CHAPTER 1

1. INTRODUCTION

Processing steps involved in sheet metal industries, and increased knowledge in this process will
help to improve the process and help in increase the production range of industry.

Now a day’s sheet metal component are widely used in the day today life its ranging from
household electrical component to big industries such as TV, camera, electrical ovens, computer
as well as in automotive parts, aviation industries to reduce the cost as well as reduce the weight
of the component and increase the performance of the product. Sheets with 0.2 to 20 mm thickness
and higher are processed in industries depending on the requirement of customer or consumer or
appl Forming processes like Piercing, Blanking, stamping and bending are very widely used in the
making of sheet metal parts and it assembles different processes to manufacture sheet metal parts.
Piercing and Blanking are metal shearing processes in which the input sheet material is sheared to
a destination shape. In blanking, the blanked piece of material is the product and while in piercing,
the material that is blanked is scrap while the remaining part of the strip is the product, as shown
in the Figure. In this project, blanking and piercing are used to produce component. Blanking is
one of the processes in which the sheet undergoes brutal deformation since the sheet metal is
separated to have the slug and part.

Industries involved in sheet metal manufacturing shear cutting methods are widely used for high
and low cost production. Shear cutting process is more advantages over the other conventional
metal or sheet metal cutting operation. Sheet metal cutting operation is common in most of the

Citation.

1.1 Types of Dies

The theory of sheet metal behavior kept as a backbone for the development of various kinds of
dies which are differentiable through their function. In some of the dies, the sheet metal should be

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cut off from the strip and the remaining part is removed as a scrap. In some other dies, the complete
part is finished within the single station. According to their construction and functions the die is
divided into following groups [1].

1.2 Compound Dies

The die which undergone to more than two cutting operations like blanking and perforating etc.
can be performed continuously in a single stroke. In compound die, the upper punch is connected
to the ram comes in constant with metal and pierces the hold. This punch is moving downward,
the springs keep on compressing and after certain limit the lower punch moves upward and blanks
the outer portion. Here, the whole operation is performed at single station, it produces accurate
result but the die design is complicated

1.3 Combination Dies

The die which undergone the cutting and forming operations are combined and carried out in a
single operation. First blank is prepared in the die and then it is held by pressure pads and drawn.
All this is achieved entirely within the die assembly by use of cam actuated punch and die members
or by designing the die for use on a double action press which has two independent rams or slides
on moving inside another.

1.4 Progressive Dies

In progressive dies, the work pieces move from the first station to successive which carries variable
operations, to be performed in individual station. Each stations works in series manner and the
work piece is placed in stock till at the end of station which cuts off finished piece. End of the each
stroke, the stock is moving towards by one station and the complete work piece is constructed in
a single stroke of ram. It can be designed for complicated operations of bending, forming etc. In
these dies, indexing at every station is very important and therefore accuracy is not much.
However, it is simple in design.

1.5 Die Construction

The die set is the primary portion of every die construction. It made up of upper die and lower die
both are machined in parallel in size. The portion of the die is provided with the shank which is
used to clamp in the ram of the press. Both the upper die and lower die are aligned with the guide

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pins. They are firmly attached to the stripper and the upper die is equipped with the bushings into
which these pins slip-fit. The die blocks are mounted in the lower die in which they are attached
through the die buttons. The punch plate is mounted on the upper shoe in which same manner as
the die block. It holds all the punches which are perforated the sheet with the help of die at the
bottom. While doing the punching operations, the punches can be prevented from the cracks by
the spring loaded stripper plate. The stripper plate is held in the top plate with an offset location of
forces of springs by means of guide pins. This die set is the combination of two die set. The upper
die set is rectangular in shape with four post die set. The lower die set is rectangular in shape with
open die set which is used for simple parts in larger quantities.

1 Materials Used In Die The die set is made up of Aluminium – Silicon alloy by replacing the tool
steel material which enhance the high ductility and high hardness level. This material is suggested
for light weight of the die and it tends to deforms while the thrust force is applied, regain its original
shape. However it is good corrosion resistance. It is able to sustain up to 10 bar pressure which is
applied by the hydraulic press [2]. Table – 1: Die components materials Sl. No Die parts Material
used Young’s modulus (N/mm²) Density g/cm³ 1 Punches 14C6 2.1 x 10⁵ 2 Die 14C6 2.1 x 10⁵ 3
Top & bottom plate LM6 Alloy 72 x 10³ 2.65 4 Guide pin & bushes LM6 Alloy 72 x 10³ 2.65 5
Shank LM6 Alloy 72 x 10³ 2.65 6 Guide supporter LM6 Alloy 72 x 10³ 2.65 7 Punch plate LM6
Alloy 72 x 10³ 2.6.

Fig -1.1: Blanking & Piercing

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1.6 Problem Statement

The aim of this project is to reduce cycle time of existing process of milling, blanking and drilling
operation for component. These all operations need be combined in a single setup of die punch
with a proper tool design. The monthly volume of component is 4000 to 6000 nos. Hence company
needs cycle time reduction and cost reduction as well on these hinges to meet global competition.
The existing cycle time of operations is approximately 4 minutes. After the implementation of this
project we can expect this to 30 secs.

