Presentation

Project ( Blanking Tool )

Prepared by :
Baravan Abdulwahid
Mohammed Sirwan
Dilshad Sarbast
Ahmed Abdullah
Dec / 2020

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 Introduction
 Introduction to die elements
 Die to Press Relationship
 Purpose of Die sets
 Terminology pertinent to die sets
 Types and styles of die sets
 Surface finishes on die set components
 Strippers
 Blanking operation
 Shearing action
 Piercing operation
 Drawing operation
 Advantage and disadvantage
 Reference

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PRESS TOOL
Press Tool is a set of plates with a relief, or depth-based design, in them. The metal is
placed between the plates, and the plates are pressed up against each other, deforming
the metal in the desired fashion. This may be blanking or piercing or drawing or
forming or coining etc. There are different types of press machines:
 C-type( fixed type & open back inclinable press)
 Single action straight side press
 Typical Hydraulic press

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A Die is an assemblage of parts used for producing different sheet metal components . The Die
is also called press tool as the dies are used on different types of presses based on the cutting
forces required for the component.

In this project a blanking die , piercing die , drawing die is produced for production of Bracket
used in supporting the fuel tank of an automobile. Before venturing into making of die , the die
making depends on many factors . Below given are the important points regarding die to press
relationships , die sets , strippers.

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Press Shut height:
The press shut height is always measured with the press stroke with the bottom dead center
position. In considering maximum shut heights, the ram adjustment is up at its highest stroke
down position. In considering minimum shut heights, the ram adjustment is down with the ram
extended to its lowest position.
Capacity of press:
The force in kilo new tons indicates the capacity of press ram can exert on work piece safely. If
the capacity of force is expressed in tones of force, then it is referred as ‘press tonnage.
Feed Height:
For dies, which are fed manually, the fed height is not critical. How ever, when dies are used in
conjunction with automatic feeding devices, the height of the stock line of the die must be with
in the range permitted by feeding device.
Die sets:
Die sets were introduced by the mass production manufacturers such as automotive appliance,
and business machine companies.

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Die sets:
The die set is one of the basic tools of the stamping industry, and while not a glamour product,
such as numerical controls, electrical discharge machines, and exotic metals, it is as vital to
metal working as the tool bit, drill, reamer, and a grinding wheel .The industries which
manufacture die sets commercially compromises six national and eight to ten regional
companies whose overall volume is relatively small in contrast to the importance of its product
to metal working mass production.

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1. Accuracy of the setup: The die can be installed in the press as a self-contained unit,
assuring proper alignment of the various punch and die members.
2. Improved piece-part quality: The quality of the work produced is enhanced by the
assured setup accuracy.
3. Increased die life: This is a result of proper alignment.
4. Minimum setup time: Setup time is kept to minimum because the die is installed as
a unit.
5. Facilitation of maintenance: Die components can be removed and reassembled
without disturbing their relationship to each other. Cutting components can be
sharpened in assembly, as units without removing them from die set.
6. Alignment of punch and die members: A die set can be a means of keeping the
punch and die members properly during the working process. However, a die set
cannot be expected to compensate foe a punch press, which is not in good
condition.
7. Facilitation of storage: On completion of the production run, the die can be stored
as a unit ready to be replaced in production again immediately.

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 Die shoe: The die set base is called the die shoe. This remains true even though punches are sometimes
mounted on this lower shoe. The great majority of standardized die sets have the guideposts in the die
shoe.

 Punch holder: The die set type member is called punch holder. This remains true even though die blocks
are sometimes mount on this top member.

 Shank: Most punch holders in the smaller sizes are made with the shank, which fits the clamping hole in
the lower end of the punch press holder to ram.

 Guideposts: Guideposts are cylindrical pins, which provide a means of alignment for the die set.

 Guidepost bushings: These are installed in the opposing whole and engage the guide posts with a closing
fit.

 Flange: A ledge which is flush with the bottom surface of a die shoe or the top surface of a punch holder.

 Die area: The area is available on the top surface of the die whole and the lower surface of the punch
holder for the mounting of punch and dies components.

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1 - Catalog sets: Advances in die sets design have brought about an almost endless choice of
catalog types and styles within a limited size rang which are produced by commercial
manufacturers of die sets and stocked for fast assembly with pins bushing,In addition to these
catalog sets, die set manufacturers can produce any practical type and size of die set the die
designer specifies
 Back post: Two guideposts are located toward the back of the set.
 Center post: Two guideposts at the left and right sides of the set on the shank centerline. The
two guideposts should differ in diameter in order to foolproof the set.
 Diagonal post: Two guideposts, one located at the right corner and the other at the left corner.
These sets can be supplied with reversed guidepost locations, the two guidepost diameters
must differ in order to foolproof this type of set also.
 Four post: One guidepost located at each of the four corners of the die set. One guidepost
center must be offset for fool proofing.

