Presentation on Press Tool Design 01

TOPICSTOPICS

• PRESS TOOLS & TYPESPRESS TOOLS & TYPES

• PRESS OPERATIONSPRESS OPERATIONS

• TYPES OF PRESSESTYPES OF PRESSES

• STRIP LAYOUTSTRIP LAYOUT

• STRIP MATERIALSSTRIP MATERIALS

PRESENTED BY

SUPEKAR RAVINDRA S.

Tool DesignTool Design

Press ToolPress Tool :- :-

Press tools are special tools custom

built to produce a particular component

mainly out of sheet metal.

Ex. – Automobile parts, Sheet metal

parts of electrical equipments, etc.


Types of Press Tools :-Types of Press Tools :-

Simple Tool Simple Tool Compound ToolCompound Tool Combination ToolCombination Tool Bending ToolBending Tool Drawing ToolDrawing Tool Progressive ToolProgressive Tool


Simple Tool :-Simple Tool :-

This tool is designed to perform piercingThis tool is designed to perform piercing

and blanking operation.and blanking operation.

Punch

Die

Work Piece

scrap


Compound Tool :-Compound Tool :-

Blanking and Piercing operation performedBlanking and Piercing operation performed

in a single stroke.in a single stroke.Piercing punch

Blanking Punch

Work

Required


Combination Tool :-Combination Tool :-

The cutting and forming operation are The cutting and forming operation are

combined and carried out in single stroke.combined and carried out in single stroke.

Forming partBlank

Combination of blank and form die

Tool DesignTool Design Bending Tool :-Bending Tool :-

This Tool is used to bend the component in specified This Tool is used to bend the component in specified

shape. shape.

V-Bend Tool V-Bend Tool

U-Bend ToolU-Bend Tool

Work piece

Die

Punch


Drawing Tool :- Drawing Tool :-

Drawing is a process of axial elongation Drawing is a process of axial elongation

through application of axial force.through application of axial force.

Die

Punch

Work piece


Progressive Tool :-Progressive Tool :-

The work piece moves from one station to The work piece moves from one station to

another, with separate operations, being another, with separate operations, being

performed at each station.performed at each station.

PunchStrip

Die

Types of press operationsTypes of press operations

There are two types of operationsThere are two types of operations

Cutting operationsCutting operations

Non-Cutting operations Non-Cutting operations

Tool Design

Types of cutting operationsTypes of cutting operations

PiercingPiercing Blanking Blanking NotchingNotching LancingLancing Parting offParting off cutoffcutoff

Cropping Cropping PerforatingPerforating NibblingNibbling LouveringLouvering TrimmingTrimming ShavingShaving

Tool Design


Piercing :-Piercing :-

Holes are cut on the sheet metal.Holes are cut on the sheet metal.


Blanking:- Blanking:-

The Cutting action must be about a complete or The Cutting action must be about a complete or

enclosed contour.enclosed contour.

Tool DesignTool Design Notching :- Notching :-

It is an operation for removing a piece of It is an operation for removing a piece of scrap from the edge.scrap from the edge.

Tool DeignTool Deign Lancing:- Lancing:-

Three side cutting and one side bending Three side cutting and one side bending operation.operation.

Tool DesignTool Design Parting Off :-Parting Off :-

Cut the material between two componentsCut the material between two components

to separate it from parent metal.to separate it from parent metal.

Tool DesignTool Design Cut Off :-Cut Off :-

The cutting action must be along a line.The cutting action must be along a line.

Tool DesignTool Design Cropping :-Cropping :-

Cutting operation to control the strip Cutting operation to control the strip movement. movement.


Perforating :-Perforating :- Maximum number of holes are pierced in Maximum number of holes are pierced in

single stroke.single stroke.


Nibbling :- Nibbling :-

To cut out the sheet to size with help of To cut out the sheet to size with help of punching.punching.


Louvering:-Louvering:-

Three side forming and one side cutting Three side forming and one side cutting operation. operation.


Trimming:-Trimming:-

To cut excess material which is left out on To cut excess material which is left out on the flange of the drawn component.the flange of the drawn component.

Tool DesignTool Design Shaving:-Shaving:-

To give finish cut to the blanks and pierced To give finish cut to the blanks and pierced holes.holes.

Types of Non-cutting OperationTypes of Non-cutting Operation

BendingBending

DrawingDrawing

EmbossingEmbossing

CoiningCoining

HemmingHemming

SeamingSeaming

CurlingCurling

BulgingBulging

Tool Design


Bending:-Bending:-

To bend the sheet at specified angle.To bend the sheet at specified angle.


Drawing:-Drawing:- It is process of changing flat, precut metal It is process of changing flat, precut metal

blank into hollow vessel.blank into hollow vessel.


Embossing :-Embossing :- Shallow forming operation at equal Shallow forming operation at equal

thickness.thickness.

Tool DesignTool Design Coining :-Coining :-

It is operation of making impression and It is operation of making impression and depression on sheet metal.depression on sheet metal.


Bulging:- Bulging:-

It expands the cups along a narrow band and at It expands the cups along a narrow band and at the same time reduce the height.the same time reduce the height.


Hemming :-Hemming :-

To join the two sheets. To join the two sheets.


