Tool and Die Design

Presented by
Dr. Vikas V. Kanake

Email: [email protected]
Mob:9689652586
 Unit 2

Press Working Operations and

Equipment
 Press Working Operations
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•Products of punching process in automotive industry.
•A wide range of fine blanking products in different industries such as:
aerospace, automotive, electrical, medical and watch industries
 Component of Press Tools
• Ram (Slide): Moving Component of the press which transfers the
mechanical or hydraulic force from the Flywheel /hydraulic system to the
Press tool for sheet metal stamping.
• Shank: The shank is used as a part for installing the top die in the slide of
the press machine.
• Punch Holder ( Upper Shoe): This is the upper part of the die set which
contains guidepost pushing. The whole upper section (generally contains
Punch, punch plate) of the die set is mounted on the upper shoe.
• Die Holder ( Lower Shoe ): This is the lower part of the die set which
contains guidepost. The whole lower section (Generally contain die,
stripper) of the die set is mounted on the upper shoe.
• Back up Plate: Backup plate is placed so that the intensity of pressure
does not become excessive on the punch holder. It is also called Punch
backplate and Pressure Plate.
• Punch Plate: The function of the punch plate is to hold punch in its proper
relative position. The punch plate fits closely over the body of the punch.
It is also called Punch Retainer.
• Punch: This is the main component of die assembly, which is directly or
indirectly moved by press ram or slide. Punch and die act together to
make a stamped part.
• Bed: The bed is the lower part of the press frame that serves as a table to
which a bolster plate is mounted.
• Bolster Plate: This is a thick plate secured to the bed which is used for
supporting & locating the die set.
• Die: Die is a part of the die block/press tool for producing the given job
work in a press. Die and punch work together to make the desired shape
product.
• Stripper: A stripper is used to strip the metal strip from a punch or die.
• Guidepost & Guide post bushing: This two-component of the press tool
guide the die set to maintain the alignment during the operation. Properly
lubricated, and positioned, they improve tool operation and contribute to
producing quality products. This is also called a pillar die set.
Steps of shearing or fracture in sheet metal cutting operations.
• Stressing the material beyond its elastic limit.
• Plastic deformation due to reduction in area fracturing starts in a reduced
area.
Forces Disposition
• The forces developed in the shearing operation is represented by a
triangle as shown in the below-given figure. The vertical shearing force
and horizontal lateral force are represented by V and H respectively. The
resultant force is represented by R.
Vertical Force
• The value of Vertical Component V depends upon the area to be sheared
and the shear strength of the material to be cut. Shear Area is a multiple
of the length of cut and sheet thickness.
Horizontal Force
• The value of horizontal or lateral force H depends upon the die clearance.
The horizontal force can be stated in terms of vertical force percentage.
This percentage is the same as the die clearance percentage.
• For perfect shearing/cutting of sheet metal, clearance must be in the
proper amount.
• The amount of space between punch cutting edge and the die-cutting
edge is known as clearance. For better understanding, “Clearance is the
amount of extra space required in the hole of the die to allow the punch
to pass through to punch a hole in the material”.
Importance of Proper press tool Clearance
• Clearance has a significant role in all cutting operations and forming
operations. The die clearance depends upon the work material, it ranges
from two to ten percent of the thickness of the worksheet. Ductile
material should have lesser die clearance otherwise soft material would
be drawn into the gap and harder material needs more die clearance for
good shearing action.
• Excessive clearance causes more burr on the sheared sheet while less
clearance reduces the burr but it also damages the edges of the die and
punch. This results in frequent resharpening of the die and the punch and
decreases the press tool life.
https://www.youtube.com/watch?app=deskto
p&v=74DggoOx34c
• Clearance= 0.0032 × t × shear strength

• Clearance: This is the gap or space between the punch and the die
in a cutting operation. Proper clearance is crucial for ensuring a
clean cut and reducing tool wear.
• t: This represents the thickness of the sheet metal or material being
cut.
• Shear strength: This is the material’s resistance to shearing forces.
It’s a measure of how much force per unit area the material can
withstand before failing in shear.
Blanking Punching

Scrap

Notching
Die = Punch size + 2 x clearance
• In a punching operation, clearance is the space between the punch and
the die. Proper clearance is crucial for ensuring a clean cut, reducing tool
wear, and minimizing the force required for the operation.
Formula:
Die size= Punch size + 2 × Clearance
• The clearance is provided on both sides of the punch. If the punch is
centered within the die, there is clearance on both sides of the punch (top
and bottom, or left and right, depending on the orientation).
• Since clearance needs to be provided all around the punch, the total
clearance is the sum of the clearances on both sides of the punch.
• In blanking, the punched-out piece (the blank) is the desired workpiece,
and the remaining material is scrap.
• Clearance: Clearance is subtracted from the die size relative to the punch
size.
Formula:
Punch = Die size - 2 × Clearance

Since the punch is cutting out the desired part, it should be slightly large
than the blank. This ensures that the blank (the piece being cut out) is
accurately sized and has smooth edges. The clearance is provided around
the punch to allow for the proper cutting action.
Why the Difference?
• Punching: The hole is the main product, so clearance is provided around
the die to facilitate the punch cutting the material.
• Blanking: The cut-out piece is the main product, so clearance is provided
around the punch to ensure the cut piece is the correct size.

