Metal Deformation Processes

Module 1
Introduction to sheet metal working,
press-types and main parts of power
press
Press Tool / Sheet Metal Working:
• Press operations
• Press – types
• Classification of the press
• Main parts of the press
• Parts of the power press
• Etc.
MECHANICAL PRESSES
1. Bed:
• The bed is the lower part of the press frame that serves as a table to which a
• Bolster plate is mounted.
2: Bolster Plate:
• This is a thick plate secured to the press bed , which is used for locating and
• supporting the die assembly. It is usually 5 to 12.5 cm thick.
3: Die Set:
• It is unit assembly which incorporates a lower and upper shoe, two or more guide parts and guide part
bushings.
4: Die Block:
• It is a block or a plate which contains a die cavity
5: Lower Shoe:
• The lower shoe of the a die set is generally mounted on the bolster plate of a press. The die block is
mounted on the lower shoe, also the guide post are mounted on it.
6: Punch :
• This is male component of a die assembly, which is directly or indirectly moved by and fastened to the
press ram or slide.
7: Upper Shoe:
• This is the upper part of the die set which contains guide post bushings.
8: Punch Plate :
• The punch plate or punch retainer fits closely over the body of the punch and holds it in proper relative
position.
9: Back up Plate:
• Back up plate or pressure plate is placed so that intensity of pressure does
• not become excessive on punch holder. The plate distributes the pressure
• over a wide area and the intensity of pressure on the punch holder is reduced
• to avoid crushing.
10: Stripper:
• It is a plate which is used to strip the metal strip from cutting a non-cutting
• Punch or die. It may also guide the sheet.
 Press Operations
• Blanking
• Punching
• Shearing
• Bending
• Embossing
• Trimming
• Knurling
• Parting off
• Etc.
Blanking:

Blanking
Punching:
BLANK DIE-WORKING ANIMATION
CATIA DMU
Shearing:

Bending:
Bending
Shear angles on punch, die and on
Punch & Die combined
Bending Basics
V bending
Embossing:

Trimming:
Knurling:

Parting off:
 Press – types
Classification of power press:
• Hydraulic press
• Pneumatic press
• Press according to capacity (tonnage)
• Press according to requirements of die
• Press according to requirements of combination
die
• Press according to requirements of Ram
• Press according to weights
• Etc.
Mild Steel Hydraulic Press Machines Capacity 60 Tons, For
Industrial, Capacity: 40-100 Ton
Hydraulic Press Machine
Automatic Hydraulic Press
Pneumatic press
Pneumatic Press - YouTube
Pneumatic Presses by Transmatic: Dye
Fixation Machines
Press according to capacity (tonnage)
What does 20 tonne press mean? -
Quoraquora.com
Jh21-100 Ton Press Machine Capacity
 OLX
Hydraulic press 100 ton capacity with
10 hp motor - Electr
Press according to requirements of die
 Main parts of the press /
Parts of the power press
• Ram
• Slide
• Base plate
• Motor
• Drive
• Actuators
• Ejectors
• Etc.
 Die details and accessories
Die details:-
• Die opening
• Clearance
• Punch and die
• Clearance between punch and die
• Die clearance
• Other parameters such as Die Safety
• Etc.
Die Safety Blocks
Components of die/ Die details
Die Components
 Die accessories
It includes the following-
include Press Tool And Die such as Die Sets,
Pillar Die Sets, Press Tool Die, Turret Punch Press
Tools and Die Button.
• Moulds, Jigs and Casting Dies
• Plate patterns
• Press Tool Die
• Any Machine and Accessories Wear Spare
Parts Pulleys Adapters Holders Nozzles
• Punching Dies
• Precision Dies
Die set
 ResearchGate
Components of the die set. |
Download Scientific Diagram
Die Cutting Diagram
 Learn Mechanical
Die (Manufacturing):
Tool Materials and Die Wear
 Die accessories
• Stripper plate
• Ejector
• Stripper
• Pad
• Plate
• Die mounting
• Etc.
Metal cutting in a punch and die set up
• Due to shearing action
• Due to actuation of punch and die
• Due to pressure
• Due to ram application
• Due to force applied on the load
• Due to penetration of the material
• Due to ejection of the material
• Etc.
Components-of-die-and-punch-
assembly
 Types of Dies
• Simple die
• Compound die
• Progressive die
• Combination die
• Wiping die
• Bending die
• Coining die
• Wire drawing die
• Drawing die
• Etc.
Compound Dies - YouTube
working of Progressive die: Progressive
Die
Progressive Die Tooling Design
Combination Die
PunchAndDieClearance
Mate Precision Technologies
Die Clearance
 Effect of punching die angular
clearance on punched hole quality
ance, angular clearance
DIE CLEARANCE:

