as
explained in Simionescu (2014).
The velocity problem is easier to solve by evaluating the first-time derivatives of equations (4), which
yields a set of two linear equations in the unknowns dS/dt and d3/dt. Before solving for velocities,
punch displacement S and transmission angle 3 must be determined for the same crank angle 2,
while the angular velocity of the crank (i.e. d2/dt = n p/30) must be specified as input.
Accelerations d 2S/dt2 and d 23/dt2 are solutions to the set of two linear equations resulting from
evaluating the second-time derivatives of equations (4). A constant angular velocity of the crank is
assumed and therefore d 23/dt2 = 0. Evidently, dS/dt and d3/dt must be known before attempting to
calculate d 2S/dt2 and d 23/dt2.
Figure 4 shows sample plots of the position, velocity and acceleration of punch displacement S and
transmission angle 3 of a mechanism with r1, r2, r3 and n p chosen according to the specifications
summarized Table 1 (see also Appendix 2).
Given the punch force F as function of the punch displacement S (see equation 2), the crankshaft load
torque can be calculated relatively easily by applying the Principle of Virtual Work i.e.
 6

𝑇 ∙ dθ2 = 𝐹 ∙ dS (7)
which is equivalent to:
d𝑆⁄d𝑡
𝑇(θ2 ) = 𝐹 ∙ dS ⁄dθ2 = 𝐹 ∙ (8)
dθ2⁄d𝑡

Once the crank torque T vs. crank angle 2 becomes known as discrete successive values, the average
torque per punch defined as:
1 2π
𝑇avg = ∫ 𝑇(θ2 )dθ2 (9)
2π 0
can be relatively easily calculated using Trapezoidal Rule.

Figure 5 Plot of the crank torque and average torque vs. crank angle.

4. Flywheel Moment of Inertia Calculation

Figure 5 shows the overlapped plots of the instantaneous crank torque T and of the average crank
torque Tavg as functions of the crank angle 2. The area above the Tavg line and colored in yellow,
corresponds to the energy released by the flywheel as it slows down from its maximum speed n pmax
right before the punch begins, to its minimum speed n pmin when the punch ends. The two areas below
the Tavg line shown in cyan, when taken together, are equal to the area in yellow, and correspond to
the energy supplied by the motor to the flywheel as it accelerates from n pmin to n pmax.
Given the energy E exchanged with the flywheel (equal either to the yellow or to the two cyan areas
in Figure 5 multiplied by /180) and the average (nominal) speed n p of the flywheel, the required
moment of inertia I of the flywheel for which a desired coefficient of speed fluctuation CS is ensured
can be now determined. This coefficient of speed fluctuation is defined as:
CS = (𝑛pmax − 𝑛pmin)⁄𝑛p = (ωpmax − ωpmin)⁄ ωp (10)
and is recommended to be around 0.2 for punch presses and rock crushers (Dresig and Holzweißig
2010, Norton 2020, Uicker et al. 2016).
For machinery exhibiting only one torque spike such as in Figure 5, the energy exchanged with the
flywheel can be calculated as:
1 2π
∆𝐸 = ∫0 |𝑇(θ2 ) − 𝑇avg |dθ2 (11)
2
The integral in equation (11) can be evaluatyed numerically using the Trapezoidal Rule.
 7

T ()
I
.

Tavg

Figure 6: Free-body diagram of the flywheel of the punch press

Figure 6 shows a free-body diagram of the flywheel, with Tavg the constant torque delivered by the
electric motor as it is amplified through the press transmission. The equation of motion of the
flywheel can be stated as:
dω dθ dω
𝑇avg − 𝑇(θ) = 𝐼 ∙ ω̇ = 𝐼 ⋅ = 𝐼 ⋅ω (12)
dθ dt dθ
This equation is integrated as
θs pmax ω 1
∫θ (𝑇avg − 𝑇)dθ = ∫ωpmin 𝐼 ∙ ω dω = 𝐼(ω2pmax − ω2pmin ) (13)
f 2

where s and f are the crank angles for which the maximum and minimum angular velocities of the
crankshaft occur. Because the left-hand-side integral has the same value as the one in equation (11)
we can further write:
1
Δ𝐸 = 𝐼(ωpmax − ωpmin)(ωpmin + ωpmax ) (14)
2
or
1 𝜋 2
Δ𝐸 = 𝐼(𝑛pmax − 𝑛pmin)(𝑛pmin + 𝑛pmax ) ( ) (15)
2 30