Seaming :-Seaming :- It is the operation of pushing the material It is the operation of pushing the material

inside/outside all around the periphery.inside/outside all around the periphery.


Curling :-Curling :-

It is the operation of turn the edge inside.It is the operation of turn the edge inside.


Types Of PressesTypes Of Presses According to ShapeAccording to Shape

1) C-Frame1) C-Frame 2) H-Frame2) H-Frame

According to Table DepositionAccording to Table Deposition 1) Inclinable1) Inclinable 2) Non-Inclinable2) Non-Inclinable

According to StrokeAccording to Stroke 1) Fixed Stroke1) Fixed Stroke 2) Variable Stroke2) Variable Stroke


Types of PressesTypes of Presses According to Number of SlidesAccording to Number of Slides

1) Single Action1) Single Action

2) Double Action2) Double Action

3) Triple Action3) Triple Action

According to Type of DriveAccording to Type of Drive 1) Geared 3) Knuckle Joint1) Geared 3) Knuckle Joint

2) Non-Geared 4) Friction Screw2) Non-Geared 4) Friction Screw

According to ActuationAccording to Actuation 1) Mechanical 2) Hydraulic 1) Mechanical 2) Hydraulic

Types of PressesTypes of Presses

According to Type of operationAccording to Type of operation

Trimming, Drawing, Bending, EmbossingTrimming, Drawing, Bending, Embossing

etcetc

Tool DesignTool DesignAccording to ShapeAccording to Shape 1)1) C-FrameC-Frame

Tool DesignTool DesignAccording to ShapeAccording to Shape

2) H- Frame2) H- Frame


According to Number of SlidesAccording to Number of Slides 1) Single Action1) Single Action


According to Number of SlidesAccording to Number of Slides

2) Double Action2) Double Action

BLANK HOLDER CAM

WORK PIECE

BLANK HOLDER

DRAWING RAM PRESS TABLE


According to Number of SlidesAccording to Number of Slides

2) Triple Action2) Triple Action

DRAWING RAM

BLANK HOLDER CAM

PRESS TABLE

BLANK HOLDER

WORK PIECE

BOTTOM RAM


According to Type of DriveAccording to Type of Drive

1) Cranked Type1) Cranked Type

Tool DesignTool DesignAccording to Type of DriveAccording to Type of Drive

2) Knuckle Type2) Knuckle Type

Tool DesignTool DesignAccording to Type of DriveAccording to Type of Drive

3) Screw Type3) Screw Type

Tool DesignTool DesignAccording to Method of ActuationAccording to Method of Actuation

HydraulicHydraulic

Strip LayoutStrip LayoutTool Design

m = 1.25 T to 1.5 T b = T to 1.25 T

MARGIN ( m )

WIDTH (w )

LENGTH ( L )

PITCH ( p )BRIDGE ( b )

where , N = No. of Components

L = P x N

T = Thickness

Strip Layout CalculationStrip Layout Calculation

Area of blank x No. of rowsArea of blank x No. of rows

Economy FactorEconomy Factor = x 100 = x 100

(%) (%) Width of Strip x PitchWidth of Strip x Pitch

ECONOMY FACTOR

Tool Design

Types Of Strip LayoutTypes Of Strip Layout

Single row one passSingle row one pass Single row two passSingle row two pass Gang strip layoutGang strip layout


Single row one passSingle row one pass Wide RunWide Run Narrow Run Narrow Run


Single row two passSingle row two pass


Gang strip layoutGang strip layout

Strip MaterialsStrip Materials

There are two types of materials usedThere are two types of materials used

Non-Ferrous MaterialsNon-Ferrous Materials Ferrous MaterialsFerrous Materials

Non-Ferrous MaterialsNon-Ferrous Materials Sr

NoDescription Temper /

Hardness

Elongation

%

UltimateStrength(N/mm²)

Tensile Shear

1

2

3

4

Aluminium 99.8%

Aluminium – Mg 4.5%, Mn1%, Cu 0.1%

Aluminium Bronze

Cu 95%, Al 5%

Common Brass

Cu63%, Zn 37%

0

½ Hard Full hard

23 8 5

88 110 120

60 70 80

0

¼ H

0

½ H

H0 ½ H H

40 15 3

28 38 45

19 25 30

30

20

10

420

540

660

280

360

440

13

8

260

300

180

200

Non-Ferrous MaterialsNon-Ferrous Materials Sr


Hardness

Elongation

%


Tensile Shear

5

6

7

8

Cartriage Brass

Cu70%, Zn 30%

Magnesium

99%

Copper 100%

Cupro-Nickel

Cu80%, Ni 20%

0

½ Hard H

45 20 5

280 360 460

190 240 280

0

0

½ H

H0 ½ H H

40 10 5

270 330 410

180 220 280

35

10

--

220

250

300

150

160

170

-- 190 130

Ferrous MaterialsFerrous Materials Sr


Hardness

Elongation

%


Tensile Shear

1

2

3

4

Mild Steel

(C25Mn75)

Low Carbon Steel

C 0.07% (EDD) 0.4% Carbon

Steel

Spring Steel

0.8% C

0 22 520 400

0

0

0 -- 650 510

18 480 380

27 340 270

Yield N/mm²

280

210

310

--

Thank YouThank You

Presentation on Press Tool Design 01

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