Angular clearance:
 Various press operations
• Blanking
• Punching
• Shearing
• Bending
• Embossing
• Trimming
• Knurling
• Parting off
• Drawing
• Deep drawing
• Shaving
• Lancing
• Etc.
 IndiaMART
Sheet Metal Dies, Sheet Metal
Punching Die
Sheet Metal Forming
 MachineSales.com
CNC Press Brake vs. Hydraulic Press
Brake
CNC Press Brake
 HARSLE MACHINE
PRESS BRAKE MACHINE FORMING
 Krrass
Hydraulic Press Brake working
principle
Sheet Metal Working - Scrap Strip
Layout
Strip Layout
 SlidePlayer
STRIP LAYOUT for BLANKING TOOL
Explain scrap strip layout ?
 SlidePlayer
STRIP LAYOUT for BLANKING TOOL. -
ppt video online download
https://www.google.com/url?sa=i&url
Design of press working tools stock
strip layout
 Tool Design
Strip layout/Scrap bridge & Economy
factor
Economy Factor in Strip Layout
Center of Pressure
Cutting Forces
Methods of reducing cutting forces
Sheet Metal Cutting (Shearing)
Types of blanking dies
Blanking die design
• There are two general types of blanking dies: the drop through dies and the inverted dies.

Drop through dies

• : In this die, the die block assembly is mounted on the bolster plate or the press bed and the
punch assembly on the press slide. The blank drops of its own weight through the die
opening and the clearance provided in the bolster plate and press bed. This design is
economical to build and maintain and is fast in working. This die is not suitable
under following cases:
• When blank is too thin and fragile to be dropped;
• When the blank is too heavy to be dropped;
• When the blank is too awkward to be removed from below the press;
• When the blank is larger than press bed opening.

Inverted die
• : In this die, the punch becomes the lower stationary part and the die is mounted on the
ram. This die is complicated, costly and slower in operation. The scrap disposal is easier but
blank removal from die opening requires use of some special knockout devices. This die is
used mostly for large and heavy blanks. Figure: 2.5.1: Inverted die
Design of Die Set (common to both piercing and blanking dies)
• The die set consists of die block, die shoe, guide posts, guide posts
bushings, punch, punch shoe, punch plate, backup plate, and fastening
elements.

Die block

• It may be solid single piece or assembled sectional pieces. If the die

opening is small and its contour is simple, a solid die block can be
selected. The sectional dies which are made up of accurately ground
matching components have following advantages:

• Dies with long and complicated contours can be broken up into sections of
simple geometrical forms which can be easily and economically machined.

• Building the die block in sections eliminate heat treatment and

accompanying distortions and cracking as the separate pieces handled are
more uniform in cross-section.

• Grinding of the sections is better-done. Figure: 2.5.2: Single piece die

• Maintenance of the die is simple and economical because if one section
happens to crack or damaged, only that particular section will need to be
replaced.
Industrial-Electronics.com
Die Design and Operation
Drawing- Blank size calculations
 YouTube
sheet Metal 03 Deep Drawing
 Science and Education Publishing
Effect of Die Design Parameters on
Thinning of Sheet Metal
Die Science: Deep drawing step by
step
Deep Drawing Operation in Sheet
Metal
Number of draws, drawing force
Bending- Bend allowance
Bend allowance and springback in air
bending
How to Calculate Bend Allowance for
Your Press Brake
Calculations
Bending force calculations
 1.2
Principles of rolling, forging:
Basic bulk deformation processes: (a)
rolling (b) forging
The working principle of rolling and its
processes
www.rajagiritech.ac.in
[PDF]FORGING
Closed Hot Forging Press
Drop, press, upset, roll forging,
extrusion, drawing, spinning
Extrusion design – dies & tooling
Hot and Cold working processes
Cold Working Processes
Cold Rolling
Metal Casting
Cold Rolling
Swaging, Forging
Extrusion- forward
Backward and impact
Backward Impact Extrusion
Roll Forming
 ResearchGate
Schematic representation of the roll
forming process
Tube Drawing, Wire Drawing
Drawing
Spinning (Metal spinning)
Types of forging presses
Advances in forging
 Module 2

