BHARATI VIDYAPEETH COLLEGE OF ENGINEERING, NAVI MUMBAI

DEPARTMENT OF MECHANICAL ENGINEERING

2023_24 - UT II
PTD Question bank
1 What are the defects in drawn as well as bent parts?

Defects in Drawn parts: Wrinkling in flange, Wrinkling in walls, Tearing (at neck/corner of cup), earing
(irregularities due to anisotropic properties), Surface scratches(due to dirt, marks on die or punch).

Defects in bending: Spring back, Improper ejection , Score marks, Cracking, Thinning,
2 Why guide bushes and pillars are hardened?

Guide bushes and pillars are subjected to repetitive sliding motion causing wear of material. To prevent
wear, surface of pillars and bushes are hardened to develop wear resistant properties.
3 Define coining and embossing.
Coining :
In this process, the metal is squeezed by the compressive force of the punch and the die, as well as edge
restraining discs. It changes the thickness of the material. E.g Coins, Medals, badges..

Embossing :
Here there is no change in thickness of the metal, as the component takes the shape of the male punch. Here,
one side has protrusions, whereas the other side has depressions.

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4 State types of Bending die.
1. V Bending, 2. Wiping or Edge Bending and 3. Channel or U double or U bending

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5 What is shut height and day light height, illustrate with a sketch
Shut height: The distance from the top of the bed to the bottom of the slide of a vertical press, with stroke
down(Bottom dead centre) and adjustment up.

Daylight height : The distance from the top of the bed to the bottom of the slide of a vertical press, with
stroke up (Top dead centre) and adjustment down.

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6 What are the various types of dies used in press working?
Simple die, Compound die, Combination die, Progressive die, transfer die etc
Explain construction and working of one of them with appropriate sketch .
Compound die: In these dies, two or more operations may be performed at one station. Such dies are
considered as cutting tools since, only cutting operations are carried out. Fig shows a simple compound die
in which a washer is made by one stroke of the press. The washer is produced by simultaneous blanking and
piercing operations. Compound dies are more accurate and economical in mass production as compared to
single operation dies

Combination Die :
.It differs from compound die in that in this die, a cutting operation is combined with a bending or drawing

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 operation. Fig.explains the working of a combination of blanking and drawing operation to make a cup..A
drawing punch of required shape is fastened to the die shoe. The blanking punch is secured to the punch

holder.
Progressive die:
A progressive or follow
on die has a series of stations. At each station, an operation is performed on a workpiece during a stroke of
the press. Between stroke, the piece in the metal strip is transferred to the next station. A finished workpiece
is made at each stroke of the press. A progressive die is shown in Fig. While the piercing punch cuts a hole
in the stock, the blanking punch blanks out a portion of the metal in which a hole had been pierced at a
previous station. Thus after the first stroke, when only a hole will be punched, each stroke of the press
produces a finished washer.

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7 A cup 105mm inside diameter and 90mm deep is to be drawn from Steel sheet 1mm thick. Yield
Strength: 35 kgf/mm2. (Assume negligible corner radius of cup)

Determine following. Blank size, Number of draws, Percentage reduction for each draw, Die
clearance, punch diameter and die opening size at each draw, Die clearance, punch diameter and die
opening size at each draw, and Drawing force.
Data given:
d = 105 mm, h = 90 mm, t = 1mm. YS = 35 kgf/mm2 , r = negligible

i) Blank size (D) : As d/r >> 20 , D = + trimming allownces

D = 220.9 + 3+3+3+3+3 = 235.9
ii)Number of draws : h/d = 90/105 =0.85 , it is deep draw,
Total reduction = (235.9-105)/235.9 = 55.57 % , Thus more than one draw is required
from table no of draws = 2
iii) Percentage reduction for each draw
Ist draw – allowed reduction is 45 %
(D-d1)/ D = 45% i.e d1 = 129.74 mm

IInd draw reduction = (129.74 – 105)/129.74 = 19.06% , which is more than allowable (30%)

