2020-24 batch

Manufacturing Methods
8TH SEMESTER B.TECH
Mechanical Engineering Department,
Jorhat Engineering College
under

ASSAM SCIENCE AND TECHNOLOGY UNIVERSITY (ASTU)

Press Working

 PressWorking (also known as cold stamping)

is defined as a manufacturing process in
which the various components are made from
sheet metal by using a press machine.
Types & different designs of Press

 The presses are available in different designs and shapes, according to the work
requirement. This article throws light upon the sixteen main types of presses.
Some of the types are:
 1. Manually Operated (Fly) Press
 2. Electric Motor Operated Press
 3. Hydraulic Press
 4. Inclined Press
 5. Inclinable Press
 6. Gap Press
 7. Arch Press
 8. Straight-Side Press and Others.
Manually Operated (Fly) Press

 1. Manually Operated (Fly) Press:

 The press is operated by human hands. It is a bench mounted press commonly
used for the production of small components. It is a simple and low cost press,
suitable for light operations, like piercing, blanking, bending, etc. As the Fig.
6.2. shows, the arm is rotated manually, the ram moves, up and down to
perform the necessary operation. The ram is fitted with punch and the job is
resting on the bed.
Manually Operated (Fly) Press:
2.Electric Motor Operated Press:

 Electric Motor Operated Press:

 The press is operated by an electric motor. The motor drives the crank shaft
which converts the rotary motion into reciprocating motion of the ram. The ram
fitted with the punch, to operate upon the job held on the die block and bolster.
Different types of motor operated presses

The different types of electric motor operated

presses are:
(a) Non-geared (fly wheel) type.

(b) Single reduction gear type.

(c) Double reduction gear type.
(d) Multiple reduction gear type.
Types of electric motor operated presses
3. Hydraulic Press:

 3. Hydraulic Press:
 The hydraulic press uses the water or oil pressure to moves the slide and ram up and down. A
Pump is employed to supply the liquid under high pressure to the cylinder.
 An accumulator system is used to store the liquid and then to supply suddenly a large volume of
liquid at a constant pressure in seconds of time. In self-contained type hydraulic presses,
accumulator is not used. All the energy is applied directly to the cylinder by the pump.
 Hydraulic presses are available in capacities up to 15000 tons. Hence, these presses are specially
employed for drawing, extruding, piercing and blanking of metals above 3mm thickness.
 ADV:
 (i) Higher amount of force can be produced.
 (ii) Uniformly pressure distribution.
 (iii) Slower and uniform ram-punch speed.
4. Inclined Press:

 As its name indicates, it has an inclined frame as shown in Fig. below

Advantages (i) Work part can automatically slide by gravity into

the container box.
(ii) Scrap discharge from the work piece is automatic.
5. Inclinable Press:

 An inclinable press is shown in Fig. below, has an adjustable frame. It can be

used for vertical as well as any inclined position.
Advantages

 (i) Very high production rates.

 (ii) Work parts are automatically slide down into the container
box and operator need not put his hand to lift the work piece.
 (iii) The danger of injury to fingers of the operator is eliminated.
 (iv) These presses are used in the production of small parts
involving bending, blanking, and punching operations.
6. Gap Press:

 Gap Press:
 A Gap-press also called C-Press, is that shown in Fig (a). below. It has an open
throat that provides excellent gap around the dies. Such type of press allows the
use of very long and wide work parts.
7. Arch Press:

 Arch Press:
 An arch-Press is shown in Fig.(b). It has an arch-shaped frame. It is used for
light work. Some products manufactured by this press are; Paint cans, shovels
etc.
 Straight-Side Press:
 A straight-side press is shown in Fig. (c). It has high capacity of work. It has a
rigid frame and is used in mechanical and hydraulic presses where heavy loads
are produced. These types of presses are used for forming of heavy and thick
metals, coming, deep drawing, etc.
Schematic diagrams of Presses:
A horn press is shown in Fig. (d). It and is used for cylindrical objects involving operations like,
seaming, flanging, embossing, riveting, and punching.
Schematic diagrams of Presses:

