Design and analysis of combination press tool for c shaped clamp

CHAPTER 2

THEORY AND CONCEPTS OF PRESS TOOL

2.1 Theory of Shearing
2.1.1 Plastic deformation
The pressure applied by the punch on the stock material tends to deform it into the die opening
when the elastic limit is exceeded by further loading, a portion of the material will be forced into
the die opening in the form of an embossed on the lower face of the material and will result in a
corresponding depression on its upper face. This stage imparts a radius on the upper edge of the
punched out material. This is called the stage of plastic deformation. Figure 2.1 shows plastic
deformation [3].

Fig 2.1 Plastic deformation [3]

2.1.2 Penetration stage
As the load is further increased, the punch will penetrate the material to a certain depth and force
an equally thick portion of metal into the die. This stage imparts a bright polished finish on both
the strip and the blank or slug. This is penetration stage. Figure 2.2 shows penetration stage [3].

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Design and analysis of combination press tool for c shaped clamp

Fig 2.2 Penetration stage [3]

2.1.3 Fracture stage
In this stage, fracture will starts from both upper and lower cutting edges. As the punch travels
further, these fractures will extend towards each other and eventually meet, causing complete
separation. This stage imparts a dull fractured edge. This is the fracture stage. Figure 2.3 shows
Fracture stage [3].

Fig 2.3 Fracture stage [3]

2.2 Bending Die Terminology

The terminology involved in wipe bending die is shown in Figure 2.4. The equation 2.1 was used
to determine the bending force required.
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Design and analysis of combination press tool for c shaped clamp

Fig 2.4 Wipe bending terminology [3]

Fb= 0.33Tmax Wt2.. (2.1)
Ls
Where,
Fb = Bending force
Tmax = Ultimate tensile strength of material
W = Width of the bent-up portion
Ls = Distance between supports of the material
2.2.1 Spring back Compensation
Spring back occurs when metals are formed because of the influence of residual compressive
stress on inside of the bend and residual tensile stress present on the outside radius of the bend
[55]. When the bending pressure is released, the metal springs back until the residual stress
forces are balanced by the materials ability to resist further strain. The common method to
compensate for spring back is to over bend the part enough to allow it to spring back to the
desired shape [56].
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Design and analysis of combination press tool for c shaped clamp

2.3 Punch and Die Material Specification

The punch and die inserts is made of D2 tool steel material. D2 Tool Steel is a versatile highcarbon, high-chromium, air/oil hardening tool steel that is characterized by a relatively high
attainable hardness and numerous, large, chromium-rich alloy carbides in the microstructure.
These carbides provide good resistance to wear from sliding contact with other metals and
abrasive material.
2.3.1 Chemical composition of D2 tool steel
Table 2.1 Chemical composition of D2 tool steel
C

Mn

Si

Cr

Mo

1.50%

0.30%

0.30%

12.00%

0.75%

0.9%

2.3.2 Physical properties of D2 tool steel

Table 2.2 Physical Properties of D2 tool steel
Density
Modulus of elasticity
Thermal expansion
Hardness
Poisons ratio
Quenching medium
Yield Strength
Ultimate tensile strength

7.7 x103 kg/mm

210 GPa
10.5 x10-6 0C-1
62 HRC
0.3
Oil, air
2200 MPa
2400 MPa

2.4 Summary
Theory and Concept of project work presents theory of shearing, bending die terminology, Punch
and die material specification. The bending operation and methods to overcome spring back
effect in press tool operation are also discussed.

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