Thus reduction in
Ist draw = 45 %
IInd = 19.06%

iv) Die clearance, punch diameter and die opening size at each draw
Draw No Punch dia (Dp) Die opening size (Dd) Die clearance ©
I d1 - 2*t Dp + 2*C 1.08 t to 1.11 t, say
129.74- 2*1 127.74 + 2.18 1.09t
127.74 129.92 1.09 mm
II 105- 2 103+2* 1.1 1.09 t to 1.12 t
1.1 t
103 105.2 mm 1.1 mm

v) Drawing force : = 190KN

8 What is spring back? How it can be compensated.
Spring back. At the end of the bending operation, when the pressure on the metal is
released, there is an elastic recovery by the material. This causes a decrease in the bend angle and this
phenomenon is termed as spring back.

To overcome the effect

1. The part is overbent by an angle equal to spring-back angle by having the face of the punch
undercut or relieved.

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 2. To overcome springback, the bend area is often placed under high compressive stress to set the
metal. This is called “Bottoming”. It is achieved by having a projection or bead on the punch

9 Differentiate between a cutting die and a forming(drawing/bending) die.

Cutting die Forming die
1.Shearing operation or physical separation of 1. Plastic deformation of sheet, change the shape of
material happens. stock
2. Force requirement is less (upto penetration of 2. Force requirement is more, as may require blank
sheet only) holding, drawing or bending force and bottoming
3. Simple mechanical presses are recommended force.
and economical. 3. Mechanica and also hydraulic presses are
recommended for mass production

10 Sketch the various mechanical press drives.

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11 What factors should be considered for selecting an appropriate press for a given job?

The factors which should be considered while selecting a press for a given job, are : the overall work size,
the stock thickness and material, kind of operation to be performed, power required and speed of operation.

For punching, blanking and trimming operations, usually the crank or eccentric type mechanical press is
used. This is due to their small working strokes and high production rates. In these operations, there is
sudden release of load at the end of the cutting stroke.

For coining and other squeezing operations, which require very large forces, knuckle joint mechanical press
is ideally suited. Hydraulic presses, which are slower and more powerful, can also be used for these
operations. Hydraulic presses are also better adapted to pressing, forming and drawing operations, which are
basically slower processes. Hydraulic presses can generate nearly 10 times more force than mechanical
presses and can also be used for large components.

12 Define “Deep Drawability”.

If the depth of the formed cup is upto half its diameter, the process is called “Shallow drawing”. If the depth
of the formed cup exceeds the diameter, it is termed as “Deep Drawing”.
13 What is the purpose of pressure pad in drawing a cup?
A pressure pad may be necessary when the workpiece contains sharp radii or intricate details or when the
workpiece may shift during the forming operations.
14 Why more than one draw is needed to draw a deep cup?
The stresses which can be imposed on the work material during the drawing process limits the amounts of
reduction in the blank diameter, and it may not be possible to go beyond certain percent of reduction in a
draw. Hence more number of draws are needed.
15 What are the various methods of bending? Sketch these.
Shown earlier

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16 How do hydraulic drives compare with mechanical drives for presses?
Press brake (mechanical) Hydraulic press brake

The ram of a mechanical press brake is actuated by a The ram is actuated by the double acting
crank or an eccentric through a gear train in which there cylinders one at each end of the ram.
is a clutch and a flywheel. The gear train is usually
designed to provide fast movement of the ram.

Shut height is adjustable by means of a screw (usually

powered) in the pit man. The length of ram stroke is
constant.

One advantage of this press over hydraulic is that it Force supplied by the press will not exceed
develops greater than rated tonnage, because of the the press rating. Therefore it is impossible to
inertia of the flywheel moving the ram and mechanical overload a hydraulic press brake.(when
advantage of the crank near the BDC. As a result most thicker metal is used inadvertently, the ram
mechanical presses are provided with extra strong frames stalls).
to allow for occasional overloading. It should not be
encored as it causes serious damage to the press brake
from improper setup.