The above two equations relate the change in kinetic energy E and the required mass moment of
inertia I of the flywheel, for which its speed fluctuation is limited between pmin and pmax or n pmin
and n pmax.
If we approximate the average angular velocity of the crankshaft as:
ωp = (ωpmax + ωpmin)⁄2 (16)
equations (10) and (14) yield
Δ𝐸 Δ𝐸 30 2
𝐼= = ( ) (17)
CS ⋅ω2p CS⋅𝑛2p 𝜋

which is the required mass moment of inertia of the flywheel.

5. Working Model 2D simulation

Students are required to validate their Excel calculations using Working Model 2D motion simulation
software (WM2D in short) available from Design Simulation (2021). A crank-slider mechanism with
constant rotational input is required to be modeled in WM2D part of the midterm project report
 8

(Figure 7). Side-by side comparisons between the Excel plots and WM2D meters are expected part of
students’ reports.

Figure 7: Kinematic simulation done using Working Model 2D .

For their final report, a second WM2D simulation must be prepared (see Appendix 3), where the
driving motor is of the constant-torque type instead, and the resistance to workpiece penetration is
modeled using a conditional force applied at the punch head. This conditional force is programed
using the WM2D formula language based on equation (2). The maximum punch force Fmax calculated
with equation (1) is supplied to the WM2D program via a textbox control. In the simulation with the
screenshot in Appendix 3, workpiece location S f and workpiece thickness h are specified using
textbox controls, as well as the crankshaft torque Tavg, and the moment of inertia I of the flywheel.
The value of the crank initial speed which is about equal to n p also provided via a textbox control.
For the motor torque Tavg and flywheel moment of inertia properly selected, the rotational speed of
the crank should fluctuate between the prescribed limits n pmin and n pmax over multiple simulation
cycles. A tendency of the crank rpm to increase indicates that Tavg is bigger than necessary.
Conversely, if the crank tends to lose speed, it means that Tavg is smaller than required (see Figure 8).
The prescribed coefficient of speed fluctuation CS can be validated using equation (10) and the n pmin
and n pmax values extracted from the crank rpm vs. time plot output by WM2D. For example, the
simulation with the screenshot in Appendix 3 yields a CS value close to the one imposed through the
 9

project specifications (see equation 18), while the calculated average crank speed is also close to the
one considered in Excel calculations i.e. n p =85.6 rpm.
𝑛pmax−𝑛pmin (93.97−77.23) 16.74
CS = = = = 0.1996 ≈ 0.2 (18)
(𝑛pmax+𝑛pmin )/2 (93.967+77.23)/2 85.6

Figure 8: Crank rpm vs. time showing the effect of a too small (above) and too big (below) Tavg torque.

6. Mechanical design and engineering analyses

After the average crank torque Tavg is determined, the corresponding input power can be
straightforwardly calculated. This power, corrected with an overload factor of about 1.75, serves to
choose a three-phase induction motor for the press.
The next step involves dividing the total transmission ratio itotal between the belt transmission (with a
ratio ib) and the gear transmission (with a ratio ig – see Figure 2) according to the equation:
𝑛mot 𝐷2 𝑁gear
𝑖total = = 𝑖b ∙ 𝑖g = ∙ (19)
𝑛n 𝐷1 𝑁pinion

where D1 and D2 are the pitch diameters of the small and of the big belt sheaves respectively. The
number of teeth of the pinion Npinion should be at least 17 teeth if standard involute gears are to be
used. A larger Npinion value may be however required to allow for a big enough gear and implicitly
Ngear, such that the desired moment of inertia I is achieved. This is because the gear is also the
flywheel of the press as shown in Figure 1.
To select the V-belt and sheeves, students follow the theory and sample problems available in the
textbook Mott et al. (2017). Similarly, students follow Mott et al. (2017) for calculating the gear-
pinion pair, to size for fatigue the pinion shaft and to select a pair of rolling-element bearings to fit
the journals at points A and C of the shaft as shown in Figure 9. Based on these analyses, students
are required to prepare a mechanical drawing of the pinion shaft, where they practice assigning
dimensioning and tolerance as they have learned in an earlier class on Engineering Graphics and
Machine Component Design.
 10

