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 PRESS TOOL
SR CONTENT PAGE
NO. NO
1 INTRODUCTION TO PRESS TOOL.
2 BLANKING TOOL.
3 PIERCING TOOL.
4 COMPOUND TOOL.
5 PROGRESSIVE TOOL.
6 FORMING TOOL.
7 DRAW TOOL.
 INTRODUCTION
• Press tool is a custom assembly device use to
produce desired parts from sheet metal without
producing chips but scrap may produce.
• Depending on the operation it is categorized as
cutting and noncutting tool.
Cutting operation includes the particular tools
like blanking, piercing, notching etc. and non-
cutting operation includes U- bend, V-bend tool
(forming tool), Draw tool.
• Sheet metal items such as automobile parts (roofs,
fenders, caps, etc.), components of air crafts parts of
business machines, household appliances, sheet metal
parts of electronic equipments Precision parts required
for horlogical industry etc, are manufacture by press
tools.
Press Tools & Operations
Blanking:
Blanking is a process of producing flat
stampings.

The entire periphery is cut from the

raw strip and cut out piece is called as the
blank which is our required part.
Piercing:
It is the operation of making hole in the
stamping. Here also the entire periphery is cut
and cut piece is a scrap.
Cut-off:
Cut off operation separates the work
material along a straight line or angular or
irregular in a single cut. No scrap is produced
in cut-off operation or may produce for the
initial and final operation on the strip.
Parting off:
Parting off is an operation which involves cut-
off operation to produce blank from the strip
as shown in the figure. During parting, some
scrape is produced. There fore, parting is the
next best method for cutting blanks.
• Perforating:
If more number of holes are pierced, it is called
perforating.
• Side cam tool :
Side cam transforms vertical motion from the
press ram into horizontal or angular motion in the
tool.
Dinking:
To cut paper, leather, cloth, rubber and
other soft materials a dinking tool is used. The
cutting edges penetrate the material and cuts.
The die will be usually a plane material like
wood or hard rubber.
Trimming:
It is the operation of cutting the edges of
the drawn components which are wavy and
irregular. The term trimming is also used when
the material of a strip or the portion of a
blanked component or a portion of a pierced
hole is partially removed.
Shaving:
It is an operation of removing a small
amount of material a around the edges of a
previously blanked stampings or pierced hole
to get a good finish on the cut edges and
accurate dimensions with min. radius at the
edge of the component.
Broaching:
It is similar to shaving operation. In this a
tool having a
series of teeth profile removes metal from the
edges of the
blanked component in a progressive way.
Lancing:
It is a combination of cutting and bending
operation along a line in the work material i.e.
three side cut & one side bend.
Bending:

It is the shaping of material around a

straight axis which extends completely across
the material. The result is a plane surface at an
angle to the original plane of the flat blanked
component.
Forming:
It is similar to bending except that the line
of bend is along a curved axis instead of a
straight one.
Drawing:
In drawing a flat blank is transformed into a
cup or shell.
Shell or cup produced may be
cylindrical or rectangular with straight or
tapered sides.
Curling:
It is an operation of rolling the edges
of a sheet metal into a curl or roll. It improves
the appearance of the piece part. It is also
increase strength.

EXAMPLE:- Hinge
Bulging:

It is an internal forming operation used

to expand portions of a drawn shell or tube.
The more common media are
rubber, urethane, oil, or water
Swaging:

The operation of swaging some times

called necking is exactly the opposite of
bulging.
Extrusion:

This is a special process to manufacture

collapsible tubes, shells etc. The blank which is
loaded in the die, is forged upward or
downward under high pressure between
punch and die.
Coining:
It is the process of pressing cold material
in a tool so that it flows into the engraved
profiles on the die face.
Assembly tool:
Assembly tool assemble two or more parts
together by press fittings ,riveting or other
means.
Planishing:
Planishing tool is used to straighten,
blanked components. Very fine serration
points penetrate all around the surface of the
component.
Progressive tool :

progressive tool are those in which

progressive tools perform work at a number of
stations simultaneously. A final component is
taken off at final station, with each stroke of
press.
Flaring, lugging or collar drawing:
The process of forming an outward flange on
parts is called flaring operation.
Compound tool :

In compound tool all or maximum

features of the component can be produced in
one stroke of the ram. Basically compound
tools are inverted tool. Used to maintain high
accuracy between the features and to get burr
on same side.
Combination tool :

In combination tool two or more

operations such as forming, drawing,
extruding, embossing may be combined on the
component with various cutting operations like
blanking, piercing, broaching and cut off.
Sub press tool:

Sub press tools blank and form very small

parts. the die components are retained in a
sub press. Sub press is a small press which is
operated in large one.
Choice of strip layout method.

