CHAPTER 3

Port Dickson Polytechnic

 Performed on sheet metal with thickness between

1/64 in (0.4 mm) to 1/4 in. (4.0 mm)

Commercially important where it is used in many
products.
Sheet metal forming processes are the primary ones
for manufacture of automobile body
Most sheet metal forming processes are cold
working.
Basic categories:
Cutting
Bending
Drawing
Tooling usually referred to as punch and die
Machine tools are presses and referred to as
stamping presses
Products are stampings.

Press may be grouped in two categories :

1. Cutting Operation.
ex : blanking, punching, nothching, lancing etc
2. Forming Operation.
ex : bending, drawing,

PRESS
Presses are the machine tools for metal

forming operations
Presses are used to apply a large force
on the piece to conduct the desired
operation; cutting or forming.
Classification of Presses:
1. Based on the drive type:
Mechanical
Hydraulic or
Manual
2. Based on Frame type
Arch
Gap
Straight-sided

3. Method of slide actuation; This

classification relate to mechanical

system with flywheel
Crank shaft
Cams
Screws
Rack and pinion
Knuckles
Toggle
4. Based on number of slides (Actions)
Single-action Press
Double-action Press
Triple-Action Press

Open Back Inclinable (OBI) Press

It is also called a gap-frame press
Most common
It has C-shape frame that allows
access to its working space
The frame can be inclined at an
angle to the base, allowing for the
disposal of the finished parts and
scrap by gravity
Open back to permit strip feeding
from front to back or ejection of
finished parts out the back
Main use is for blanking and
piercing operations in small
workpiece

 Basic Components of a Press :

Press bed: Supports the bolster

plate, open in the center to allow

finished parts or scrap to fall by
gravity
Bolster plate: A flat steel or cast
iron plate fastened to the top of the
bed. The die set is usually fastened
to it. Bolster plates have a
standard dimensions and openings
set forth by Joint Industrial
Council (JIC). Standard
Dimensions are given in Table 1.
Knockouts: Used for ejection of
works or blanks, usually operates
on the up-stroke

Table 1

 Ram or Slide : Provides the motion to the punch holder through its

stroke. The length of ram stroke is function of the machine design

or machine size.

Pitman Arm : The connecting link between the ram and the

crank or main shaft.

Power supply : Mechanical; Flywheel, or Hydraulic power
Cushion: An accessory located beneath or within a bolster plate

for producing upward motion or force. It is actuated by air, oil,

rubber, springs or high pressure

 Press Tonnage : The force in tonnes that a press can apply safely on work.

Stroke : The reciprocating motion of the slide. it is the distances travelled

by ram of press during it downward or upword motion. It is expressed in
centimetres.
Shut Height : It is the distance from the die shoe to die holder of the punch
holder when the die is in its closed position. Distance H indicate shut
height.
Die Space : It is the area available for mounting dies in the press.
Standard Press Identification : Developed by JIC as
S2-450-36-28 : S for single action, D for double action, T for triple
action, 2 indicates two-point suspension, 450 press rate capacity
450-ton, and 36 and 28 are the bed size in inches; left to right and
front to back.

Common component of a simple die:

- A die is a tool to cut or shape thin metal.

 Right half the die shown in

closed position
Left half shows the die in
open position.
Pilots are used to guide the
punch.
Note: Blank holder and
stripper are not shown

Process plan
Punch or pierce the two
holes in one stage
Make Blank in the second
stage, use pilots to register
the work piece for blanking.

A. Wide strip layout

B. Narrow strip layout
Selection of layout is
function of:
the available sizes of the
sheet strips, and
the feed; the length of the
travel of the strip between
stations.

 Punch holder and die holder

for a Die Set.
Punch plate: Block of steel to
retains the punches with their
head against the punch holder
Blanking punch and piercing
punches
Pilots

 Stripper plate: Free punches from

the scrap strip after operation
Finger stops: For locating strip at
the first station
Automatic stop: Automatically
locates the strip at the second
station
Back gage and front space: Guide
the strip during travel
Fasteners: For holding various
components of the die
Bushings
Dowel
etc.