Figure 9: Schematic for pinion shaft calculation, where Wr and Wt are the radial and tangential gearing forces,
and Fb is the resultant belt force (see also Appendix 1 for additional recommendations on this pinion-shaft
design).

7. Student perception

The project described in this paper has been assigned in the last three years to the undergraduate
students in the Engineering Department at Texas A&M University Corpus Christi. Below are some of
the favorable comments formulated by students in their end-of-semester course evaluations.
• I enjoyed doing the punch-press project. I think it was a good taste of what a full-scale mechanical
design and analysis may entail.
• First time I have ever gone so in depth in calculations about a machine. Felt good! Also, I had no idea
how well Excel could be utilized for different types of problems.
• I liked the project. Never working with the Working Model program before it was interesting.
Refresher on AutoCAD was great as well.
• The project though tough, was extremely helpful in testing my engineering skills
• The project required in depth critical analysis that facilitated a greater understanding of the course
material and its significance in the workplace.
• The project was very cool. Real–world applications to theoretical content.
• The project was very interesting and fun to do. Though it had its challenges, it was worth it.

There were fewer negative comments received as well, mainly from students dissatisfied with the
workload, and the use of Working Model 2D software.
• The project takes up too much time and is rather difficult. By the time I have completed the project I
will have spent approximately 60–70 hours on it.
• The project is hard and takes forever to do it.
• I learned a lot because of the project, but why would we use Working Model and not Solid Works?
 11

• The biggest challenge, in my opinion, was Working Model. I loved the idea behind it. I hated the lack
of resources for learning it. Took more time trying to figure out the software than doing the
calculations and typing the report.

8. Conclusions

In this paper, a comprehensive project for an undergraduate course on Mechanical Systems Design
has been presented. Students perform kinematic and load torque analysis of a crank-driven punch
press. Based on the calculated required torque, they choose an electric motor, and size the flywheel of
the press such that a suitable coefficient of speed fluctuation is satisfied. The kinematic and load
calculations are implemented in Office Excel, and are validated using Working Model 2D
simulations. Students then select the V-belt and sheaves for the first stage of the press transmission,
size for endurance the second transmission stage consisting of a pinion shaft and its mating gear, and
select a pair of rolling-element bearings for the pinion shaft. Finally, students generate detailed
mechanical drawings of the pinion shaft with dimensions, tolerances and surface finishes . The project
was well received by the Mechanical Engineering students at Texas A&M University Corpus Christi,
and can potentially be adopted in other undergraduate engineering programs.

9. Lessons Learned

When the project was first introduced, students were required to submit only one report at the end of
the semester. To keep them on track however, a midterm project report was additionally introduced,
covering only steps 1 to 11 in Appendix 1. It was also noted that occasionally students produce
pinion shafts that appear too slender, and a shaft deflection analysis requirement was added to the
final project.

References

Constans E. and Dyer K. B. (2018) Introduction to Mechanism Design: with Computer Applications,
CRC Press, Boca Raton FL.
Convergence Training (2021) Mechanical power press safety,
www.convergencetraining.com/mechanical-power-press-safety.html
Design Simulation (2021) Working Model 2D, www.design-simulation.com/WM2D/
Dresig H. and Holzweißig F. (2010) Dynamics of Machinery: Theory and Applications, Springer-
Verlag, Berlin.
Frank M., Lavy I. and Elata D. (2003) Implementing the Project-Based Learning Approach in an
Academic Engineering Course, International Journal of Technology and Design Education 13, 273–
288.
Gary K. (2015) Project-Based Learning, Computer, 48(9), 98-100.
Halicioglu R., Dülger L. C. and Bozdana A. T. (2015) Mechanisms, classifications, and applications
of servo presses: A review with comparisons, Proc Inst Mech Engr Part B Journal of Engineering
Manufacture 230(7), 1177-1194.
 12

Halicioglu R., Dülger L. C. and Bozdana A. T. (2015) Structural design and analysis of a servo crank
press, Engineering Science and Technology, an International Journal, Vol. 19, 2060–2072.