The difference comes from whether you want the main product to be the
hole (punching) or the cut-out piece (blanking). This changes where you
apply the clearance—either added to the die size or subtracted from it.

empirical constant derived from industry practices

• shearing force:
 Simple Die Punching Machine
• A simple die punching machine performs one operation, such as cutting,
bending, or punching, in a single stroke of the press.
• If the machine is set up to punch a hole in a sheet of metal, it will only do
that one task in one operation.
 Compound Die Punching Machine
• A compound die punching machine performs two or more operations in a
single stroke, but these operations occur at the same station.
• In one stroke, it could punch a hole and cut the outer profile of a part, all
in one go at the same station.
 Combination Die Punching Machine
• A combination die machine performs different types of operations in a
single stroke, such as cutting and forming, but the operations may occur in
different stations within the die.
• In one stroke, it could punch a hole at one station and form a bend at
another station.
Progressive Die Punching Machine
• A progressive die punching machine performs a series of operations at
multiple stations. The metal strip moves from one station to another, with
each stroke of the press performing a different operation until the final
part is completed.
• The first station might punch a hole, the second might cut the part to size,
and the third might form it, all as the strip progresses through the die.
• Progressive die stamping saves time and money by performing multiple
operations simultaneously.
 Fine Blanking-Burr free blanking
• Fine blanking is a metal stamping procedure with high accuracy to produce
sophisticated parts with exceptional surface finish and tight tolerances.
• It involves a combination of shearing and punching operations, typically
using a specialized fine blanking press and custom tooling.
• Unlike conventional stamping techniques, fine blanking produces parts
with a uniform, burr-free edge that requires little or no further finishing.
• The process is in use in various industries, where the quality and precision
of the parts are critical to their performance and functionality.
• Due to its detail-intensive nature, fine blanking is a specialized and
demanding process requiring substantial knowledge, experience, and
equipment to produce the highest precision and quality parts.
• The fine blanking process starts with feeding a piece of metal into the
blanking press. The process also involves a die and stripper that works
together to make the part.
• While the stripper holds the metal in place, the press and die clamp
together and hold the metal down till the part forms, ensuring the
finished part maintains accurate dimensions.
• In the end, the stripper releases the part and reveals a part with a smooth,
burr-free finish.
• Traditional blanking and fine blanking are both processes for stamping and
cutting metal into different shapes. Though they are similar, they have
some significant distinctions.
• Firstly, the sheet is placed on the die, and the V-ring is fixed to prevent the
worksheet from moving unnecessarily.
•Then, the mechanical lever or automatic mechanism in the blanking
machine advances the punch towards the die opening; the high-pressure
punch fully blanks out the part and returns to its original position.
•At the same time, the counter punch holds the part against the advancing
punch face.
• Like stamping and punching, fine blanking includes a die and its
counterpart punch.
• The V-ring and counter-punch mechanism are also present in the fine
blanking process.
• In the standard blanking process, the high and instant pressure of the
punch causes deformation and rough cuts.
• Meanwhile, the counterpunch mechanism supports the upward pressure
to produce precise and smooth cuts in fineblanking.
• The diagram below illustrates a typical fine blanking tool setup, which
includes several key components: the punch, blank holder with V-ring,
sheet metal, die with V-ring, and counter punch.
• Traditional blanking requires simple tools that are cheaper.
• On the other hand, fine blanking requires specialized tools like precision
die sets.
• Traditional blanking produces parts with simple shapes; any special
feature will require an additional process.
• In a single operation, fine blanking can produce parts with special features
like holes, ridges, etc.
• Traditional blanking uses local tools and can handle materials with wider
thicknesses.
• Fine blanking can only handle materials about 6mm thick.
• With traditional blanking, you will produce parts with rough or burr edges,
while fine blanking produces parts with smooth, burr-free edges.
• Fine blanking tolerances, traditional blanking produces parts with looser
tolerances due to the lack of precision.
• Fine blanking, on the other hand, will produce parts with tight
dimensional tolerances.
 Materials for Fine blanking

Fine blanking tool material is a specialized process that requires a

specified set of materials. Types of fine blanking material include:
• Steel: one of the most common materials for fine blanking is steel. If it is a
tool that requires great durability and wear- resistance, tempered steel is
a good fit.
• Stainless Steel: Apart from its aesthetic appeal, stainless steel is a regular
choice for fine blanking because of its strength and corrosion resistance.
Parts for the medical, aerospace and automotive industries come from
stainless steel.
• Aluminum: aluminum sheets are malleable, lightweight, and often have
great corrosion resistance, making them suitable for fine blanking. It is a
good fit for parts for the aerospace and automotive industry.
• Copper and Brass: these materials are malleable, soft, and possess good
electrical conductivity. Parts made from these materials are mainly for the
telecommunications and electronics industries.
 Maintaining Fine Blanking Tools

Proper maintenance will ensure that your fine blanking tools remain in
optimum condition for longer. Some practices you can adopt to maintain
your fine blanking tools include
• Storing them in a clean, dry area when not in use.
• Using the correct type and amount of lubricant for the tools.
• Cleaning it regularly to remove any debris or buildup on them.
• Regular inspection of the tools to spot any damage or signs of wear and
tear.
• Repair any faulty parts to avoid greater damage.
 Center of pressure
• The cutting force of the shearing-cut blanking die must be concentrated
in a point called center of pressure.