Fig -1.2 : 3D model of die punch

1.7 From Sheet Metal Forming Processes and Die Design

Blanking and punching dies are known as cutting dies. They may be simple, combination, or
compound. A blanking die is generally cheaper to make and faster in operation than a trim die. A
single blanking die can produce either a right or left part, while two trim dies are needed for
trimming: one die for right-hand parts and another die for left-hand parts. When a sheared flat
blank drops through the die block (die shoe) it piles up on top of the bolster plate. If the blank goes
through the hole, it is called a drop-blank die. A die in which the sheared blank returns upward is
called a return-blank die. Return-blank dies are slower in operation and cost more to build than
drop-blank dies.

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A punching die is a typical single-station die design for production holes made in flat stock, which
may be manually or automatically fed. The stock guide keeps the stock on a straight path through
the die. The amount of stock travel is controlled by the method of feeding, by stops of various
designs, or by direct or indirect piloting. A combination die is a single-station die in which both
cutting and non-cutting operations are accomplished at one press stroke.

1.8 Blanking Services Information

Show all Blanking Services Providers Blanking is a manufacturing process where a punch and die
are used to remove blanks in preparation for processing and finishing. This cutting process is done
by applying a shearing force to a material sheet. In blanking, the removed piece is the desired
workpiece and is referred to as a blank. The process can be used to cut out almost any 2D shape
and is commonly used for simple workpieces with simple geometry. Due to the shearing force, the
pieces often need a finishing to smooth out burrs.

Fig 1.3: Blanking process. Blanking workpiece.

1.9 Image Credit: custompartsnet.com | metalstampingdies.com

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The machinery consists of a blanking press, sheet metal, blanking punch, and blanking die. The
dies used can be a generic shape or customized for a specific design but instead of having a cavity,
it has a cutout in the shape of the desired workpiece. The sheet metal is placed over the die and
below the punch tool (typically 10-20% of the material thickness clearance), which is also in the
desired shape of the workpiece. The tools are made from a steel or carbide and pare hydraulically
powered. The hydraulic press drives the punch downwards at a high speed into the sheet, the metal
quickly bends and then fractures. The created blank falls into the gap of the die.

1.10 Types

Fine or Precision blanking - Produces metal pieces with tight tolerances of +/- 0.0003. The blank
is sheared from the sheet using three separate forces. The first is a downward holding force applied
to the top of the sheet, the second force is applied under the sheet, opposite the punch. The two
forces act together to reduce the bending of the sheet for flatter blanks. The third force is the
blanking punch impacting the sheet and shearing the blank into the die opening. This technique
produces a part with a flatter part with smoother edges so higher quality parts that do not require
finishing can be produced. The clearance is around 0.001 inches and the blanking is performed at
slower speeds. The additional equipment and tooling makes this process more expensive so it is
better suited for high volume productions.

Fig 1.4: Fine or precision blanking.

1.11 Material

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 The material is usually a sheet but it may also be in rolls.

 Sheet Metal- Metal components can be formed using a punch. The punch is usually the upper
member of the complete die assembly and is mounted on the slide or in a die set for alignment
(except in the inverted die).
 Plastic- Plastic pieces are usually scrap materials, such as tails, molding flash and slugs from
bottles, which need to be removed from the workpiece.
 Paper, board, PP- or PE- foil- Paper and related products such as those used for labels can be
self-adhesive or plastic laminated.
Service Considerations
When selecting a blanking service provider there are several specifications to consider.

 Who will the material? The customer or the service company?

 Does the service company custom-produce dies?
 Do they offer discounts for large volume orders? Much of the cost associated with blanking is
setting up and calibrating the equipment.
 Does the service company provide additional finishing services such as removing burrs,
stamping, and polishing?
This video compares several metal stamping processes.

1.12 U-Profile Bend Dies

Fig. 10.1 illustrates a simple die for bending a U-profile. In this example, the blank of
length L, width b, and thickness T, is positioned on the die (1) between stop pins (11). The die (1)
is mounted on the lower plate (3) in the conventional position. The punch (2) is attached to the
punch holder (4), which is fitted a shank (6) for that purpose, to the ram of the press. The pressure
pad (10) applies pressure to the blank so that as the punch pushes the blank into the die, the
workpiece is formed by a single stroke of the press. The bent workpiece is ejected from the die by
the pressure pad mechanism (a) when the press ram retracts. For bending workpieces of small
dimensions and thin material, the punches and dies are made from a single block of metal.

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 Figure 10.1: Simple bending die.