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2 - Special sets: A special die set is one, which differs in anyway from the standard catalog
specifications. Special die sets are made to order. They may be similar to catalog sets, or they
may be radically different. Special die sets may have pockets, slots, or cutout areas. These may
be rough in or completely finished by the die set manufacturer.
 Die sets are [through] stress relieved by the manufacturers before finishing rough machining
of deep pockets cut outs etc should be done by the die set manufacturer before the stress
relieving operation, if residual stresses are not removed, they will be gradually released in
service. This can be the source of distortion and dimensional changes, which can have serious
consequences.

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 Punch and die holders: Top and bottom surfaces of these parts are usually ground, with some
manufacturers finishing surface – ground finish for ease of layout on the working areas where
shank are cast integral or welded, the shanks have a smooth turned finish.
 Guide pins: Most guide pins are ground with a 20in. finish, but major manufacturers of the
die sets now improve this finish to 9in., which is ideal for wear and lubrication qualities
required in the operating die sets.
 Bushings: Press fit or slip fit diameters on bushings are also ground with a fine finish, but
only to simplify insertion into holes in the punch holders. The ID of the bushing is ground
smooth but always honed or lapped to a smooth finish when fitted to the guide pins.

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Strippers is the act of removing the work from the punch or punches. A stripper is a

device for stripping.

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Materials required for stripping plates:
Choice of material for stripper plate depends upon the cost and quality factors pertaining to each specific
instance. In the majority of box stripper applications, the stripper plate is made of low-carbon steel, left soft.
Both cold drawn and hot rolled steel are used. Plain stripper plates are often made from cold drawn steel,
because it is well suited to this type of stripper construction and because its initial cost is low. The following
materials listed in descending order of quality and durability are commonly employed for making stripper
plates

 Tool steel, hardened

 Pretreated alloy steel

 Tool steel, left soft

 High strength, low alloy steel

 Hot rolled low carbon steel, including low carbon ground stock

 Cold drawn low carbon bar stock, commonly called cold rolled steel

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Stripping Force for Blanking and Piercing:
Accurate calculations of stripping force requirements can be made. There are so many visible factors
involved that an accurate calculation must be a highly specialized computation for a specified job.

Important factors which affect stripping force:

 Stock material: Material, which have a high friction value and material, which tend to cling more and
more difficult to strip.

 Conditions for cutting edges: When the cutting edges are sharp, less stripping effort is required.

 Surface condition of side walls: A punch which has a smooth finish on its side walls strips more easily
than a punch which is not as smooth.

 Distance between punches: More effort is required to strip punches that are close together.

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Blanking is used to produce blanks of desired contour and size by cutting them out of the stock
strip. Blank is the desired ‘piece part’ made by Blanking Die. The material. remaining after
blanking is called as ‘scrap’.

Introductory Terminology:
Piece part: A piece part is the product of a Blanking Die. It may be complete product or it maybe only the
component of a product consisting of many and different parts.

Stock material: It is the raw sheet metal from which the piece part is produced.

Die: The word Die has different meanings.

➢ A complete Production Tool, the purpose of which is to produce piece parts consistently to required
specifications.

➢ The female part of a complete Die.

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Punch: A punch is the male member of a complete die, which mates in conjunction with female die to
produce a desired effect upon the material being worked.

Stripper: Stripper is a device, which is used for stripping the piece part from the punch as the punch
traverses in the reverse direction.

Pilot: a locating device, which position the work or stock strip accurately for die working.

Shedder & Knockout: Shedder is a device, which acts to expel the work piece from the die cavity.

Nest gage: The next gage is a device, which is used to locate and position the work piece properly in the
die.

Pushers: Pushers are installed for the purpose of holding the required edge or edges of the work securely in
contact with the appropriate gauging member.

Die stops : Die stops are installed in dies for the purpose of arresting the feeding movement of the stock
strip.

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The result of the forces imposed on the stock material by the working of the blanking dies is a
shearing action. The shearing action may be considered in three stages, which are important to
the Die maker because of their direct relationship to the dimensional qualities and appearance of
piece parts. They are also related to the effective working and life of the die.

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Critical stages of shearing action:
 First stage – Plastic Deformation:

The stock material has been placed on the die, the press has been tripped, and the punch is being driven
toward the die. The punch contacts the stock material and exerts pressure upon it.

 Second stage – Penetration:

As the driving force of the ram continues, the punch is forced to penetrate the stock material, and the blank
or slug is displaced into the die opening a corresponding amount..

