PRESSES

&

PRESS WORK
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 Press working has been defined as a chipless manufacturing
process by which various components are made from sheet
metal.

Press working operations are carried out with the help of a

metal forming machine called press which shears or forms
the component by applying force.

Processing of sheet metal is done in cold state.

Press tool operation of sheet metal is by far the cheapest

and fastest method of complete manufacture of component.

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Punch and Die
Components

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 Press Working Operations

1) Cutting Operations

Shearing to separate large sheets.

Blanking to cut part perimeters out of sheet metal.
Punching to make holes in sheet metal.
The work piece is stressed beyond its Ultimate Shear Strength
and Cut Off into pieces.

2) Forming Operations

The work piece is stressed below the Ultimate Shear Strength,

as there is no cutting of metal, only the contour of the work piece
is changed to the desired shape.
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Figure :Shearing of sheet metal between two cutting edges: (1)
just before the punch contacts work; (2) punch begins to push
into work, causing plastic deformation;
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Figure : Shearing of sheet metal between two cutting edges: (3)
punch compresses and penetrates into work causing a smooth cut
surface; (4) fracture is initiated at the opposing cutting edges
which separates the sheet.
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 Shearing
Sheet metal cutting operation along a straight line between two
cutting edges
Typically used to cut large sheets

Figure : Shearing operation: (a) side view of the shearing operation; (b)
front view of power shears equipped with inclined upper cutting blade.
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 Blanking and Punching
Blanking - sheet metal cutting to separate piece (called a blank)
from surrounding stock
Punching - similar to blanking except cut piece is scrap, called a
slug.

Figure : (a) Blanking and (b) punching. 8

Figure (a) Schematic
illustration of shearing
with a punch and die,
indicating some of the
process variables.
Characteristic features of
(b) a punched hole and
(c) the slug.

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Recommended clearance is calculated by:
c = at
where c = clearance; a = allowance; and t = stock thickness
Allowance a is determined according to type of metal

Metal group a
1100S and 5052S aluminum 0.045
alloys, all tempers
2024ST and 6061ST aluminum 0.060
alloys; brass, soft cold rolled steel,
soft stainless steel

Cold rolled steel, half hard; 0.075

stainless steel, half hard and full
hard 10
 Punch and Die Sizes
For a round blank of diameter Db:

Blanking punch diameter = Db 2c

Blanking die diameter = Db
where c = clearance

For a round hole of diameter Dh:

Hole punch diameter = Dh

Hole die diameter = Dh + 2c
where c = clearance
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Figure : Die size determines blank size Db; punch
size determines hole size Dh.; c = clearance
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 Angular Clearance
Purpose: allows slug or blank to drop through
die
Typical values: 0.25 to 1.5 on each side

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Figure : (a) Punching (piercing) and blanking. (b)
Examples of various die-cutting operations on sheet
metal.

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 Other Sheet-Metal Cutting Operations

Cutoff (one cutting edge)

Parting (with 2 cutting edges)
Slotting (rectangular hole)
Perforating (pattern of holes)
Notching (cutting a portion on the edge)
Semi-notching (from the interior)
Trimming (remove excess metal)
Shaving (smooth cutting edges)
Fine Blanking (close tolerances, smooth with pressure pad)

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