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Tooling Knowledge
Tooling Knowledge
Pressing process
Cutting Clearance
Cutting Force
Invention of printing press
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Pressing process
General press part application
Car body
Fenders
Doors
Gears
Cams
Links
Levers
Keys
Hinges etc.
Why Sheet metal & Pressing process ?
Ease of manufacture & less
process complexity
technology
SHEARING
SLITTING
7
Shearing
It is a method of cutting sheets without forming chips
Punch
Punch
Sheet
Sheet
Die
Critical stages of shearing
There are three stages of
shearing
Penetration Fracture
Plastic deformation
Plastic
Penetration deformation
Fracture
Peak load
Punch
Stress
Sheet
Die
time
Types of Pressing operation
Pressing process
Etc.,
What is Blanking ?
Blanking is a process of producing flat stampings. The entire
periphery is cut and cut out piece is called the blank
Blanking
Punch punch
Sheet
Scrap
Die
Output
product
What is Piercing ?
It is also a shearing operation similar to the blanking process.
Piercing Blanking
punch punch
Scrap
Scrap Required
part
operation
What is Cutting off ?
What is Parting off ?
Parting is very similar to a cutoff,
except two simultaneous cuts are
required instead of one.
Slug
What is Shaving operation?
Shaving finishes a previously cut
edge by shearing off the small
amount of the remaining rough
portion
The cutting clearance between
punch and die will be less than the
ordinary blanking which lead to
shaving of metal.
Why Shaving operation ?
Shaving increases accuracy and
smoothness.
Drawing Trimming
Scrap
What is the operation needed to produce this part?
What is Lancing operation?
Shearing an interior portion of the
sheet to create a bent tab that
remains attached on one end is
Lancing
What is Notching operation?
What is Notching operation ?
Notching
What is Notching operation?
Notching removes a portion of
metal from the side.
Blanking Drawing
Drawing Tool
What is Embossing operation?
Embossing compresses sheet
metal against a patterned die in
order to create a raised surface
The collar wall can also be used for as rivet when two sheets are to be
fastened together.
What is Planishing operation?
It is used to straighten the
blanked component.
Tool related
Pillar / die set
Die & Punch
Cutting / Angular clearance
Stripper
Stopper
Guide plate
Part related
Nesting, RM utilization
Strip layout, pitch
Stock
GUIDE BUSHINGS:
Guide bushings are engaged with the guide pillars for aligning the top plate
with the bottom plate. Most bushings are made up of tool steel, they are
also available in bronze.
There are two types :
1. Plain bushing are simple sleeves, pressed into the top plate.
2. Shouldered bushings are turned down at one end and they are pressed
into the top plate against the shoulder thus formed.
Pressing process terminologies – Tool related
Advantages:
Easily replaceable.
Reduces cost of the die
manufacturing.
Applications:
In large piercing dies.
Pressing process terminologies – Tool related
Stripper
The main function of the
stripper is to strip the
stock material off the
punches after each stroke
Other functions :
Stripper
Pressing process terminologies – Tool related
Stripper
BOX STRIPPER
Stripper
They are true pressure pads. They bears against the stock material,
applying pressure to it. The material is clamped between stripper
and die. Clearance must be large enough to ensure clamping.
Pressing process terminologies – Tool related
Strip guide
Pressing process terminologies – Tool related
Stopper
For each and every stroke of the
press the strip has to be feed
forward for one pitch length
Stopper
Pressing process terminologies – Tool related
Stopper
STOP POSITION
This is the location of the actual stopper position surface
against which the stock strip is halted.
Pressing process terminologies – Tool related
Stopper
Registry position.
• This is the exact location in which the stock strip must be established in
order to obtain dimensionally correct component.
• The work is located by the stop and is registered by the pilots.
• The registry position may or may not be the same as the stop position.
• When a stop functions as an approximation gauge the stop position does
not coincide with the registry position.
Pressing process terminologies – Tool related
EJECTORS
If the expulsion of the blank achieved by
forcing it upwards, the action is known
as "ejection". The element of the tool
which ejects the blank is called an
"ejector“.
Ejectors may be actuated by
compression springs. Rubber, pneumatic
devices or hydraulic devices.
Ejectors if used with spring strippers,
always return the blank into the strip due
to the simultaneous stripping and
ejecting action.
Pressing process terminologies – Tool related
EJECTORS
Pressing process terminologies – Tool related
SHEDDERS
In inverted tools, die becomes the upper member of the tool,
being clamped to the press ram. The expulsion of the blanks is
achieved by forcing them downwards. This action is generally
known as "shedding" and the element of the tool which sheds
the blanks is known as the "shedder".
Press tools
Tools - Used for Pressing process
Pressing tools are made in at least two sections called the punch
and the die.
The dies and punches are normally made of OHNS, HC HCr or other
alloy steels. These tool steels have the strength, wear resistance,
and thermal shock resistance to withstand thousands cutting /
Forming operations
Pressing process terminologies – Tool related
Guide plate
The guide plates are provided to
locate and guide the strip / coil Guide
plate
Pressing process terminologies – Tool related
Guide plate
The guide plates are provided to locate and guide the strip / coil
Types of tools used for Pressing process
Tools
Progressive tool
It performs two or more
operations at different stages
every time the press ram
descends
Progressive tool
Types of Tools used for Pressing process
Compound tool
In compound tool, two or more
cutting operations are performed
at the same stage carried out in a
single stroke of the press
Compound tool
Types of Tools used for Pressing process
Compound tool
Types of Tools used for Pressing process
Compound tool
Types of Tools used for Pressing process
Compound tool
Types of Tools used for Pressing process
Compound tool
Types of Tools used for Pressing process
Compound tool
Types of Tools used for Pressing process
Compound tool
Types of Tools used for Pressing process
Combination tool
In this type of tool, two or more
operations such as forming,
drawing, embossing may be
combined with one of the cutting
operations such as blanking,
piercing and cut off
Assembly tool
Rivets are continuously fed from a hopper to the riveting head, via
tracks which orientate the rivet correctly.
Pressing process terminologies – Part related
Stock material
The material out of which stampings are made is known as “Stock
material”
Stock strip : Stock strips are fed into the tool. They are advanced through the
required distance at each press stroke for a series of repetitive operations
Unit Stock : Stock materials which are fed individually into the tool for
processing are called unit stock.
Cutting clearance
Punch
Clearance
It is the gap between a side of a
punch and the corresponding side
of the die opening on one side of
the edge, when punch is entered
Die
into the die opening
Optimum clearance
If the cutting clearance is more Fracture
Cut band
Edge radius
than the specified limit, excessive Excess clearance Large burrs
Fracture
burrs will be present along the cut Large radius
Small Cut band
Insufficient clearance
General cutting clearance = 0.06 x t Fracture
Small burrs
Multiple
Small radius Cut band
Importance of Cutting clearance
For Blanking:
Blanking punch = Blanking size – 2 clearance.
Blanking size = Die size
Clearance = c X s X
Angular clearance
Punch Die
It is a draft or taper applied to the
side walls of the die opening in
order to relieve the internal
pressure of the blank or slug as it
Clearance
passes through the opening
Shear and tensile strengths for most materials are not the same.