Calculate the distance X, of the center of pressure C from the axis Y- Y by

Find COP and required cutting force of following
blank shear strength=40kg/mm2 and t=2mm.
 4.4

R1.1
.75
2.55

2.5

6
3.5

1.5

.5 2 3
• Perforating:Perforating is an operation is which a number of uniformly
spaced holes are punched in a sheet of metal. The holes may be of any
size or shape. They usually cover the entire sheet of metal.

• Lancing: It is a piercing operation in which the work piece is sheared and

bent with one strike of the die. A key part of this process is that there is
not reduction of material, only a modification in its geometry. This
operation is used to make tabs, vents etc.
 Forming
• Sheet metal forming processes are those in which force is applied to a
piece of sheet metal to modify its geometry rather than remove any
material.

• Sheet bending is defined as the straining of the metal around a straight

axis.
• During bending operation, the metal on the inner side of the neutral
plane is compressed, and the metal on the outer side of the neutral
plane is stretched.
• Bending causes no change in the thickness of the sheet metal.
Bottoming
• In this technique, you compress the sheet metal part to the bottom of the
die to create a specific shape and angle. The resulting bend represents the
configuration of the die tooling.
• Bottoming overcomes the spring back problem by punch and die force and
angle parameters shape the metal part permanently.
Coining
• The accuracy and distinctive capacity to produce exemplarily metal parts
makes coining a popular metal bending technique. The sheet metal bent
parts don’t spring back during the procedure. This is due to the coin only
slightly denting the sheet metal part, allowing you to identify the
difference.
Air bending
• Compared to bottoming and coining, air bending is a less accurate
technique that is also susceptible to spring back. Nonetheless, it is easy to
use since you do not employ tools.
• In this process, a punch applies pressure to the sheet metal part in the die
cavity. During the bending process, the metal part doesn’t touch the die
bottom necessitating use of a press brake.
• In V-bending, the sheet metal is bent between
a V-shaped punch and die set up.
• In edge bending, cantilever loading of the
sheet is seen. A pressure pad is used to apply
a force to hold the sheet against the die, while
the punch forces the sheet to yield and bend
over the edge of the die.
Q) Calculate total developed length
L3 L1

5 10
3 3

t
5 10 3
L2

L3=42mm, L1=37mm, L2=79mm, B1=18.06mm, B2=9.40mm

• Since R2>2T, K=0.50
• BA2 = 90 x π (10 + 0.5x 3)
180
= π (10 + 1.5)
2
=18.06
Since R1<2t, K=0.33
BA1 =
Since R1<2t, K=0.33
Bend allowance(B1) = (90/360)* 2*Pie(5+0.33*3)
B1= 9.42mm
Since R2>2T, K=0.50
Bend allowance (B2)= (90/360)*2*Pie(10+0.5*3)
B2 = 18.06 mm

Length= [50-(R1+t)+ 100-{ (R1+t)+(R2+t)}+50-(R2+t)+All allowances(B1+B2)

Length = [50-(5+3)+100-{ (5+3)+(10+3)}+50-(10+3)+All allowances(9.40+18.06)

Length=185.46
 Drawing
• Deep drawing die design is the process of designing
a die used for the deep drawing process, which is a
metal forming process in which a sheet metal blank
is drawn into a forming die by a punch to form a
desired shape. The design of the die is critical to
achieving the desired shape and minimizing defects
such as wrinkling, tearing, and excessive thinning of
the material.
• The following are some of the key considerations in deep drawing die
design:
1. Material selection: The material used for the die must be able to
withstand the forces and temperatures involved in the deep drawing
process. Typically, tool steels or carbide materials are used.
2. Die shape: The shape of the die must be designed to allow for the flow of
material and minimize stresses and strains. The die must also be
designed to allow for easy removal of the finished part.
3. Punch shape: The shape of the punch must be designed to match the
desired final shape of the part. The punch must also be designed to allow
for easy removal of the finished part.
1. Die clearance: The clearance between the punch and die is critical to
achieving the desired part shape and minimizing defects. Too much
clearance can cause wrinkling, while too little clearance can cause tearing
or excessive thinning.
2. Lubrication: Lubrication is essential to minimizing friction and preventing
defects such as galling or scoring. The type and amount of lubricant used
must be carefully selected based on the material being formed and the
specific die design.
3. Cooling: Heat buildup can cause deformation or cracking of the die.
Therefore, cooling channels must be designed into the die to dissipate
heat and maintain the desired temperature.
4. Die maintenance: Regular maintenance of the die is essential to ensure
consistent quality and prolong the life of the die. This includes cleaning,
lubrication, and repair or replacement of worn or damaged components.