Higher operating speed which is useful for longer

production runs of workpiece that are easily handled.

Stroke can not be adjusted or controlled to the same In hydraulic press brake, length of the stroke
degree as is possible with the hydraulic type. Even and location of the top and bottom of the
though devices are available that permit some control of a stroke (within the limits of the cylinder) are
mechanical press brake, the degree of control that is adjustable. The point of rapid advance and
possible for hydraulic press brake is considerably greater. return of the ram and its speed during
contact with the workpiece are adjustable.
The adjustable makes possible a dwell
period. The degree of stroke control, a
hydraulic press brake is often preferred for
segmental forming.

A mechanical press brake is usually preferred for Conversely a hydraulic press is generally
quantity production because its speed is greater than that preferred for varied short run production
of hydraulic press brake. because it is more versatile in size, shape,
tonnage.

17 What is the usual reduction for the first and the succeeding draws?
45 % for 1st draw and 30 % for 2nd draw
18 A press has minimum of DLH 300 mm and press adjustment of slide of 75 mm. Stroke can be varied
from 12.5 mm to 100 mm. Draw appropriate sketch and calculate permitted shut height for die if
stroke is fixed at 50 mm.

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 As seen from sketch
Min DLH = 300
DLH for 50 mm stroke = Min DLH + 18.75 = 318.75
Min SH for 50 mm stroke = Min DLH – required stroke = 318.75 – 50 =268.75
Max SH for 50 mm stroke = Min SH + PA = 268.75 + 75 = 343.75

19

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 L1 = 300- 30m = 270
L3 = 200-30-30 = 140
L5 = 100-30 =m 70
L2 = L4 : (radius of inner edge >=2 *t) 20>=20 , distance of neutral axis from inner edge is 0.5 * t
L2 = L4 = 90 * π/180 (20 + 10 *.5) = 39.27
L6 : (radius of inner edge >=2 *t) 150>=20 , distance of neutral axis from inner edge is 0.5 * t
L6 = = 180 * π/180 (150 + 10 *.5) = 489.9

Developed length = L1 + …+ L6 = 1048.44

20 Explain safety features in press

Emergency Stop Button: An easily accessible emergency stop button allows operators to quickly halt the
operation of the press in case of an emergency.
Safety Guards: Safety guards are physical barriers or enclosures designed to prevent operators from
coming into contact with moving parts or hazardous areas of the press.
Two-Hand Controls: Use both hands simultaneously to initiate the press cycle ensures that operators keep
their hands clear of the point of operation during the stamping process.
Light Curtains: An array of light beams around the point of operation, interupting these beams, the press
machine stops automatically, preventing injuries.
Sensing Devices: Detect the presence of operators or objects within a specified area and stop the machine to
prevent accidents.
Die Safety Blocks: Physical barriers placed between the upper and lower dies to prevent unintentional
closure of the press when setting up or servicing the tooling.
Automatic Shut-Off Systems: To monitor various parameters such as hydraulic pressure, temperature, or
electrical current, exceeding which, machine will stop.
Noise Reduction Measures: Noise reduction measures such as soundproof enclosures or damping materials
help mitigate risk of high level noise.
Training and Safety Procedures: Comprehensive training programs and safety procedures educate
operators on how to safely operate press machines, recognize hazards, and respond to emergencies.
Regular Maintenance and Inspections: Checking for worn or damaged components, lubricating moving
parts, and addressing any safety concerns promptly.
21 State the various materials used for press tools (dies and punch)
1. Zn alloy
2. Water hardening steel : 0.6-1.4C, Hardness = 62-66HRC
3. Oil hardening steel : 0.9 C, 1 Mn, 0.5Cr, Hardness = 57-62 HRC
4. Air hardening steel : 1C, 5Cr, 1Mo, Hardness = 57-62 HRC