• Blanking tools produce blanks out of the strip or unit stock.

• Blanking is the most efficient and popular way of producing
intricate
and closely tolerated blanks.
• The profile and accuracy built into the tool will be reproduced on
the blank.
• In the strip layout, blanks can be positioned in different ways in
the strip.
 STRIP LAYOUT

A strip layout represents the sequence of the logical, workable operations, which is
to say a sequence of ideas.
If this sequence of operations has error, the error will be surely emerge in a try out
press.

Factors to be considered while designing the layout are.

1. Shape of the blank.
2. Production requirement.
3. Grain direction.
4. Burr side.
5. Stock material.
Shape of the blank:
•The contour of the blank, decides the position of the strip.
•Some of the blanks are laid at an angle.

Production Requirement:
•If production requirement is less, then material conservation is necessary.
•This must not increase the tool cost.
•Gang die may be suitable for the mass production.

Grain Direction:
•The grains are found in the sheets when they are rolled.
•Bending the strip along the grain direction results in crack and fracture.

Burr Side:
•It is a decisive factor in laying the strip.
•In blanking, burr is found on the punch side.
•In piercing ,burr is found on the die side.

Stock Material:
•Every means is to be seen to conserve the stock material.
•A double pass layout would justify the cost of stock material conserved.
EXAMPLE
TERMS TO BE CONSIDERED AND CALCULATED IN STRIP LAYOUT:

Pitch(p):
Distance between two consecutive operations on a strip.

Scrap bridge (b):

This is the portion of the material remaining after blanking operation between
one edge of the strip and the cutout portion. The portion of material remaining between
the two adjacent openings after blanking is also called as the scrap bridge.

Front Scrap:
This is the scrap bridge on that edge of the strip which is towards the operator.

Back Scrap:
This is the scrap bridge on that edge of the strip which is away from the operator

Width of Strip: component size + scrap bridge

ECONOMY FEACTOR:

Calculate the economy factor to punch the mild steel washer in single row feeding.
Outside diameter is 30mm, Inside diameter is 18mm and Thickness is 2mm
Scrap bridge width is = 1.2 x t
Scrap bridge width = 1.2 x 2
=2.4 mm
Pitch = 30 + 2.4 = 32 mm
Strip width = 30 + 4.8 = 34.8 mm
Number of rows = one
Area of blank = Л D²
4
= Л 30²
4
= 706.65 mm²

Area of blank x No. of rows x 100

pitch x strip width
Calculate the economy factor to punch the same washer in
double row feeding
Single row one pass layout

• This is the most popular way of laying out the strip.

• The blanks are arranged in a single row.

• The strip is passed through the tool only once to punch out the
blanks from it.

• There are two possible ways of laying out this strip.

• Narrow run.

• Wide run.
WIDE RUN

• Wide run is more desirable due to the following reasons.

• Shorter advance distance of the strip feeding promotes easy
• More" blanks could be produced from a given length of strip compared
to narrow run.
• Fewer number of strips are to be handled to produce a given
number of blanks.
• Narrow run is used when the grain direction of the piece part
has importance.
BLANKS HAVING AT LEAST TWO STRAIGHT PARALLEL
EDGES.
• In such cases the strip width should be equal to the distance between the
parallel sides.
• The blanks are produced by a cut off or parting operation.
• If the blank has got two sets of parallel sides, a cut off operation is sufficient
to produce the blanks.
• But if the blank has got only one set of parallel sides, these sides become
the sides of the stock strip and the other non-parallel sides are produced by
a parting operation.
STRIP LAYOUT FOR CUT OFF AND PARTING
• Cut off punch cuts with only one edge.
• No scrap is produced.
• A parting punch cuts with two opposite edges thereby producing a scrap.

NOTCHING
• Notching is a cutting operation for cutting off small portions from the edge
of a strip or a pre blanked component.
STRIP LAYOUT FOR CUT OFF
• Cut off punch cuts with only one edge.
• No scrap is produced.
• A parting punch cuts with two opposite edges thereby producing a
scrap.
• Trimming is an operation of cutting off material to alter the shape
of the
strip or blank.
• In notching only a small area of the blank is cut off.
• In trimming a larger area of material is removed.
• Blank can be produced by combining notching, trimming and
piercing
operations with cut off or parting operations.
 BLANKS HAVING IRREGULAR CONTOUR

• The following factors must be considered before determining

the best method of positioning a blank in the strip.

1. Contour.
2. Minimum material wastage.
3. Less tool cost.
4. No scrap strip to handle which renders the production faster.
5. Accuracy in strip width.
6. Accuracy of the blank.
7. Flatness.
 CONTOUR.

• If the blank has two parallel sides, it can be produced by cut off
operation.