 Crank-Driven Press:
 A crank-driven press is shown in Fig. (a). It uses a crank to convert the rotatory motion of shaft
into up and down motion of the ram. The ram is guided between guides.
 Eccentric-Driven Press:
 An eccentric-driven press is shown in Fig.(b). It uses an eccentric to convert the rotary motion
of the shaft into up and down motion of the ram. It is used where a shorter stroke length is
required. The advantages of these presses are: better rigidity and less tendency of deflection as
compared to a crank-driven press.
 12. Rack and Pinion-Driven Press:
 A Rack and pinion-driven press is shown in Fig.(c). It uses a rack and a small gear (pinion) to
obtain the up and down movement of the ram. These presses are used where the length of
stroke is very long. In these types of presses, the length of stroke can be adjusted as required.
For upward movement of ram, a quick return mechanism may be used.
Schematic diagrams of Presses:
Hydraulic-Driven Press:
A hydraulic driven press is shown in Fig. (d) Hydraulic presses are used for large force and slow
speed requirements.
Main Operations of Press Working

 This article throws light upon the eleven main operation of press
working. The operations are: 1. Shearing Operation 2. Cutting-Off
Operation 3. Parting Operation 4. Blanking Operation 5.
Punching Operation 6. Notching Operation 7. Shaving Operation
8. Piercing Operation 9. Bar Cropping Operation 10. Fine
Blanking Operation 11. Bending Operation.
. Shearing Operation:

 Operation # 1. Shearing Operation:

 The shearing operation is shown in Fig. When the sheet metal is cut along a
straight line, the operation is known as shearing. It involves the use of inclined
blades in order to reduce the force requirement.
 The cutting takes place gradually in steps not all at once over the width of the
sheet metal. Here, the upper blade is inclined while lower blade is straight and
fixed. The angle of inclination of upper blade usually ranges between 4° and 8°
and must not exceed 15°.

Cutting-Off Operation:

 2. Cutting-Off Operation:
 The cutting off operation is shown in Fig.a (slide no 21). When the cutting takes place along and open
curve (may be line), the operation is known as cutting-off. The cutting-off operation results in almost
no or little wastage (at the ends) of stock.
 Therefore, it is considered to be a very efficient material utilization operation. This operation is done
with the help of die mounted on a crank press. In cutting operation the metal is subjected to both
tensile and compressive stresses, as shown in Fig. b, (slide no 21).
Cutting-Off Operation:
 Parting Operation:

. Parting Operation:
3
The parting operation is shown in Fig. (Nxt Pg). When the cutting takes place along two
open curves (or lines) the operation is referred as parting.

The parting operation is not efficiently utilizing the material as in case of cutting-off
operation. The wastage of stock is more compared to the cutting-off operation.
Parting Operation:
Blanking Operation:
 4. Blanking Operation:
 The blanking operation is shown in Fig. below. When the cutting takes place along a closed
contour, the operation is known as blanking. The blanking operation results in a relativity high
percentage of waste in stock material.
 It is less efficient among all other cutting operations. An efficient layout of blanks on the metal
sheet can result in considerable saving of metal. Fig. attached, shows a good layout where circular
blanks are staggered.
Blanking Operation:

 Also there is a limit to the minimum distance between two adjacent blanks i.e.

In blanking the part separated from the sheet metal is the product output and remaining sheet
metal is the scrap metal. This process is employed in mass production of blanks that cannot be
produced by shearing, cutting-off or parting operations.
Punching Operation:

 5. Punching Operation:
 The punching operation is similar to the blanking operation only difference is that, the remaining part
of sheet metal is the product output. The blanks produced are wastage material punching of small hole
patterns are referred as perforating. The perforated products are used for light distribution or for
ventilation as shown in Figure as shown.
Notching Operation

6. Notching Operation:
The notching operation is a special case of punching in which the part is removed from the edge of the
strip, as shown in Figure. This operation is usually employed in progressive dies. Fig. shows a similar
operation called semi-notching where the separated part is not attached to the side of the strip.
 Shaving Operation:

 7. Shaving Operation:
 The saving operation is sometimes carried out on blanks to remove the rough side. This
operation is also needed for proper dimensioning of the blanks. In shaving operation the excess
or rough metal is removed in the form of chips, as shown in Fig. below, the punch die clearance is
kept very small.

Shaving Operation:
 Piercing Operation:
 Piercing Operation:
 The piercing operation is shown in Fig.as shown. It involves a tearing
action of metal and uses a pointed punch. The piercing operation results in
neither blanks nor metal waste. In place of wastage of materials, a short
sleeve is generated around the hole which has functional applications.