Dies are classified by the types of operation

perform and by type of construction.
Various types of operation dies are :
1. Simple Dies : Perform only one operation such as
blanking, piercing, notching, trimming.
2. Multi Operation Dies : perform several
operations in stroke of ram.
Further Classified ;
a) Compound Dies
b) Progressive Dies
c) Combination Dies

Compound dies two or more cutting

operations such as blanking and piercing can be

perform in a single stroke at single station.
Combination dies cutting and forming are

combine and carried out in single operation.

Progressive dies workpiece moves from one

station to another, with separate operations being

performed at each station.

 Designed to perform several

sheet metalworking processes
Can be designed to blank,
draw, pierce, etc. in the same
time
Figure shows the following
processes:
Blank at A
Drawing at B
Trimming at C
Shearing of the center at D

 A progressive has a series of

stations.
At each station, an operation
is performed on a workpiece.

 First station for piercing

three holes
Second station idle
Third station for
piercing two notches
Fourth station idle
Fifth and sixth station
perform forming
Seventh station idle
Eighth final forming
process and part ejection

PUNCH CHARACTERISTIC :
Punches should not defect during use
ii. Punches should be of proper hardness
iii. Should be strong enough to withstand force
iv. Should not rotate as a result of cutting action
i.

Types of punches
Numerous types to be discussed
Basic types :
Plain punch
Pedestal punch
Perforator punch
Punches mounted in plates

1. Plain Punch
Block of hardened tool steel
shaped to conform to the
cutting contour.
Either mounted directly to the
punch holder, or onto a flat
punch plate, an extra length is
needed.
Secured by screws and
dowels.
Easy and economical to
construct.

2. Pedestal Punches (Flanged

Punches)
Constructed by
machining with a flange.
Base area larger than
cutting force.
Stability is an advantage.
Suitable for heavy
cutting loads.

3. Perforated-Type Punches
Punches with cutting
face diameter less than
or equal to 1.
Commercially available
punches or inserts.
There are many methods
for mounting perforator
type punches as shown
in the figure.

4. Punches mounted in punch plates

Odd shaped punches are not as easy as the perforators to mount
on punch plates.
Fig. a: mounting to increase
rigidity.
Fig. b: A stephead punch
mounted in the punch plate.
Interference fit used between
punch and punch holder to
ensure adequate location.
Fig. c: Shows bevel head punch
similar to a step head punch.
Square or rectangular punches
are difficult to mount, because of
requirement to machine corners.

Piercing punches should not be smaller in diameter than

the thickness of the strip.
If it is necessary, then punch shank diameter should be
at least 2 times the hole diameter.
The maximum allowable punch length (L) can be
calculated using the following formula :

where:
d = punch diameter,
t = strip thickness,
E= Modulus of elasticity, and
Ss/Fs= unit shear strength of stock.

 The punch should have sufficent compressive strength so it can apply

necessary force required during punching :

Let d = Minimum diameter of hole (mm)

t = material thickness (mm)

fs = Shear strength of work material
fc = compressive strength
P = Cutting force = dtfs
Fc = Compressive strength of punch = d fc
4

1.

Stepped Punches

2.

Single Shear on die or punch

3. Double Shear on die and punch

The amount of shear to be ground on the punch or die

depends on the reduction in punch force required

Function of a pilot is to position the workpiece

or stock strip accurately

Pilots are made of steel heat treated for

maximum toughness and to a hardness of
rockwell HRC 56 to HRC 60

Pilots are two types :

1. Acorn @ Spherical Types
2. Flattened End
Type

Pilots are be fitted to the punch by following

methods :
i.
Press fit pilot (pic. a)
ii. Threaded shank pilots (pic. b)
iii. Socket set screw pilots (pic. d)

Cutting sheet metal usually done by shearing action between sharp

edges.

Figure (Groover) depicts the stages of shearing actions in sheet metal.

1. Just before the punch contacts the work
2. Punch begins to punch into work,
causing plastic deformation
3. Punch penetration into work;
about one-third of the sheet thickness,
appearing as smooth cut surface
4. Fracture initiation at opposing cutting edge
and leads to separation

Symbols: V = motion, F = force

The characteristics of sheared edge

are:
Rollover at the top as a result of
plastic deformation
Burnish is a result of punch
penetration, and relatively
smooth
Fractured zone, rough surface
of the cut edge, due fracture of
the sheet.
Burr, sharp edge due to the
elongation of the metal during
the final separation stage.
Figure 15-36 (DeGarmo) shows
a photograph for a blanking
edge without treatment.

