TYPES OF DIES

1: Bed:
The bed is the lower part of the press frame that serves as a table to which a
Bolster plate is mounted.
2: Bolster Plate:
This is a thick plate secured to the press bed , which is used for locating and
supporting the die assembly. It is usually 5 to 12.5 cm thick.
3: Die Set:
It is unit assembly which incorporates a lower and upper shoe, two or more guide
parts and guide part bushings.
4: Die Block:
It is a block or a plate which contains a die cavity
5: Lower Shoe:
The lower shoe of the a die set is generally mounted on the bolster plate of a press.
The die block is mounted on the lower shoe, also the guide post are mounted on it.
6: Punch :
This is male component of a die assembly, which is directly or indirectly moved
by and fastened to the press ram or slide.
7: Upper Shoe:
This is the upper part of the die set which contains guide post bushings.
8: Punch Plate :
The punch plate or punch retainer fits closely over the body of the punch
and holds it in proper relative position.
9: Back up Plate:
Back up plate or pressure plate is placed so that intensity of pressure does not become
excessive on punch holder. The plate distributes the pressure over a wide area and the
intensity of pressure on the punch holder is reduced to avoid crushing.
10: Stripper:
It is a plate which is used to strip the metal strip from cutting a non-cutting Punch or
die. It may also guide the sheet.
CONVENTIONAL DIES:

• Punch holder fastened to the ram of the press

• Die shoe fastened to the bolster plate
• Punch is fastened to the punch holder and
aligned with the opening in the die block using
guide pins
• Stripper holds the scrap strip so that the punch
may pull out of the hole
CONVENTIONAL POSITION
OF THE DIE SET
INVERTED DIES
 INVERTED DIES

• Punch and die positions are interchanged

• Reason: The opening in the bolster plate is too
small to permit the finished part to pass through
bolster opening
• Die block fastened to the punch holder and
punch fastened to the die shoe
• As the ram descends the blank is sheared from
the strip
 INVERTED DIES

• The punch is forced through the scarp strip and

a spring attached to the stripper is compressed
and loaded

• On the upstroke of the ram the shedder pushes

the blank out of the die opening

• Stripper forces the scrap strip off the punch

 COMPOUND DIES
• Combine the principles of conventional and
inverted dies in one station
• Workpiece is pierced and blanked in one station
and in one operation
• The piercing punch is fastened in conventional
position to the punch holder
• Die opening for piercing is machined into the
blanking punch
 COMPOUND DIES
• The blanking punch and blanking die opening
are mounted in an inverted position

• The blanking punch is fastened to the die shoe

• The blanking die opening is fastened to the

punch holder
COMPOUND DIES
 PROGRESSIVE DIES
• These dies perform two or more operations at
different stages every time the ram descends
• The stock strip is advanced through a series of
stations that perform one or more distinct
operations on w.p
• The strip must move from first through each
successive station to produce a complete w.p
• The distance from one station to the next must
be same
 PROGRESSIVE DIES
Each station performs an operation on
the work piece, so that the work piece is
completed when the last operation has
been accomplished. For a four station die,
each successive stroke will produce a
finished part.
Operations that can perform are piercing,
blanking, forming, drawing etc
PROGRESSIVE DIES
 COMBINATION DIES
• In these types of dies cutting operation is
combined with a non-cutting operation