Non-traditional machining
Electro Discharge Machining (EDM)
• Electrical discharge machining (EDM), also known
as spark machining, spark eroding, die sinking,
wire burning or wire erosion, is a metal
fabrication process whereby a desired shape is
obtained by using electrical discharges (sparks).
... The process depends upon the tool and work
piece not making physical contact.
References:
• https://nptel.ac.in/content/storage2/courses/112
105127/pdf/LM-39.pdf
• http://www.mitpublications.org/yellow_images/
75182-me-book.9-12.pdf
• An air gap of 0.005 to 0.05 mm is maintained between the tool and the
work.
• The die electric fluid which is non-conductor of electricity is forced under
pressure through the gap.
• When a DC power is supplied, the fluid in the gap gets ionized and
produces a spark between the tool and workpiece, causing a local rise in
temperature at about 1000 degrees Celsius, when melts the metal in a
small area of the workpiece and vaporizes.
• The DC supply generates a pulse between 40 to 3000 V and the
frequency of spark at the rate of 10000 sparks per second can be
achieved.
• The electric and magnetic fields on heated metal cause a compressive
force which removes the metal from the work surface.
• The die electric fluid acts as a coolant carry the cooled metal from the
work surface.
• The die electric fluid acts as a coolant carries the eroded metal particles
which are filtered regularly and supplied back to the tank.
• A servomechanism is used to feed the tool continues to maintain a
constant gap between two electrodes.
• The accuracy of about 0.005 mm can be achieved in this process.
 Working Principle of EDM
• Working principle: The principle of working of
EDM is based on the erosion of the material by
repetitive sparks between the workpiece and
the tool submerged in a bath of the dielectric
medium. The working system is illustrated in Fig.
2.1. The workpiece and tools are two electrodes
connected by D.C pulse generator.
• It consists of an electric power supply, the
dielectric medium, the tool, workpiece, and servo
control.
• The workpiece is connected to the positive
terminal and the tool is connected to a negative
terminal of the DC power supply.
 Applications of Electro Discharge
Machining:
These are some of the applications of Electro
discharge machining:
• Drilling for micro holes in the nozzle.
• This is used in thread cutting.
• Used in wire cutting.
• Rotary form cutting.
• Helical profile milling.
• Curved hole drilling.
• Engraving operation on harder materials.
• Cutting off operation.
• The shaping of alloy steel and tungsten carbide
dies.
 Advantages of Electrical Discharge
Machining:
Here are some advantages of Electro discharge machining:
• It can be used for any hard material and even in the heat-
treated condition.
• Any complicated shapes made on the tool can be reproduced.
• High accuracy of about 0.005 mm can be achieved.
• Good surface finish can be achieved economically up to 0.2
microns.
• Machining time is less than the conventional machining
process.
• No mechanical stresses are developed in this process (There is
no contact between tool and work)
• Higher tool life due to proper lubrication and cooling.
• Hard and erosion resistant surface on the dies can be developed
easily.
• It can be applied to any electrically conductive materials.
 Disadvantages of Electrical Discharge
Machining:
Electro discharge machining still has some
disadvantages and those are:
• Excessive tool wear.
• High power consumption.
• The sharp corner cannot be reproduced.
• High heat developing causing the change in
metallurgical properties of materials.
• The workpiece must be an electrical conductor.
• Surface cracking may take place in some materials.
• Redressing of a tool is required for deep holes.
• Over-cut is formed.
• Difficult finding expert machinists.
 Summary of EDM:-
What are the applications of EDM?
1. Drilling for micro holes in the nozzle.
2. This is used in thread cutting.
3. Used in wire cutting.
4. Rotary form cutting.
5. Helical profile milling.

What is EDM?
• Electrical Discharge machining is the process of metal removal
from the work surface due to an erosion of metal caused by
electric spark discharge between the two electrodes tool
(cathode) and the work (Anode).

What does an EDM machine do?