Stripper plates remove the material strip from around blanking and piercing punches. Severe
adhesion of strip to punches is characteristic of the die cutting process. Because of their low cost,
solid strippers are the most frequently used type, particularly when running strip stock. Spring
strippers, though more complex, should be used when the following conditions are present:

1. When perfectly flat, accurate blanks are required, spring strippers flatten the sheet before
cutting begins.

2. When very thin material is to be blanked or pierced, to prevent uneven fracture and rounded
blank edges.

3. When parts are to be pressed from waste strip left over from other operations, spring strippers
provide good visibility to the operator for gaging purposes.

4. When stripping occurs immediately, small punches are not as subject to breakage.

5. When conducting secondary operations, such as in piercing dies, increased visibility provided
by spring strippers allows faster loading of work and increased production.

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Stripper plates may be made of cold-rolled steel if they are not to be machined except for holes.
When machining must be applied to clear gages, the plates should be made of machine steel, which
is not as subject to distortion. This chapter describes numerous methods of applying stripper plates
and their components. These methods further explain Step 10 in Chapter 5 14 Steps to Design a
Die.

1.13 Presses (metalworking) Information

Show all Presses (metalworking) Manufacturers

Fig 1.5: Image Credit: Savage Engineering, Inc.

Industrial presses (metalworking) use a ram to shear, punch, form, or assemble metals or other
materials by cutting, shaping, or using dies attached to slides.

1.14 Types of Presses (Metalworking)

Selecting industrial presses (metalworking) requires an understanding of equipment types. Some

examples include:

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 Die cutting machines are used in the manual conversion of web or sheet materials such as
woven cloth, non-woven textiles or rubber sheeting. Clicker presses and rotary die cutter are
designed for die cutting operations.
 Forming machines are used to form or bend metal sheets and plates. Shop presses are suitable
for general-purpose applications. Wire forming presses are designed or suitable for wire
forming or wire bending operations.
 Punch presses are machines that use a set of dies under pressure to put holes into materials to
shape metal parts.
 Stamping presses operate stamping and other types of dies by powering the opening and
closing of die sets, which are composed of punches and die blocks. Die sets assemble upper
and lower die shoes, guide pins, bushings, and punch and die holders. Stamping
presses fabricate components from sheet metal via blanking, piercing or punching, forming,
bending and drawing.
 Turret presses are industrial presses that have an open frame and a turret with multiple punches.
Turret punch presses, typically numerically controlled, are used mainly to perform shearing
operations. Industrial presses such as the turret press can allow metal to be weaved together by
creating tabs with a lanced dimple that, when mated, falls into another dimple of an opposing
tab. Depending on the application, the tool can eliminate welding or other joining processes.
Specifications

Machines differ in terms of features and specifications. Operational method, technology, force and
pressure specifications, and speed and stroke specifications are important parameters to consider
when selecting industrial presses. Some industrial presses are driven by mechanical power, such
as the mechanical punch press, which can be driven by flywheels, cranks, or clutches.

1.15 Standards

Nas982 - hot forming, sizing, and straightening press specification

bs en 14673 - safety of machinery - safety requirements for hydraulically powered open die hot
forging presses for the forging of steel and non-ferrous metals

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saa as 4024.3001 - safety of machinery part 3001: materials forming and shearing - mechanical
power presses
saa as 4024.3002 - safety of machinery part 3002: materials forming and shearing - hydraulic
power presses
Help with presses (metalworking) specifications:

1.6 Press Type

Press Type

Your choices
are...

Clinching machines use a cold forming process to fasten sheet metal

components together. During the clinching process, a punch forces
Clinching the two layers of sheet metal into a die, creating a permanent
Machine connection. Clinching machines are an economical alternative to
riveting and welding operations. Clinching is commonly used in the
HVAC, automotive, manufacturing and housing industries.

Die cutting presses are used in the manual conversion of web or

Die Cutting sheet materials such as woven cloth, non-woven textiles, and rubber
Machine sheeting. Clicker presses and rotary die cutters are designed for the
die cutting of web or sheet materials.

Forming and
Forming machines are designed to form or bend metal sheets or
Bending
plates.
Machine

Hydroforming presses are designed to process metal source-material

sheets, plates or tubes. The resulting parts are typically of higher
Hydroforming
quality than those produced from traditional stamping methods.
Press
Compared to stamping, finished parts from a
hydroforming process often offer better strength, geometry, surface

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 finish, aerodynamics, and other desired performance
characteristics. Low-drag and visually-pleasing automobile hoods
are one example of a hydroform-pressed component.

Punch presses are used for punching, blanking, piercing, nibbling,

Punch Press
tab forming, stamping, press forming, embossing and slug cutting.

Shop presses are designed for general-purpose job shop operations.

Shop Press They include arbor presses, ironworkers, metal shears, and press
brakes.

Sheet metal equipment is designed to fabricate components from

Sheet Metal
sheet metal. These industrial presses are capable of stamping,
Equipment
blanking, punching, bending, spinning, stretching, or nibbling.

Stamping presses fabricate components from sheet metal

Stamping Press using blanking, piercing or punching, forming, bending and
drawing.

Wire forming presses are designed or suitable for wire forming or

Wire Forming
wire bending operations.

Other unlisted, specialized, or proprietary presses or forming

Specialty
machine tools.