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 5. Cold working die steel : 1.5C, 12Cr, 1Mo, Hardness = 58-64 HRC
6. Water hardening steel, Hardness = 60-62 HRC
7. Mo H.S.S., Hardness = 60-65 HRC
8. WC

In general, the following materials are used for press tool component.
Mild steel(MS): Most of the parts which do not require hardening are made from this cheap material. The
parts which require hard skin can also be made from this material. They can be case hardened to provide
tough exterior surface.. Thus, guide pillars and bushes, as well as cheap bending drawing dies and punches
used for non-cutting can be made form case hardened mild steel.
Carbon steel(CS): High carben steel (0.85% C) can be water hardened upto 61 HRC, which can be used
for styudy dies and punches. Surface hardened of this material often causes distortion due to heat treatment,
which need additional grinding operation. C40 steels are used for elements like screw subjected to high
tensile stresses.
High carbon high chromium (HCHC) non shrinking tool steel : This steel have less distortion with heat
treatment. And are more suitable to Delicate and slender punches.
Cast Iron : Strength of CI being less than MS, they require hevier section and suitable for top and bolter
plate of die set. Drawing dies for non ferrouis material can also be made from CI.
Rubber : Rubber pads are fast replacing material for springs in drawing tools. They provide good
compressive strength and are less immune for damage.

22 Explain overloading of Presses with respect to load and energy considerations.

Load capacity : Though press is capable of exerting more force at dead ends, press members such as cranks
and connecting links cannot be designed for infinite load. They have to be designed for finite force. This
safe finite force is to be determined by the dimensions, strength and allowable deflections of press
components such as press frame, connecting link, crank etc. This safe value is known as press capacity and
specified as tonnage at crank angle. Let us say press of 63T at 20 degrees.

Energy consideration: A press is designed to exert defined amount of force at given crank angle  . Main
crankshaft is designed keeping in view some value of torque. The energy needed for cutting and forming
operations during each stroke is supplied by the flywheel. Flywheel slows down to a permissible percentage,
usually 10−20% of its idle speed, releasing some limited value of energy, after every stroke. This energy
supplied (limited value) by flywheel must be more than energy needed for operations, which ensures energy
satisfying criteria, else it would be energy overloading.

23 Give reasons for the following:

i) Shear is provided on die in blanking operation
Size of blank is decided by the size of die opening. Hence, in order to reduce cutting force, shear is
provide on die in blanking operation.
ii) Correct orientation of grain direction is necessary in arranging the strip layout.
Normally, the grain of coiled strip is parallel to its length. To eliminate any tendency to fracture, the forming
operating are usually performed perpendicular to the grain. Thus, while layout of the developed blank, the
bend line is kept perpendicular to the strip
iii) Shaving operation is needed after blanking operation.
The edges of a blanked part are generally rough, uneven and unsquare. In order to get Accurate dimensions
of the part, shaving operation is done after blanking removing a thin strip of metal along the edges
iv) Clearance is provided on punch in blanking operation.
In blanking operation, where the slug or blank is the desired part and has to be made of required Size. This
required blank size equals the die opening size and the punch size is obtained by subtracting the clearance
from the die-opening size
v) Cutting and non-cutting operations are not combined in one station of progressive die
Cutting and non-cutting operations often require different types of tooling, such as punches, dies, and
forming tools. Combining these operations in one station would require complex tooling setups that may not

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 be feasible or practical. Combining these operations in one station would likely result in slower production
speeds and increased downtime for tool changes and adjustments
25 What is press tonnage? How it is decided?
A press is engineered to apply a specific amount of force or tonnage at a given crank angle. While a press
can generate significant force at dead ends, certain components such as cranks and connecting links cannot
sustain such immense loads. They must instead be designed to handle a finite force. This safe limit is
determined by considering the dimensions, strength, and permissible deflections of press elements like the
frame, connecting link, and crank. This safe value, referred to as press capacity or press tonnage, is
accessible at a particular crank angle. For instance, a press may be rated at 63 tons at a 20-degree crank
angle.

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