• The advantages of cut off or parting operation are:

• Minimum material wastage.
• Less tool cost.
• No scrap strip to handle.
• Speeds up production.
 ACCURACY IN STRIP WIDTH.

• Sheared strips cannot be held to an accuracy closer than ± 0,2mm.

• If the blank must be held to close limits on its width sides cutting off or
parting cannot be employed.
• When the blank dimensions are to be controlled to close limits it
should be produced with a blanking tool, regardless of the parallel
sides it may contain.

FLATNESS.

• If the blank has to be flat, a blanking tool is preferred.

• A blanking tool produce considerably flatter components than other tools.
 SINGLE ROW TWO PASS METHOD

• This strip layout demands the strip to be fed twice through the tool.

• This is to achieve greater economy in stock material utilization.

• A two pass tool requires two stops.

• The stop used for the first pass should be removed or made to retract
spring loaded stoppers) from the working surface so as not to interfere
with the second pass.
• The front and back scrap as well as the scrap bridge should be
wider than those for he single pass (about 50 to 100%).

• Two pass layouts are justified only when the wastage is

considerable and
the stock material is costly.
 DOUBLE ROW LAYOUT.

• Higher economy can be attained by positioning the blanks in double rows.

 GANG DIES
• A gang die consists of two or more similar sets of tool members so as to
produce 2 or more number of components during a single stroke of the
press ram.
• A gang die eliminates the cumbersome process of double pass.
• The higher tool cost will be off set by higher rate of production.
• Gang dies are not recommended for very complex work.
 ANGULAR LAYOUT

Some of the piece parts will be require to be laid out to an angular position to
make the layout more economical.
ASSIGNMENTS
 BLANKING TOOL
• Design Guidelines:
 In blanking operation the blank produced is a desired part and rest is scrap.

 Identify the operation i.e. blanking.

 Required design- Blanking tool.
 Cutting Clearance:
CC = c X t X (Ʈ/10)1/2

c - 0.01- For average work t – sheet thickness in mm, 1250

c - 0.005 - For precise work
Ʈ – shear strength in N/mm2
 Strip layout:
Scrap bridge (b): 1.2 X t t - sheet thickness. b

We shall get factors i.e. P (pitch) and W (width) from strip layout.

Economy Factor: Use maximum percentage of strip from available

raw material.

E.F. = Area of blank X no. of row

Pitch X Width
 Sizes for punch and die:
Die size = part size
Punch size = part size – cutting clearance. COMPONENT
 Plate Thickness

• Die plate thickness (Dpt) = (cutting force in ton) 0.33 ͢ (cm)

• Top/Bottom plate thickness

= 1.5 x Dpt
• Punch Holder = Dpt

• Stripper plate = 0.8 x Dpt

• Thrust or impact plate (if required)

= 6 to 8 mm

Cutting force = L X t X Ʈmax

L – Cutting length in mm,

t – sheet thickness in mm,
Ʈ – shear strength in N/mm2

Press tonnage = 1.5 X cutting force

in ton.
 PIERCING TOOL
 In piercing operation the blank produced is a scrap and pierced hole is desired.
• Design Guideline:
• Identify the operation i.e. Piercing
• Required design- Piercing tool.
• Cutting Clearance
CC = c X t X (Ʈ/10)1/2
c - 0.01- For average work
t – sheet thickness in mm,
Ʈ – shear strength in N/mm2
c - 0.005 - For precise work
• Sizes for punch and die:
Die size = part size + cutting clearance
Punch size = Hole size (part size).
Actual punch size= desired hole+0.2
Actual die button size= Actual punch size + CC.
Minimum length of die button= 30 mm
• Cutting force = L X t X Ʈ
L – Cutting length in mm,
t – sheet thickness in mm,
Ʈ – shear strength in N/mm2
• Press tonnage = 1.5 X cutting force in ton
COMPOUND TOOL
PROGRESSIVE TOOL
 FORMING TOOL (V-BEND)
• Identify the operation i.e. FORMING
• Required design- Forming Tool.
• Flat blank length= L1+L2+A
• A=2πθ(R+0.5*T)/360
• Spring back Assumption = 2⁰
• Bending force calculation : KLF𝑇 2 /W ,
• W=WIDHT OF DIE

PUNCH AND DIE ARRANGEMENT COMPONENT

 U(CHANNEL)-BEND
• Identify the operation i.e. FORMING
• Required design- Forming Tool.
• Flat blank length= L1+L2+L3+A
• A=2πθ(R+0.5*T)/360
• Spring back Assumption = 2⁰
• Bending force calculation : 2KLF𝑇 2 /W , W=WIDHT OF DIE.

PUNCH AND DIE ARRANGEMENT COMPONENT