• The cutting operations may include blanking,

piercing, trimming etc. and are combined with
non-cutting operations like bending, extruding,
forming etc.
 DESIGN OF PIERCING AND
BLANKING DIES AND PUNCHES
 PUNCH DESIGN
• The punch must withstand the maximum
blanking or piercing pressure
• They should not deflect during operation
• Deflection of punches may be avoided by
making the body diameter of punch larger than
cutting diameter
• Small punches may require punch support to
prevent breakage
 PUNCH DESIGN
• Punch plates serve to hold, position and
strengthen the punch
• Piercing punches should not be smaller in
diameter than the thickness of the stock they are
to pierce
• Always avoid designing punches that would
have more than 4 in. of unguided length
PUNCH DESIGN
 PUNCH DESIGN
PLAIN PUNCHES:
• They are simply a block of hardened tool steel
shaped to conform to the cutting contour
• Screws and dowels secure plain punches
• Plain punches must be large enough in area to
allow for screws and dowels
• Screw and dowel holes should be located at
least 1 ½ to 2 times the screw or dowel diameter
from the cutting edge
 PUNCH DESIGN
PLAIN PUNCHES:
 PUNCH DESIGN
PLAIN PUNCHES:
 PUNCH DESIGN
PEDESTAL PUNCHES:
• Constructed by machining in such a manner that
leaves a flange around the base of the punch
• This punch always has a base area larger than
its cutting face area
• Its major advantage is stability caused by the
large base and solid construction
• Cutting forces are dispersed through the large
base, so used for heavy cutting loads
 PUNCH DESIGN
PEDESTAL PUNCHES:
 PUNCH DESIGN
PUNCH SHEDDERS:
• In piercing and blanking, sometimes, slug or blank
clings to the punch face called ‘slug pulling’
• Another factor of slug pulling is lubricant
• Heavy lubricants make slugs cling to punch face
• Slug pulling caused by heavy lubricants can be
reduced by using lower viscosity lubricant
• Another method is to use shedders
 PUNCH DESIGN
PUNCH SHEDDERS:
• Spring-actuated shedder pins are located
in the center of the punch
• Air pressure may also be used to prevent
slug pulling
• This method is more complicated and also
tends to blow lubricant away from cutting
areas
 PUNCH DESIGN
PUNCH SHEDDERS:
 PUNCH DESIGN
The maximum allowable punch length:
Lm = πD/8 (E.D/fs.t)½
Where
D = Diameter of punched hole
fs = Shear stress
t = Material thickness
E = Modulus of elasticity of punch material
Where
D/t = 1.1 or higher
 KNOCKOUTS
• In normal operations the slug clings to the die
wall because of spring back in the blank or slug
• Knockouts are used to remove workpieces that
adhere to the die opening
• The upper end of the knockout registers against
the knockout bar of the press which pushes the
shedder down so that the workpiece is pushed
back
KNOCKOUTS
 PILOTS
• The function of the pilot is to position the work
piece or stock strip accurately
• In progressive dies to locate the work strip so
that the relationships between stations may be
maintained.
• Advantage is taken of these holes so that the
blank formed is exactly concentric to the pierced
hole
• This piloting is obtained with the help of pilots
secured to the blanking punches
 PILOTS
Pilots are fitted to punches by the methods:
• Press fit pilot
• Threaded shank pilots
• Socket set screw pilots

• If the operation is slow the pilots may be press

fitted into a hole in the center of punch
• If there is any danger of pilot dropping out, it
should be fastened
PILOTS
 STRIPPERS
• They are used to remove the stock from the
punch after a blanking or piercing operation
• Classified as fixed and spring-operated
• Fixed strippers are solidly attached to the die
block or die shoe
• Spring operated strippers travel up and down on
the shank of the punch
 STRIPPERS
CHANNEL STRIPPERS:
• A type of fixed stripper
• Consists of a rectangular plate mounted on top
of die block
• A channel or groove is milled through which the
strip is passed
• The height of the channel should be 1 ½ times
the stock thickness
• The width must be equal to the strip width plus
some clearance to allow variation in strip width
 STRIPPERS
CHANNEL STRIPPERS:
SPRING-OPERATED STRIPPERS

• Also called pressure pad strippers

• Employ springs to apply pressure to the stock
strip
• Suspended from punch holder with stripper bolts
and compression springs
• An advantage of this type is that it tends to hold
the strip flat during the press cycle
SPRING-OPERATED STRIPPERS
 DIE STOPS (STOCK STOPS)
• Used to locate the stock in the die set when
hand feeding
• The simplest form of stock stop is dowel pin
• An edge of previously blanked opening is
pushed against this pin
• The stock is lifted above the pin on return stroke
to release the strip from pin
• Demands considerable skill on the part of
operator
 STOCK STOPS
Dowel pin used as stop
 STOCK STOPS
• ‘Trip stop’ is another type of stock stop
• The pawl rises on ratchet principle
• When the operator pulls the stock back, the pawl
drops and locates the stock

A ratchet is a device used to restrict motion in

one direction
STOCK STOPS
 Die Stops
•Stops are essentially used for stopping the stock
while feeding, so as to register the correct position
under the punch.
•While using in conjunction with a pilot, the strip is
stopped at a position from which, the pilot brings
it to the registry position.