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Thermal presses or machines are suitable for elevated temperature

operations such as hot stamping, hot forming, or diffusion bonding
Hot Press of metals. The metal or material is heated to a plastic state, allowing
a level of deformation that would cause cracking or excessive
residual stress in a cold forming operation.

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Press / Operation Type

Operation

Your choices
are...

Bending Presses can produce simple bends of at least 90 degrees or more.

Presses are suitable for blanking operations. Blanking is the cutting

Blanking
of a part from sheet stock.

Presses are designed to cut gears or splines by forcing a broach or

Broaching
multi-toothed cutter along the internal or external surface of a part.

Cut-off / Presses are designed for cutting-off or shearing stock of various

Shearing thicknesses.

Presses can perform deep drawing, stretching, and other press-

Deep Drawing
forming operations.

Presses are suitable for fine blanking operations. Fine blanking cuts
a part from sheet stock, while maintaining much higher tolerances
Fine Blanking
than conventional blanking. A stiffener and high-precision
machining are required.

Extrusion Presses form parts such as tin paste tubes through extrusion or back-
Forming extrusion operations.

Marking / Presses can perform marking or coining operations. Marking or

Coining coining results in a local change in cross-section.

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 Presses perform nibbling operations. Nibbling is a punch-cutting
process where irregularly-shaped holes are formed via a series of
Nibbling rapid punch hits or strokes across the part. Nibbling can also refer to
presses or shearing machines that cut contours in a sheet with a series
of small or scissors-like cuts.

Piercing / Hole Presses can perform piercing, perforating, or hole-punching

Punching operations.

Presses can perform stamping, embossing, or other shallow press-

forming operations. These presses or machines may also be capable
Press Forming /
of simple bending or forming operations such as tab or louver
Embossing
forming. Embossing is used to form beads, stiffen ribs, or locate
features.

Presses can side-punch, notch, or pierce a tube or component.

Side Punching /
Notching may also refer to the removal of corners or outer edges
Notching
from a sheet or part.

Straightening /
Presses can straighten or flatten sheet metal, plates, or other stock.
Flattening

Tube Sheet Presses can form tube sheets for boiler or heat exchanger
Forming applications.

Other unlisted, specialized, or proprietary press operations for

Other
forming or cutting materials.

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Technology

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Press Technology -
Drive / Actuation

Your choices are...

Air / Pneumatic The press is driven or powered by a pneumatic cylinder.

The press is driven or powered by a hydraulic cylinder.

Hydraulic Hydraulic presses can generate extremely high forces to form
metals or other materials.

Hydro-mechanical presses are driven by a hydraulic cylinder

Hydro-mechanical
or hydraulic motor.

The press is driven by a rotary motor through a screw, toggle,

Mechanical
lever, or other mechanism.

Servo (Driven / The press or machine is servo-controlled or directly driven by

Control) a servo motor.

The press is driven or powered by hand, or with manual force

Manual
that is magnified with screw, lever, or other mechanism.

Other Other unlisted, specialized, or proprietary technologies.

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Frame Type &

Orientation:

Your choices are...

Smaller presses or forming machines can be mounted on a

Bench Mounted
bench, stand, or pedestal. Typically bench-mounted presses are

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 used in shop operations or for the preparation of laboratory
samples.

Open back presses have a one-piece frame with an opening at

the back between the two gap uprights. This opening
Open Back (OBI /
is typically slightly more than the left-to-right dimension of the
OBS)
slide flange. Open back inclinable (OBI) gap presses are very
common. OBS refers to open back stationary presses.

Gap frame, C-frame, or open-fronted presses have a C-shaped

C-Frame / Gap
configuration where the front and side of the press are open for
Frame
easy access.

Column (4 Post) / Four-post or column presses have a frame with posts at the
Straight-Side corners.

Inclined or inclinable presses tilt back or remain tilted to

Inclined / Inclinable
facilitate the removal of punched parts.

H-frame presses consist of structural steel shapes (I-beams and

angle iron) that are welded or bolted into an H-shape.
H-Frame Additional beams are attached to provide floor mounts and
cylinder support across the top. The central beam holds a
mounting plate for tooling, vises, or clamps.

On sliding-bed presses, the bed or bolster plate slides in-and-

Sliding Bed / Roll out from under the ram for the placement and set up of the
Frame workpiece. Roll frame presses have a stationary bed that
supports a movable frame which is mounted on rollers.

Other unlisted, specialized, or proprietary frame types or

Other
orientations.

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Force / Pressure Specifications Pressure is applicable to isostatic presses.

The operating press load required to cut or form a part or rivet assembly
during production. The rated capacity of a press is the ton pressure,
Capacity /
which the slide or ram will safely exert at the bottom of the stroke while
Operating
working within the range of the press. In a mechanical press, the
Force:
capacity is determined by the bending capacity of the main shaft (crank,
toggle, or eccentric shaft).

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criteria.

Pressure is the hydraulic force per unit area exerted by the industrial
Pressure
press upon the piece being worked.