• This is a manufacturing operation in which we used to make
desired shapes by using an electrical spark.
Electro Chemical Machining (ECM)
• Electrochemical machining is a method of
removing metal by an electrochemical
process.
• It is normally used for mass production and is
used for working extremely hard materials or
materials that are difficult to machine using
conventional methods.
• Its use is limited to electrically conductive
materials.
• Electrochemical machining (ECM) is a method of
removing metal by an electrochemical process. It
is normally used for mass production and is used
for working extremely hard materials or materials
that are difficult to machine using conventional
methods.[1] Its use is limited to electrically
conductive materials. ECM can cut small or odd-
shaped angles, intricate contours or cavities
in hard and exotic metals, such as titanium
aluminides, Inconel, Waspaloy, and
high nickel, cobalt, and rhenium alloys.[2] Both
external and internal geometries can be
machined.
• ECM is often characterized as "reverse electroplating",
in that it removes material instead of adding it.[2]
• It is similar in concept to electrical discharge
machining (EDM) in that a high current is passed
between an electrode and the part, through
an electrolytic material removal process having a
negatively charged electrode (cathode), a conductive
fluid (electrolyte), and a conductive workpiece (anode);
however, in ECM there is no tool wear.[1]
• The ECM cutting tool is guided along the desired path
close to the work but without touching the piece.
Unlike EDM, however, no sparks are created. High
metal removal rates are possible with ECM, with no
thermal or mechanical stresses being transferred to the
part, and mirror surface finishes can be achieved.
• In the ECM process, a cathode (tool) is
advanced into an anode (workpiece).
• The pressurized electrolyte is injected at a set
temperature to the area being cut.
• The feed rate is the same as the rate of
"liquefication" of the material.
• The gap between the tool and the workpiece
varies within 80–800 micrometers (0.003–
0.030 in.)[1] As electrons cross the gap,
material from the workpiece is dissolved, as
the tool forms the desired shape in the
workpiece. The electrolytic fluid carries away
the metal hydroxide formed in the process.[
 Applications of ECM:-
• The ECM process is most widely used to produce
complicated shapes such as turbine blades with
good surface finish in difficult to machine
materials.
• It is also widely and effectively used as
a deburring process.[2]
• In deburring, ECM removes metal projections left
from the machining process, and so dulls sharp
edges. This process is fast and often more
convenient than the conventional methods of
deburring by hand or nontraditional machining
processes.
 Advantages of ECM

• Complex concave curvature components can be

produced easily by using concave tools.
• Tool wear is zero, same tool can be used for producing
infinite number of components.
• High surface quality may be achieved.
• No direct contact between tool and work material so
there are no forces and residual stresses.
• The surface finish produced is excellent.
• Less heat is generated. [4]
 Disadvantages of ECM
• The saline (or acidic) electrolyte poses the risk
of corrosion to tool, workpiece and
equipment.[2]
• Only electrically conductive materials can be
machined. High Specific Energy consumption.
• It can not be used for soft material.
 Applications of ECM
Some of the very basic applications of ECM
include:
• Die-sinking operations
• Drilling jet engine turbine blades
• Multiple hole drilling
• Machining steam Turbine blades within close
limits
• Micro machining
• Profiling and contouring
• Rifling barrel
 Similarities between EDM and ECM
• The tool and workpiece are separated by a very small
gap, i.e. no contact in between them is made.
• The tool and material must both be conductors of
electricity.
• Needs high capital investment.
• Systems consume much power.
• A fluid is used as a medium between the tool and the
work piece (conductive for ECM and dielectric for
EDM).
• The tool is fed continuously towards the workpiece to
maintain a constant gap between them (ECM may
incorporate intermittent or cyclic, typically partial, tool
withdrawal)
ECM
Water jet Machining (WJM)
 ScienceDirect.com
Water Jet Machining - an overview
Abrasive Water Jet Machining (AWJM)
 AWJM
• 1.The AWJM process produces very small stresses
and negligible heat and is suitable for heat-
sensitive materials such as plastics.
• 2.The process is suitable for cutting complex
contours on wide range of materials.
• 3.The process has the capability to cut thin pieces
with least bending.
• 4.The process is comparatively faster due to
combined action of waterjet and abrasive action.
• The main disadvantages of this process include
the limited range of surface finish, the expensive
equipment, as well as safety issues.
Laser Beam Machining (LBM)
Laser Beam Machining Principles and
Applications
LBM
Electron Beam Machining (EBM)
 Mitsubishi Electric
Electron Beam Machines
Plasma Arc Machining (PAM)
Ultrasonic Machining (USM)
USM
 ethesis
[PDF]Study of Parameters of
Ultrasonic machining
USM