Fine Blanking Operation:

fine Blanking Operation:

The fine blanking operation is a special case of blanking operation
in which the blanks has straight and smooth sides. The operation
involves the use of a triple action press and a special die with a very
small punch-die clearance as shown in Fig below.

A die, an upper punch and a lower punch is used to

squeeze the metal and restrain lateral movements of
the work. This is a precise operation and able to
produce irregular outer contours.
Mechanics of Sheet Metal Cutting:

Shows the circular punch, the die, and the sheet metal during a blanking operation.
The product obtained is a blank.
Blanking operation

 The profile of the edge of a blank involves four zones:

 (i) A rollover
 (ii) A burnish
 (iii) A fracture surface
 (iv) A burr
 Also, the profile of the edge of the generated hole consists of the same four
zones, but in opposite order.
 STEPS Blanking operation
 (1) When a load is applied through the punch, the upper metal surface is elastically bent over the edge of
the punch, while the lower metal surface is bent over the edge of the die. On Further increasing of punch
load, the elastic curvature becomes plastic deformation i.e., permanent deformation. This is known as
rollover.
 (2) Now, the Punch sinks into the upper surface of the sheet, while the lower surface sinks into the die hole.
This process involves the plastic flow of metal by shearing. Here, there are two forces equal in magnitude
but opposite in direction, subjecting the cylindrical surface to intense shear stress.
 The result will be a smooth cylindrical surface called burnish. The burnish ranges approximately between
40 and 60 percent of the Stock thickness. This value may go up to 80 percent in case of ductile metals like
lead, aluminums, etc.
 (3) Next, the two crake are developed simultaneously in the sheet metal. One at the edge of the die and
other at the edge of the punch, these two cracks progressively increases and meet each other to separate
the blank from the sheet metal. This creates a rough surface called Fracture surface.
 (4) Finally, when the blank is about to completely separate from the sheet metal, a bum is formed all
around its upper edge.
Bending Operation:
Bending Operation:
Bending is the simplest operation of sheet metal working. It can be earned out by employing simple hand tools or bending dies, as
shown in Figure below

The force applied by dies, generates the bending

moment. This will bend a part of the sheet to be bent,
with respect to the rest of it, through plastic
deformation.
As can be seen, the displacement between forces is
maximum in the case of the V-type die, therefore, less
force is needed to bend sheet metal.
Mechanics of Bending:

 1. Elastic Deformation:
 When the load is applied, the bend zone undergoes elastic deformation. The external fibers in the bend
zone are subjected to tension; while the internal fibers are subjected to compression, as shown in Fig.
a) .The neutral plan lies at the middle of the thickness. The length of the neutral axis remains constant,
either in elongation or contraction.
 2. Plastic Deformation:
 When the load increases, plastic deformation starts. In plastic deformation, the neutral plane
approaches the inner surface of the bend, as shown in Fig (b). The location of the neutral plane
depends upon number of factors, such as the radius, thickness, degree of bend of the sheet metal.
Usually, for blank development calculations, the position of the neutral plane is taken as 40 percent of
the thickness, from the inner plane.
Mechanics of Bending:
 Spring back phenomenon
 The spring back phenomenon occurs in bending process. It can be defined as, an elastic recovery of the
sheet metal after the removal of the bending load. This phenomenon is shown in Fig belowin which
bending by an angle of 90°, will produce some amount of spring back. The resultant will be bending of
more than 90°.
Mechanics of Bending:

 The zone around the neutral plane is subjected to elastic stresses; as a result,
the elastic core tries to return to its initial flat position, as soon as the load is
removal.
 The following are some methods to eliminate spring back
phenomenon:
 1. Bottoming:
 Localized plastic deformation, in which a punch is made so that a projection
squeezes the metal locally. See Fig.a (Slide no 40)
Stretch-Forming

 2. Stretch-Forming:
 A high tensile stress is superimposed upon bending. Fig. (b).
 Over Bending:
 A third method is the over bending. The amount of over bending is equal to the
amount of spring back. Fig. (c).
Requirement of Stock Material in
Bending:

 Since the length of the neutral plane does not undergo any deformation during the bending operation and
therefore remains unchanged.
 This principle is used to determine the length of the blank before bending operation. This is shown in Fig.
 According to this, the length of the blank before bending = The length of the neutral plane within the final
product can be expressed as:

Fig shows a bending product with straight

&circular sections for blank development