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Speed & Stroke Specifications

Stroke is the ram travel from top dead center (TDC) to bottom dead center
Stroke:
(BDC).

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 Search User may specify either, both, or neither of the "At Least" and "No More
Logic: Than" values. Products returned as matches will meet all specified criteria.

Stroke Stroke speed is the linear speed of the slide or ram during pressing or ram
Speed: advancement steps.

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Logic: Than" values. Products returned as matches will meet all specified criteria.

The number of forming, punching operations, or units produced per time;

and usually stated as the number of strokes, hits, cut-outs, cycles or hits per
Rate: minute that the machine is capable of performing. In a progressive or
indexing on complex parts, the total production rate will depend on the
number of steps or operations required to fabricate the complete part.

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Logic: Than" values. Products returned as matches will meet all specified criteria.

The number stations in an indexing, automatic press, such as a turret punch

press. The turret holds several different tool sets that rotate into place
Stations:
allowing the punch press to perform a series of operations for the
production of complex parts.

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Special Features

Automation / Control:

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Your choices are...

The press is controlled manually through an operator interface

Manual (Footswitch /
device such as a footswitch, pendant, or push-button
Pendant / Pushbutton)
controls.

The press or forming machine automatically loads parts into

the system and operates without operator intervention. The
Automatic / Indexing
machine changes or adjusts tooling and other parameters,
such as speed or applied load, in a pre-programmed manner.

A CNC controller is used to program and perform a sequence

CNC Control
of operations on the press.

A PLC controller is used to program and perform a sequence

PLC Controller
of operations on the press.

Windows® / PC The press or forming machine is controlled or programmed

Control through a PC interface.

Other unlisted, specialized, or proprietary automation or

Other
control technology.

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Features

Your choices are...

Presses have two-or-more slides for multiple, independent,

parallel movements. Double-acting presses are used in draw
Double / Triple Acting forming processes because they provide a way to hold down
or clamp the rim of the sheet. There are two types: mechanical
and hydraulic. With mechanical double-acting presses, one

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 slide is operated by crankshaft; the outer or blank holder slide,
which dwells during the drawing process, is usually operated
by a toggle mechanism or cams. Hydraulic double-acting
presses have multiple cylinders to drive the different
slides. Triple-acting presses typically have a lower slide
mechanism with an upward or opposing motion.

Multi-station presses use rotary tooling or turrets, progressive

dies, transfer systems, or other multi-station die sets. Rotary
turret punch presses are automatic machines that index the
Multi-Station (Rotary material and select the required tool from the rotary tool
Turret) holding device or turret, usually by computer
control. Depending on the program selected, turret punch
presses are used for piercing, blanking and forming
workpieces.

Multi-tool systems consist of multiple tool turrets within a

Multi-Tool
single turret. They provide automatic indexing.

Coil feeders and web feeders are integral or optional sub-

Coil / Web Feeder systems that are used to feed sheet-metal coil
stock, or cut strips and other web materials.

Machines provide the integral shearing or cut-off of sheet or

Integral Cut-Off /
web materials, or excess scrap material. Examples include a
Shear
flying shear on a rolling mill machine.

Presses feature an integral laser-cutting system to provide

Integral Laser Cutter
additional fabrication capabilities.

Equipment is designed for laboratory applications such

Laboratory as process parameter studies, material development, or
sample preparation.

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 Presses have sensors and monitoring systems for detecting the
Load / Press Monitor
load and thickness of compacted materials.

Presses are complete manufacturing cells, production lines,

or turnkey systems with material handlers, degreasing
Manufacturing Cell units, or other sub-systems for fabricating parts from coils,
(Loader / Stacker) metal sheets, or web materials. Alternatively, these press or
stamping systems may have loading, stacking, or
destacking features for handling sheets, parts, or materials.

Other Other unlisted, specialized, or proprietary features.

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1.17 SHEARING

Shearing is a cutting operation used to remove a blank of required dimensions from a large
sheet. To understand the shearing mechanism, consider a metal being sheared between a punch
and a die, Fig 5.1 Typical features of the sheet and the slug are also shown in this figure. As can
be seen that cut edges are neither smooth nor perpendicular to the plane of the sheet.

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22
Fig 1.6: (a) Shearing with a punch and die (b) features of a punched hole and (c) features of the
slug.

Shearing starts as the punch presses against the sheet metal. At first, cracks form in the sheet
on both the top and bottom edges (marked T and T', in the figure). As the punch descends further,
these cracks grow and eventually meet each other and the slug separates from the sheet. A close
look at the fractured surfaces will revel that these are quite rough and shiny; rough because of the
cracks formed earlier, and shiny because of the contact and rubbing of the sheared edge against
the walls of the die.