Solid
Stop
End mounted
Solid Stop
 Pilots
The pilots in progressive dies are used in
order to bring the stock into the correct
position for the succeeding blanking or piercing
operations.
Drawing
• Drawingis the process of making cups, shells,
and similar articles from metal blanks.
• Theset up is similar to that used in blanking
except that the punch and die are provided
with the necessary rounding at the corners to
allow for the smooth flow of metal during
drawing .
• The blank is first kept on the die plate. The punch
slowly descends on the blank and forces it to take
the cup shape formed by the end of the punch, by
the time it reaches the bottom of the die.
• When the cup reaches the counter bored portion
of the die, the top edge of the cup formed around
the punch expands slightly due to the spring back.
• When the punch moves in the return stroke, the
cup would be stripped by this counter bored
portion.
 Shallow drawing
• This description is true in the case of shallow
drawing operation only.
• Shallow drawing is defined as that where the cup
height is less than half the diameter.
Deep drawing

• For drawing deeper cups it is necessary to make

specific provisions to confine the metal in order
to prevent excess wrinkling of the edges.
• For this purpose, a blank holder is normally
provided on all deep drawing dies.
 Rigid blank holder
• The rigid blank holding is normally used for
thicker materials which are less likely to wrinkle.
• A more common usage is the spring loaded
pressure pad similar to the stripped used in
cutting dies.
• The spring loaded pressure pad which moves with
the punch, maintains a more uniform pressure on
the blank throughout the drawing operation.
 Ironing
• In deep drawing, because of the radial flow of
material, the side walls increase in thickness as the
height is increased.
• There would be a slight thinning of metal at the
bottom corners.
• For applications requiring uniform side walls, an
operation called ironing is carried out on drawn
cups.
 Ironing
• Ironing is the operation of thinning the side walls
and increasing the height.
• The die and punch set used is similar to that of
drawing operation except that the clearance
between the die and punch is smaller than that
used in the drawing operation.
• The material gets compressed between punch and
die which reduces the thickness and increases the
height, and thus is a severe operation.
• The wall thicknesses can be reduced to as much as
50 % in a single ironing operation.
Ironing Force = Pi d (t – t1) x Compressive
stress of material
t1 is die clearence
Drawing die design

Corner radius on punch

Draw radius on die
Clearances
Blank size
Drawing force
Blank holding force
Ironing force
Percent reduction
Air vent
Drawing speed
27 February 6, 2012
Corner radius on punch
• Though there is no set rule for the provision of corner
radius on the punch, it is customary to provide a radius of
four to ten times the blank thickness.
• Too small a corner radius makes for the excessive thinning
and tearing of the bottom of the cup.
• Ideally, the punch radius should be the same as the corner
radius of the required cup, because it takes its form.
• It is not possible in deep drawing to obtain the final cup
size in a single drawing operation.
• Depending on the geometry of the cup, it may be
necessary to go in for more than one drawing operations,
in which case, the subsequent operations are called
redrawing operations.
 •Draw radius on die
• Since the draw radius on die does not contribute to
the cup shape, it can be made as large as possible.
• Higher the radius, higher would be the freedom for
the metal to flow.
• Too high a radius causes the metal to be released early
by the blank holder and thus lead to edge wrinkling.
• Too small a radius causes the thinning and tearing of
the side walls of the cups.
•draw radius = 4 t normal
= 6 to 8 t when the blank holder is
used
= 0.8 p (D-d) t
•where t = blank thickness
Clearances

• Ideally, the clearance between punch and die should

be same as the blank thickness.
• But the blank gets thickened towards the edge
because of the metal flow and hence, the actual
clearance provided is slightly higher to account for
this thickening.
• An allowance in the range of 7 to 20% of the blank
thickness is provided depending on the cup material
and cup dimensions.
 Blank First draw Second Sizing draw
thickness draw
(mm)
upto 0.40 1.07 to 1.09 1.08 to 1.10 1.04 to 1.05
0.41 to 1.25 1.08 to 1.10 1.09 to 1.12 1.05 to 1.06
1.30 to 3.00 1.10 to 1.12 1.12 to 1.14 1.07 to 1.09
above 3.01 1.12 to 1.14 1.15 to 1.20 1.08 to 1.11
Blank size
• Itis often difficult to find a blank of the exact size
required for making a given shell, because of thinning
and thickening of sheet during drawing.
• The calculation could be based on volume, surface
area or by layout.