CUTTING OPERATIONS
The basic components include:
Punch is the cutting tool
attached to the ram of the
press. Punch face is usually
ground normal to the axis of
motion or to an angle called
shear. The shear helps in
reducing the cutting force.
Die is attached to the bolster
plate of the press.
Stripper plate to prevent
material from riding upward
on the punch as it moves
upward.
Basic Component of Blanking Die

Shearing, Blanking and Punching

SHEARING
It is the cutting operation along a
straight edge
It is performed on a large sheet using
power shears (Figure 15.40 DeGarmo)

PRESS OPERATIONS
BLANKING

cut out part from the material strip (blank)

is the required component/product.
The hole and metal left behind as waste.
Blanking is performed
by a set of a die and a punch.

BLANKING

CUTTING OPERATIONS
PUNCHING / PIERCING

Shaped hole are made in sheet metal.

Cut out from sheet metal is waste,
hole left in the strip being required.

PUNCHING/PIERCING
Punching/Piercing

CUTTING OPERATIONS
NOTCHING

This operation is used to remove

small amount of metal from the
edges of the metal strip (sheet metal).
LANCING

Combined bending and cutting

operation.

CUTTING OPERATIONS
CUTTING OFF

separate the work material along

a straight line in a single line cut

PARTING

separate the work material but

in a double line cut way.

CUTTING OPERATIONS
Clearance, c
Typical value 4% to 8% of sheet metal thickness t,
Figure 22.5 (Groover).
Small clearance tends to cause double burnishing
and larger cutting force
Large clearance leads to heavy burrs.
In special operations requiring straight edge such as
shaving and fineblanking clearance = 1% of stock
thickness.
clearance:
c = at
where c = clearance in in. (mm),
a = allowance,
t = stock thickness, in. (mm)

CUTTING OPERATIONS
The clearance can be used to

calculate the size of the punch

and die. Figure 22.6 shows the
die arrangement.
The dimensions depends on the
die punch function; blanking or
punching.
For round blank of Diameter Db:
Blanking punch diameter = Db - 2c
Blanking die diameter = Db

CUTTING OPERATIONS
For round hole punching of

diameter Dh:
Hole punch diameter = Dh
Hole die diameter = Dh + 2c
Die opening should have angular

clearance of 0.25 to 1.5 on each

side to allow the blank or slug to
drop out (see figure beside).
Angular Clearance

CUTTING OPERATIONS
CUTTING FORCE
Cutting force is a function of the area of the cut edge being
sheared at any instant and the shearing strength of the
workpiece material.

P = Cutting force (tonnes)

= D t (for round hole)
= L t s ( for other contours)
s

Where:

s = shear strength of the sheet metal, lb/in2 (Mpa), if s is unknown,

s = 0.7 to 0.8 TS.

t = stock thickness, in. (mm);
L = length of the cut edge, in. (mm)
D = hole diameter (mm)

CUTTING OPERATIONS

CUTTING OPERATIONS

CUTTING OPERATIONS
Compound dies
1. More than one
operation at one time
at one station.
2. Tonnage press is
more because need
double action or
tripple action press.
3. More accurately
4. More expensive to
construct and repair

Progressive dies
1. Perform one
operation at a time at
a station.
2. Simpler in
construction
3. Economical to repair

 Economical stock utilization is of high importance.

The goal should beat at least 75 % utilization.

In preparing layout should consider the distance
between nearest two point of blanks and between the
blank and the edge of strip should be less than the
sheet thickness

 The part could run using any of, say,

four

layouts:
Wide run positioning
Requires wider die and
High waste of material

Narrow run positioning

Useful when bend is required, however, it is
high waste of material.

Double raw layout

Less waste of material, but may lead to
expensive difficult to run dies

Nesting
Can be optimized for material utilization
Can be arranged for optimal run and die
design.