Ham K. C. and Jang D. H. (2009) Kinematical analysis on the several linkage drives for mechanical
presses, Journal of Mechanical Science and Technology 23() 512-524
Hosford W. F. and Caddell R. M. (2011) Metal forming: mechanics and metallurgy, Cambridge
University Press, New York
Karakoulidis K. (2015) Automated Determination of the Power Required and Selection of Electric
Motors for Forging Fly-Press Mechanisms, Journal of Engineering Science and Technology Review
8(3) p.78-82
Kokotsaki D., Menzies V. and Wiggins A. (2016) Project-based learning: A review of the literature.
Improving Schools, 19(3), 267–277.
Lange K. (1995) Handbook of metal forming, Society of Manufacturing Engineers, Southfield,
Michigan, USA
Mott R.L., Vavrek E.M. and Wang J. (2017) Machine Elements in Mechanical Design, Pearson, New
York, NY.
Norton R.L. (2020) Machine Design: An Integrated Approach, 6th Ed. Pearson, New York.
Simionescu P.A. (2014) Computer Aided Graphing and Simulation Tools for AutoCAD Users, CRC
Press, Boca Raton FL.
Uicker Jr. J.J., Pennock G. R. and Shigley J. E. (2016) Theory of Machines and Mechanisms, Oxford
University Press.

Appendix 1: Project report requirements

(1) Research known designs of slider-crank punch presses (consider patents also), and identify
their main parts and functions.
(2) Using the shear strength of the aluminum material selected and the diameter of the hole to be
punched, derive the equations of the punch force vs. punch penetration, assuming a linear reduction
of the shear force during punching.
(3) Write the vector equations and the corresponding scalar equations for position, velocity and
accelerations of the slider displacement and transmission angle.
(4) Calculate the minimum and maximum slider displacement values and draw the press
mechanism at scale in these two positions.
(5) Calculate the minimum and maximum transmission angle values and draw the press
mechanism at scale in these two positions.
(6) Program in Excel the equations derived at steps (4) and (5) with columns for (A) time,
(B) crank angle in radians, (C) crank angle in degrees, (D) punch displacement, (E) punch velocity,
(F) punch acceleration, (G) transmission angle, (H) punch force, (K) required crank moment
calculated using the principle of virtual work.
(7) Use trapezoid integration to calculate the average torque required per one press cycle.
 13

(8) Assuming a constant input motor-torque, calculate the required flywheel moment of inertia to
be placed on crankshaft that will limit the coefficient of speed fluctuation of the press to acceptable
values.
(9) Model the press in Working Model 2D. Assign small masses and small moments of inertia to
the slider and to the connecting rod of the press, such that their flywheel effect is negligible.
(10) Plot in Working Model 2D the crank rpm vs. time and use it to confirm that the press satisfied
the desired coefficient of speed fluctuation.
(11) Select a three-phase motor for the press.
(12) Select a V-belt and pulley for the first stage of the press transmission.
(13) Calculate and size the gear pair of the press, for the pinion being solid with its shaft.
(14) Calculate for infinite fatigue life and size the intermediate shaft of the press. Assume the
pinion to be halfway between the bearings, and the distance between bearings to be 2.5 – 3 times the
pitch diameter of the pinion (see Figure 9).
(15) Select a pair of bearings for the pinion shaft of the press.
(16) Draw full page, landscape the pinion-shaft with dimensions, tolerances and surface finishes.
(17) Draw at scale a schematic of the entire mechanism as shown in Figure 2-a.
 14

Appendix 2: Excel spreadsheet for kinematic and torque analysis

 15

Appendix 3: Working Model 2D dynamic simulation

View publication stats