ARAMAN VELMURUGAN 4

PRESS TOOL DESIGN

SHEET METAL OPERATIONS

• Sheet metal is any metal that has a thickness in between 0.3mm to 6mm.
• Anything thinner is referred to as a foil and thicker is considered as a plate.
• Sheet thickness is generally measured in gauge. Greater the gauge number,
thinner the sheet of metal
• Sheet metal can be cut, bent and stretched into nearly any shape.
PRESS:
v “It is a machine by which we can do cutting and non cutting process
by applying force without removing chip on metallic or non metallic
sheet.”
Introduction
• Pressworking has been defined aschipless manufacturing process by which component
are madefrom sheetmetal.
• “Metal forming is one of the manufacturing processes which are almost chip
less. These operations are mainly carried out by the help of presses and press
tools. These operations include deformation of metal work pieces to the
desired size and size by applying pressure or force. Presses and press tools
facilitate mass production work.
• These are considered fastest and most economic way to form a sheet metal
into finished products.”
• Workpieces are produced or formed as the punch descends onto
the die block.
• In most cases processing of sheet metal is done in cold state.
Material like magnesium may sometimes be heated slightly to make
themmore workable.
 Press working cutting operation
• In cutting operation the work piece is stressed beyond itsultimate
shear strength and cut off into piece.
• In forming operation the stresses applied are below the ultimate shear
strength of the material. As such there is no cutting of the metal only
the contour of the work piece is changed to the desired shape.
vNOTCHING
• A shearing operation that removes a section from the outer edge of the metal strip
orpart.
• Similar to blanking however the full surface of punch does not cut the
metal
• In this operation the metal pieces are cut from the edges of a sheet.
• Common cutting operation using dies and punches
include the following:-
1. Blanking Press Tool Operations
2. Punching
3. Trimming
4. Shaving
5. Notching
6. Nibbling
7. Perforating
8. Parting
9. shearing (c) TMH New Delhi, Manufacturing
Technology Vol 1, Foundry, Forming and
 Shearing Mechanism in Sheet Metal

(c) TMH New Delhi, Manufacturing

Technology Vol 1, Foundry, Forming and
ctober 2008 Welding by P N Rao 7
(c) TMH New Delhi, Manufacturing
Technology Vol 1, Foundry, Forming and
22 October 2008 Welding by P N Rao
vBlanking & Piercing
• Blanking and piercing are shearing processes in which a punch and
die are used to modify webs. The tooling and processes are the same
between the two, only the terminology is different: in blanking the
punched out piece is used and called a blank; in piercing the punched
out piece is scrap. The process for parts manufactured simultaneously
with both techniques is often termed "pierce and blank." An
alternative name of piercing ispunching.
v Trimming
• The trimming operation is the last operation performed because it
cuts away excess or unwanted irregular features from the walls of
drawn sheets
vShaving
• The shaving process is a finishing operation where a small amount of
metal is sheared away from an already blanked part. Its main purpose
is to obtain better dimensional accuracy, but secondary purposes
include squaring the edge and smoothing the edge. Blanked parts can
be shaved to an accuracy of up to 0.025 mm (0.001 in)
vLancing
• Lancing 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.
vNibbling
• The nibbling process cuts a contour by producing a series of
overlapping slits. This allows for complex shapes to be formed in
sheet metal up to 6 mm (0.25 in) thick using simple tools.
• Punches are available in various shape and sizes; rectangular punches
are common because they minimize waste and allow for greater
distances between strokes. Nibbling can occur on the exterior or
interior of the material, however interior cuts require a hole to
insert the tool
vPerforating
• Perforating is a piercing tooling that involves punching a large number
of closely spacedholes
vParting
• Parting is a operation in which metal is cut
simultaneously along two parallel lines or contour in
such a way that the side thrust in neutralised.
• Cutting of material between the two components from
parent material
vBENDING
Bending means deforming a flat sheet along a straight line to
form the required angle. Various sections like angles, channels
etc., are formed by bending, which may then be used for
fabrication of steel structures.
Three common methods of bending are illustrated inFig.
v EMBOSSING
• In embossing, impressions are made on sheet metal in such a manner that
the thickness of the sheet remains uniform all over even after embossing
has been done. It means that if one side of the sheet is raised to form a
design, there is a corresponding depression on the other side of the sheet.
Basically it is a pressing operation where not much force is needed. The
sheet is spread on the bottom die and the stroke of the punch is so
adjusted that, when it moves down to its lowest position, it leaves a
uniform clearance between the impressions carved in the punch and the
die which is equal to the thickness of the sheet being embossed.
Forming
•In forming operation, sheet metal is stressed beyond its yield
point so that it takes a permanent set and retains the new
shape.
•In this process, the shape of punch and die surface is directly
reproduced without any metal flow
•The operation is used in the manufacturing of door panels,
steel furniture, air-craft bodies, etc.
Coining (squeezing)
•In coining operation, the metal having good plasticity and proper
size is placed within the punch and die and a tremendous pressure
is applied on the blank from both ends
•Under severe compressive loads, the metal flows in the cold state
and fills up the cavity of the punch and die
•The operation is used in the manufacturing of coins, ornamental
parts etc
Deep drawing
•It is a process of making a cup-shaped parts from a flat sheet-metal
blank
•To provide necessary plasticity for working, the blank is first heated
and then placed in position over the die or cavity
•The punch descends and pushes the metal through the die to form a
cup, hence this process is called as cupping.
Thank you