Nesting

 The formula used in calculating scrap strip dimension (over 2mm

thickness):

L = Length of part
H = Width of part
W = Width of scrap strip
t = thickness of material
D = Lead of die
B = Allowance between successive blanks
= 1 t when D is less than 60 mm
= 1 t when D is 60 mm or more
D=L+B
N = Number of blank that can be punch
=S-B
D
S = length of stock

 Thickness (less than 2 mm), then B use table

below :

Values of stock allowance B (when t > 0.625 mm) :

i.
ii.
iii.
iv.
v.
vi.

It is the centre of gravity of the line (the perimeter of the

blank).
Centre of pressure determine by :
Draw the outline of the actual actual cutting edge .
Draw XX and YY axis at right angle in convention position.
Divide the cutting edge into line element such as straight line, arc
etc. Find lengths L1,L2,L3,L4, etc
Mark the centre of gravity of these elements say C1,C2,C3,C4 etc
Find X1,Y1 the distance of gravity C1 from YY axis and XX axis
Determine the distance X and Y of centre of pressure :

 Example :

Calculate the centre of pressure of the component

below.

BENDING OPERATIONS
Bending in sheet metal is defined
as straining of the metal around
a straight axis (see Figure).
Neutral axis
Outside fibers exposed to
tension and inside fibers
exposed to compression
Metal goes through plastic
deformation to bend metal
permanently
Bending operations usually
performed using a punch and
die

BENDING OPERATION

i.

ii.
iii.

Edge Bending
V-bending
U-bending

Material bent at one edge with help of punch

Low production, also called air bending
Used U-shaped punch

Fig : Edge Bending

Fig : V-bending

BENDING OPERATION

BENDING OPERATION

BENDING OPERATION

1.
2.
3.

4.
5.

Material to be bend be ductile and strong. It

should not be hard
Bending is smooth if the axis of the bend is
perpendicular to the direction of grains.
Spring back phenomenon should be taken care
of
Hole pierced before bending will be distorted if
they are close to the bend area
In most of bending operation lubrication
required is very less

BENDING OPERATION

t = thickness of
material
S = set back
A = Bend
allowance

BENDING OPERATION

(Mpa)

Konstant function for K;

For
V-bending = 1.33 for (W=8t)
= 1.2 for ( W=16t)
U-bending = 2.66 for (W=8t)
= 2.4 for (W=16t)
Edge bending = 0.67 for (W=8t)
= 0.6 for (W=16t)

BENDING OPERATION
For edge bending width ( W ) between contact

point on die :

W = R1 + R2 + C
where ;
R1 = Die radius
R2 = Punch radius
Clearance, C = t

t = thickness

BENDING OPERATION

In order to estimate the required flat work piece length to make a bend.

R = internal radius of bend

t = thickness
K = Constant
= when R t
= 1/3 when R 2t
= when R > 2t

Length of flat blank ;

L = L1 + L2 + A
L1 = length of bend leg 1
L2 = length of bend leg 2

BENDING OPERATION

Metal tries to resume its original position causing a

decrease in bend angle

Such a metal movement is calles spring back phenomenon
It is causes by elastic stress remaining in the bend area.

BENDING OPERATION

1. Calculate the blank length to make the part

shown in figure 1. Also

determine the bending force required if the ultimate tensile strength of
material is 3500 kg/cm2. And die radius is 8 mm.The bend length
being is 120 cm.

Figure 1

DRAWING OPERATION

DRAWING OPERATION

DRWAING OPERATION

Other Drawing Operation

Redrawing
If r > 50%, redrawing is required.
Redrawing of a cup
Reverse drawing

DRAWING OPERATION

Drawing without blank holder:

The limits are:
Db - Dp < 5t ,
where Db = blank diameter,
Dp = punch diameter
Die should have a funnel or conical
shape

* IRONING
Performed after drawing to
reduce the thickness of the
cups walls to the desired value.

DRAWING OPERATION

Wrinkling
Wrinkling happens when t/Db is
less than 1%, wrinkling appears
on the flange
If drawing continues, wrinkling
appears on the walls.
Tearing: Occurred due high tensile
stress and thinning of the walls at the
bottom of the cup.
Earing: Appears when the blank
material is not perfectly isotropic.
Surface stretches: Can occur if the die
and the punch are not smooth or if the
lubricant is not enough.