• where r = corner radius on the punch, mm

• h = height of the shell, mm
• d = outer diameter of the shell, mm
• D = blank diameter, mm
• For practical purposes, it is necessary to add additional
allowances to provide for trimming of the uneven and
irregular rim of the deep drawn cup. This is termed as trim
allowance.
• The trim allowance could be 3 mm for the first 25 mm cup
diameter.
Drawing force
• The drawing force depends on the cup material,
itsdimensions and the configuration. The Drawing
force for cylindrical shell is given by

Where P = drawing force, N

t = thickness of the blank material, mm
s = yield strength of the metal, MPa
C = constant to cover friction and bending.
Its value is between 0.6 and 0.7
Blank holding force

• The blank holding pressure required depends on the

wrinkling tendency of the cup, which is very difficult to
determine and hence it is obtained more by trial and
error.
• The maximum limit is generally to be one third of the
drawing force.
Air vent
• An air vent is normally provided in the punch to
reduce the possibility of formation of vacuum in the
cup, when it is stripped from the punch.
• For cylindrical shells, one vent located centrally
would be enough, where as for other shapes it may
be advantageous to provide two.
 Drawing speed

• The speed with which the punch moves through the blank
during drawing, is termed as the drawing speed.
• This is a very important parameter in drawing because
higher speeds are sometimes detrimental.
• Particularly harder and less ductile materials are likely to
be excessively thinned out due to excessive drawing
speeds.

Material Drawing speed

(m/s)
Aluminium 0.90
Brass 1.00
Copper 0.75
Steel 0.28
Zinc 0.75
BENDING DIES
 Bend line - That defines the end of
the level flange and the start of the
bend.
Outside mold line - This line defines
the edge of a mold that would
bound the bent sheet metal.

Flange length - The length of either of the two flanges, extending

from the edge of the sheet to the bend line.
Mold line distance - The distance from either end of the sheet to the
outside mold line.
Setback - The distance from either bend line to the outside mold line.
Also equal to the difference between the mold line distance and the
flange length.
Bend axis - The straight line that defines the center around which
the sheet metal is bent.
Bend length - The length of the bend, measured along the bend
axis.
Bend radius - The distance from the bend axis to the inside
surface of the material, between the bend lines. Sometimes
specified as the inside bend radius. The outside bend radius is
equal to the inside bend radius plus the sheet thickness.
Bend angle - The angle of the bend, measured between the bent
flange and its original position, or as the included angle between
perpendicular lines drawn from the bend lines.
Bevel angle - The complimentary angle to the bend angle.
 K-factor - calculated as the ratio of the
distance of the neutral axis (measured
from the inside bend surface) to the
material thickness. The K-factor is
dependent upon several factors
(material, bending operation, bend
angle, etc.) and is typically greater than
0.25, but cannot exceed 0.50.

Bend allowance - The length of the neutral axis between the bend lines, or in
other words, the arc length of the bend. The bend allowance added to the
flange lengths is equal to the total flat length.
Bend deduction - Also called the bend compensation, the amount a piece of
material has been stretched by bending. The value equals the difference
between the mold line lengths and the total flat length.
V-BENDING AND EDGE BENDING
Bending operations are performed using punch and die
tooling. The two common bending methods and
associated tooling are V-bending, performed with a V-
die; and edge bending, performed with a wiping die.
•This method uses a single bending unit comprising two primary
components, the saddle and the rocker. This unit can be mounted on
upper or lower die shoes.
•During bending the rocker acts as both a holding pad and forming
steel. As the press continues downward, the rocker rotates, creating a
gentle bending action. Because of this rotary action, a primary bend
angle of about 120 degrees can be achieved.
Here w will be width between contact points on die & is
determined as shown:
w=R1+ c +R2,where
R1 =Punch edge radius
R2=Die edge radius
c=clearance=t
For U bends, where bottoming is necessary, a blank holding pad is
employed.
FC=F+ (a* Pb)
where, Fc =minimum press capacity
a = area of pad face
Pb=Average blank holding pressure,
ranging from1.05 N/mm2 for less
ductile & thick materials to 2.88N/mm2
for more ductile & thin materials.

Pad force may be taken as =0.67 σuttl

Spring back: When the bending pressure is removed at the end of
deformation, elastic energy remains in the bend part, causing it to
recover partially toward its original shape.
SB = (A’ – Ab’)/Ab’
Where SB – springback; A’ – included angle of sheet-metal part; and Ab’
– included angle of bending tool, degrees.
Compensation for springback can be accomplished by
several methods. Two common methods are overbending
and bottoming.
In overbending, the punch angle and radius are fabricated
slightly smaller than the specified angle on the final part so
that the sheet metal springs back to the desired value.
Bottoming involves squeezing the part at the end of the
stroke, thus plastically deforming it in the bend region.
ØBottoming force:
To overcome spring back, the bend
area is often placed under high compressive stress to
set the metal. This is called Bottoming.
Bottoming force= σclb
where, b =plan project width of bend
σc=compressive pressure