The clearance between the punch and the die plays an important role in the determination of
the shape and quality of the sheared ege. There is an optimum range for the clearance, which is 2
to 10% of the sheet thickness, for the best results. If the clearance increases beyond this, the
material tends to be pulled into the die and the edges of the sheared zone become rougher. The
ratio of the shining (burnished) area to the rough area on the sheared edge decreases with increasing
clearance and sheet thickness. The quality of sheared edge is also affected by punch speed; greater
the punch speed better the edge quality.

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1.18 Shearing Operations

For general purpose shearing work, straight line shears are used. as shown in Fig 5.2, small
pieces (A, B, C, D……….) may be cut from a large sheet.

Shearing may also be done between a punch and die, as shown in Fig 5.1. The shearing
operations make which use of a die, include punching, blanking, piercing, notching, trimming, and
nibbling.

1.19 Punching/Blanking

Punching or blanking is a process in which the punch removes a portion of material from
the larger piece or a strip of sheet metal. If the small removed piece is discarded, the operation is
called punching, whereas if the small removed piece is the useful part and the rest is scrap, the
operation is called blanking, see Fig 5.3.

Fig 5.3 Comparison of basic stamping operations.

In punching, the metal inside the part is removed; in blanking, the metal around the part is removed.

A typical setup used for blanking is shown in Fig 5.4.

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 Fig 1.7 : Blanking punch and die.

The clearance between the die and punch can be determined as c = 0.003 t. t where t is the
sheet thickness and t is the shear strength of sheet material. For blanking operation, die size =
blank size, and the punch is made smaller, by considering the clearance.

The maximum force, P required to be exerted by the punch to shear out a blank from the
sheet can be estimated as

P = t. L. t

where t is the sheet thickness, L is the total length sheared (such as the perimeter of hole),
and t is the shear strength of the sheet material.

Stripping force. Two actions take place in the punching process – punching and stripping.
Stripping means extracting the punch. A stripping force develops due to the spring back (or
resiliency) of the punched material that grips the punch. This force is generally expressed as a
percentage of the force required to punch the hole, although it varies with the type of material

25
being punched and the amount of clearance between the cutting edges. The following simple
empirical relation can be used to find this force

SF = 0.02 L.t

where SF = stripping force, kN

L = length of cut, mm

t = thickness of material, mm

Example: A circular blank of 30 mm diameter is to be cut from 2 mm thick 0.1 C steel sheet.
Determine the die and punch sizes. Also estimate the punch force and the stripping force needed.
You may assume the following for the steel : Tensile strength: 410 MPa ; shear strength : 310 MPa

Solution:- For cutting a blank, die size = blank size

\ Die size = 30m

Clearance = 0.003 x t x t = 0.003 x 2 x 310

= 1.86 mm

Punch size = blank size – 2 clearance

= 30 – 2 x 1.86 = 26.28 mm

Punch force needed = L. t. p = p x 30 x 2 x 310

= 58.5 kN

Stripping force needed = 0.02 L.t

= 0.02 x p x 30 x 2

= 3.77 kN

Piercing:

It is a process by which a hole is cut (or torn) in metal. It is different from punching in that
piercing does not generate a slug. Instead, the metal is pushed back to form a jagged flange on the
back side of the hole.

26
 A pierced hole looks somewhat like a bullet hole in a sheet of meta

1.20 Trimming:

When parts are produced by die casting or drop forging, a small amount of extra metal gets
spread out at the parting plane. This extra metal, called flash, is cut – off before the part is used,
by an operation called trimming. The operation is very similar to blanking and the dies used are
also similar to blanking dies. The presses used for trimming have, however, relatively larger table.

1.21 Notching:

It is an operation in which a specified small amount of metal is cut from a blank. It is

different from punching in the sense that in notching cutting line of the slug formed must touch
one edge of the blank or strip. A notch can be made in any shape. The purpose of notching is
generally to release metal for fitting up.

1.22 Nibbling:

Nibbling is variation of notching, with overlapping notches being cut into the metal. The
operation may be resorted to produce any desired shape, for example flanges, collars, etc.

1.23 Perforating:

Perforating is an operation is which a number of uniformly spaced holes are punched in a

sheet of metal. The holes may be of any size or shape. They usually cover the entire sheet of metal.

DIFFERENCE BETWEEN BLANKING, PUNCHING & PIERCING IN SHEET METAL

27
Blanking, Punching and piercing are sheet metal operations in which punch & Die are used to give
shape to sheet metal parts. All these are shearing operations that can be done on CNC punching
machine and on hydraulic press.

Blanking is a process in which the punch operation removes a final product from a larger piece of
sheet metal.

Fig: 1.8: Punching is a material removal process

Punching is a material removal process in which the punch operation removes material from a
final piece of sheet metal.

28
 Fig: 1.9: Piercing is process

Piercing is process in which punch operation cuts a hole / material by tearing operation from a
final piece of sheet metal. Piercing is a blanking operation

Fig: 1.10: Piercing is process

1.24 Metal-Cutting Process

29
Metal cutting is a process used for separating a piece of material of predetermined shape and size
from the remaining portion of a strip or sheet of metal. It is one of the most extensively used
processes throughout die and sheet-metal work. It consists of several different material-parting
operations, such a piercing, perforating, shearing, notching, cutoff, and blanking.