 Third Stage – Fracture:

Further continuation of the punching pressure causes fractures to start at the cutting edge of the punch and
the die. These are points of greater stress concentration. Under the proper cutting conditions the fractures
extend toward each other and meet. When this occurs, the fracture is complete and the Blank or Slug is
separated from the original stock material.

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Piercing : This operation consists of simple hole punching. It differs from blanking in
that the punching (or material cut from stock) is the scrap and the strip is the work
piece. Piercing is nearly always accompanied by a blanking operation before, after or
at the same time.

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Fundamentals of Drawing:
 A flat blank is formed into a cup by forcing a punch against the center portion of a blank that
rests on the die ring.

 The progressive stages of metal flow in drawing a cup from a flat blank are shown
schematically in Fig. 1.

 During the first stage, the punch contacts the blank (Fig. 1a), and metal section 1 is bent and
wrapped around the punch nose (Fig. 1b). Simultaneously and in sequence, the outer sections
of the blank (2 and 3, Fig. 1) move radially toward the center of the blank until the remainder
of the blank has bent around the punch nose and a straight-wall cup is formed (Fig. 1c and d).

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 During drawing, the center of the blank (punch area, Fig. 1a) is essentially unchanged as it
forms the bottom of the drawn cup. The areas that become the sidewall of the cup (1, 2, and
3, Fig. 1)change from the shape of annular segments to longer parallel-side cylindrical
elements as they are drawn over the die radius.
 Metal flow can occur until all the metal has been drawn over the die radius, or a flange can be
retained.

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Types of drawing:
Drawing is a method of forming under compressive and tensile conditions whereby a
sheet metal blank is transformed into a hollow cup, or a hollow cup is transformed into
a similar part of smaller dimensions without any intention of altering the sheet
thickness

 Single draw drawing

 Redrawing

 Reverse drawing
 Hydro mechanical drawing

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1) Using the single-draw drawing technique it is possible to produce a drawn part from
a blank with a single working stroke of the press (Fig).

2) In case of large deformations, the forming process is performed by means of

redrawing, generally using a number of drawing operations.(Fig)

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3) This can be performed in the same direction by means of a telescopic punch or by
means of reverse drawing, which involves the second punch acting in opposite
direction to the punch motion of the previous drawing operation (Fig).

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 The most significant variation of drawing is done with a rigid tool.

 This comprises a punch, a bottom die and a blank holder, which is intended to prevent the
formation of wrinkles as the metal is drawn into the die.

 In special cases, the punch or die can also be from a soft material. There are drawing methods
which make use of active media and active energy.

 Drawing using active media is the drawing of a blank or hollow body into a rigid die through
the action of a medium.

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4) The greatest field of application of this technique is hydro mechanical drawing, For

example for the manufacture of components from stainless steel.(Fig)

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Materials for Drawing:
 Sheet steels and other sheet metals with higher strengths and better formability have
recently become available.

 Other metals and alloys that can be deep drawn include aluminum and aluminum
alloys, copper and alloys, some stainless steels, and titanium.
 Low-carbon sheet steels are the materials that are most commonly deep drawn and
are commonly used, for example, in the Automotive industry. Materials such as
1006 and 1008 steel have typical yield strengths in the range of 172 to 241MPa (25
to 35 ksi) and elongations of 35 to 45% in 50 mm (2 in.)

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 excellent dimensional control, accuracy, and repeatability through a production run.

 excellent part flatness is retained.

 straight, superior finished edges to other metal stamping processes.

 smaller holes possible relative to thickness of material.

 little need to machine details.

 multiple features can be added simultaneously in 1 operation.

 more economical for large production runs than traditional operations when additional.

 machining cost and time are factored in (1000–20000 parts minimum, depending on
secondary machining operations)

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 slightly higher tooling cost when compared to traditional punching operations.

 slightly slower than traditional punching operations.

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❑ A. M. Gandjar Kiswanto, S. S.-i. (2015). the infuence of die clearance and punch
velocity in micro-blanking process .the 14th international conferance om QIR(quality
in research (pp. 231-235). lombok, indonesia : print.
❑ BOLJANOVIC, P. D. (2004). sheet metal forming process and die design.
newyork10016: industrial press inc.
❑ F. Vollertsen, M. M. (2013, springer). design and fabrication of blanking tool.
germany.
❑ G.-L. Chern and S.-D. Wang. (2007). punchingof noncirclar micro-holes and
development of micro-forming . print.
❑ J. Xu, B. G. (11//2012). development of micro-foring system for micro-punching
process . journal of materials processing technlogy .
❑ J. Xu, B. G. (9//2012). blanking clearance and grain size effects on micro
deformation . international journal of machine tools and manufactoring , 27-34.

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