In blanking, the piece is cut off from the sheet, and it becomes a finished part. In piercing, the
cutout portion is scrap which gets disposed off while the product part travels on through the
remainder of the die. The terminology is different here, though both processes are basically the
same and therefore belong to the same category, which is the process of metal cutting (Fig. 6-1).

The actual task of cutting is subject to many concerns. The quality of surface of the cut, condition
of the remaining part, straightness of the edge, amount of burr, dimensional stability-all these are
quite complex areas of interest, well known to those involved in sheet-metal work.

Most of these concerns are based upon the condition of the tooling and its geometry, material
thickness per metal-cutting clearance, material composition, amount of press force, accurate
locating under proper tooling, and a host of additional minor criteria. These all may affect the
production of thousands and thousands of metal-stamped part

CHAPTER 2

2. DESIGN OF DIE PARTS

Deflection and stress calculation

Let us assumed to be a SSB beam which are mounted

through four corners in the punch plate. It is loaded in the

centre of the plate and their deflection should be.

δ = ----------------------------------- ⑬

30
Where, F = 80% of the cutting and forming forces

= 2666.752 N

L is the beam frame distance = 150 mm

Young’s modulus (E) = 72 x 10³ N/mm²

where, b = 200 mm (width of the plate)

h = 32 mm (height of the plate)

I = 860160 mm⁴

δ = 0.0004 mm < 0.025 mm

σ = F/A

= 0.4166 N/mm²

The stress applied to the punch plate is 0.4166 N/mm² which

is much less than 160 N/mm². Hence, the design is safe.

3.5 Guide Pins and Bushes

Guide pins and bushes are made up of aluminium silicon

alloy (LM6) which is used to align the punches and the die

block. It attached between the top plate and stripper plate.

2.1 Buckling for guide pins

The guide pins materials are made up of LM6 alloy having a

tensile strength of 160 N/mm² and their young’s modulus is

72x10³ N/mm².

= 2l for one side is fixed and other side is set free.

l = 146 mm

31
I = ------------------------------- ⑭

D = 22 mm

I = 1165.68 mm⁴

A = 379.94 mm²

S.R = / ------------------------------ ⑮

= = Radius of gyration ----------------------------- ⑯

= 20

S.R = 17.6 = Slenderness ratio

T.S.R = = Transition slenderness ratio -------------- ⑰

T.S.R = 94.2 mm

Here, the Johnson equation should be applied for critical

buckling load. Since, the S.R ratio is lesser than that of

T.S.R [7].

--------------------- ⑱

= 2166.6 N > critical load

Hence the structure is safe.

Load per pillar = 2166.6/4

= 541.65 N / pillar

2,2 Punch

The punches are mounted in the punch plate which is made

up of plain carbon steel 14C6. The lengths of the punches

32
are properly quoted for the die performance. If the punches

are having too much length, the compressive stress become

excessive which results in tip breakage. The lengths of the

punches are calculated from the Euler’s formula. The critical

force is calculated through one is fixed and other end set as

free [7].

---------------------------------- (19)

The length of the punches are calculated by

-------------------------------- (20)

D = dia. of the punch = 7.5 mm

This shows that the length of the punch which is safe and it

can perform without failure

33
Fig -2.1: Component Model (Male and Female part)

Fig -2.3: 2D Drawing of die punch assembly

34
 Fig-2.4: Fatigue characteristics of tool stee

Details Specifications

Material St-37

Thickness 6mm

Shear strength 320-350N/mm2

Tensile strength 370-450N/mm2

Table -1: Material Properties of component

35
 Property Value Units
Young’s Modulus 210000 N/mm²
Poisson’s
Ratio 0.3 -
Shear
modulus 7900 N/mm²
Mass density 7700 Kg/m³
Tensile strength 1736 N/mm²
Compressive Yield 2150 N/mm²
strength
Yield
strength 2150 N/mm²
Expansio
Thermal n 1.04e.005 1/K
Coefficient

Thermal Conductivity 20 W/(m-K)

Specific Heat 460 J/(Kg-K)

Table -2: Material Properties of Die Punch material (D2 steel)

36
 CHAPTER 3

3. ANALYSIS IN ANSYS

In this project the analysis is carried out in Ansys 14.0 work bench. The punch is critical element
in die punch, hence analysis is carried out on punches and the results are compared with theoretical
calculations for validation. The material used for punches is D2 steel/HCHCr.

It provide the stress result with the design cycle. It helps to predict the part to perform under load.
Whenever the problem arise related to analysis, need a comprehensive analysis of the product is
required [8]. 4.1 Analysis of Punches The analysis of punches are analyzed by the simulation
express tool in which each punch is made fixture at the top of the punch and the load is applied at
the tip of punch. The maximum shear load is occurred in the edges of the punch and deformed to
maximum deflection which is calculated. The following figures show that the punches are
deformed only at the tip.

Analysis of Piercing punch

Fig- 3.1: Meshed model of Piercing punch.

37
Fig- 3.2: Von-Mises stresses on piercing punch.

38
 Fig- 3.4: Total deformation of piercing punch.

As shown in the analysis results, the minimum deformation is 0 mm at top of the punch and
Maximum deformation is 0.2290 mm at the tip of punch.

As shown in the analysis results in fig 8, the minimum life is 250 cycles and Maximum life is
100000 cycles

39
 Fig- 3.5: Fatigue life of piercing punch

Analysis of slotting punch

40
Fig- 3.6: Meshed model of Slotting punch.

41
 Fig- 3.7: Total deformation of piercing punch.

As shown in the analysis results, the minimum deformation is 0 mm at top of the punch and
Maximum deformation is 0.1937 mm at the tip of punch.

42
 Fig-3.8: Von-Mises stresses on slotting punch.

As shown in the analysis results, the minimum Von-Mises stress is 87.749 Mpa and Maximum
Von-Mises stress is 1503Mpa.

43
 Fig- 3.9: Fatigue life of slotting punch.

As shown in the analysis results, the minimum life is 1108 cycles and Maximum life is 1.15e7
cycles.

Analysis of profile blanking punch

Fig- 13:

44
Fig- 3.10: Meshed model of profile cutting punch.

45
 Fig- 3.11: Total deformation of profile blanking punch.

As shown in the analysis results, the minimum deformation is 0 mm at top of the punch and
Maximum deformation is 0.01662 mm at the tip of punch.

46
 Fig- 3.12: Von-Mises stresses on profile blanking punch.

As shown in the analysis results, the minimum Von-Mises stress is 4.33 Mpa and Maximum Von-
Mises stress is 92.71Mpa.

47
 Fig- 3.13: Fatigue life of profile blanking punch

As shown in the analysis results, the minimum life is 65000 cycles and Maximum life is 100000
cycles.

3.1 Results and Discussion

First step is to decide the geometry of the Die-Punch tool, while having consideration on this; we
need to take component which is selected for the optimization or alteration of manufacturing
process. Here alternative method of manufacturing selected is punching; when a punching
operation is selected first parameter under scanner is the amount of material required to be
eliminated from the original raw material. Further in this process we need to decide the number of
cycles for which this punch is been designed, here we are utilizing this punch for at least fifty
thousand repeating punching operations, keeping in mind the monthly production of these parts
around five thousand quantities.

48
 Total
Sl.No Description Deformation(mm)

Theoretical Ansys Error

(%)

1. Piercing 0.2200 0.2290 3

Punch

2. Slotting 0.1896 0.1937 2.1

Punch

3. Profile 0.01582 0.0166 4.8

blanking
Punch

Table -3: Fatigue life results.

Sl.No Description Fatigue life(cycles)

Theoretical Ansys Error

(%)

1. Piercing 97000 100000 3

Punch

2. Slotting >1e6 >1e6 -

Punch

3. Profile >1e6 >1e6 -

49
 blanking
Punch

Sl. Description Von-Mises Stress (N/mm2)

No
Theoretical Ansys Error

(%)

1. Piercing 1020 979 3.5

Punch

2. Slotting 1480 1503 1.5

Punch

3. Profile 96 93 3.5
blanking
Punch

Maximum working stress for piercing punch is 927 N/mm², which is less than the Von-Mises stress
1020 N/mm².Hence punch will not fail under applied load of 59383N.

Maximum working stress for Slotting punch is 400 N/mm², which is less than the Von-Mises stress
1480 N/mm².Hence punch will not fail under applied load of 358400N.

Maximum working stress for profile blanking punch is 37 N/mm², which is less than the Von-
Mises stress 96 N/mm².Hence punch will not fail under applied load of 226800N.

Critical buckling load for piercing punch is 356029N.Actual load on piercing punch is 59383N,
which is less than 356029N.Hence buckling will not occur.

50
 CHAPTER 4

CONCLUSION

In this project a die punch for blanking and piercing operation is designed and analysed for
component. The theoretical calculations were done for calculating cutting force, tonnage required,
fatigue life and stresses. The 3D models created in Catia-V5 and analysis is done on Ansys 14.0
workbench. The main objective of the project is to improve productivity and reduce production
cost. The exiting cycle time for blanking and piercing operation is approximately four minutes
which manufacturing cost is around six rupees. After implementation of this project we can expect
the cycle time will be 30 to 40 secs and cost will be around 1.5 to 2 rupees.

51
 REFERENCES

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fatigue strength of the M330-35A electrical steel by Helmi Dehmani, Charles Bruggerb, Thierry
Palin-Lucb, Charles Mareauc, Samuel Koechlina.

6. Analysis of Wire-EDM finishing cuts on large scale ZrO2-TiN hybrid spark plasma sintered
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10. Fatigue strength of marked steel components by Natalie Stranghöner, Dominik Jungbluth.

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Kalnins.

52
13. Buckling analysis of pressure vessel based on finite element method by J Shen.

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53