Production Tooling Design

B.Sc. Industrial & Manufacturing Engineering

7th Semester, Session 2018

1 6/26/22
 18-01

2 6/26/22
 Sheet Metalworking Processes

3 6/26/22
 Sheet Metalworking Basics

4 6/26/22
 Sheet Metalworking Defined
Cutting and forming operations performed on
relatively thin sheets of metal

Thickness of sheet metal = 0.4 mm (1/64 in) to 6

mm (1/4 in)

Thickness of plate stock > 6 mm

Operations usually performed as cold working

5 6/26/22
 Sheet and Plate Metal Products
Sheet and plate metal parts for consumer and industrial
products such as
Automobiles and trucks
Airplanes
Railway cars and locomotives
Farm and construction equipment
Small and large appliances
Office furniture
Computers and office equipment

6 6/26/22
 Sheet-Metal Parts

(a) (b)

Examples of sheet-metal parts. (a) Die-formed and cut stamped parts. (b) Parts produced
by spinning.

7 6/26/22
 Advantages of Sheet Metal Parts
High strength
Good dimensional accuracy
Good surface finish
Relatively low cost
Economical mass production for large quantities

8 6/26/22
 Sheet Metalworking Terminology
 Punch and Die - tooling to perform cutting, bending, and
drawing (custom‑designed for particular part)

 Stamping press - machine tool that performs most sheet

metal operations

 Stampings - sheet metal products

9 6/26/22
 Basic Types of Sheet Metal Processes

1. Cutting
 Shearing to separate large sheets
 Blanking to cut part perimeters out of sheet metal
 Punching to make holes in sheet metal
2. Bending
 Shaping of sheet material by straining sheet around a
straight axis. (in ductile materials)
3. Drawing
 Forming of sheet into convex or concave shapes
 Sheet metal forming operation used to make cup shaped,
box shaped and other complex curved hollow shaped parts.

10 6/26/22
 Sheet Metalworking Basics Video

11 6/26/22
 Presses Used In Sheet Metal
Working Operations

12 6/26/22
 Presses
 In sheet metal working large forces are applied for a short time interval which
results in the cutting (shearing) or forming (deformation) of work material

 In sheet metal working forces are setup, guided and controlled in a machine
referred to as ‘press’ (hence these operations are also called sheet metal
pressworking operations)

 A press in sheet metal working is a machine tool with a stationary bed and a
powered ram (or slide) that can be driven toward and away from the bed to
perform various cutting and forming operations

 The forces may be applied through the use of mechanical or hydraulic

systems

13 6/26/22
 Presses
 When selecting a press for a given application,
consideration should be given to
The capacity required
The type of power
The number of slides or drives
The type of drive
The stroke length, the number of strokes per minute
The shut height
The type of frame construction
Speed of operation

14 6/26/22
 Power-Press Types
Presses can be classified in different ways
(1) CLASSIFICATION BY TYPE OF FRAME:
 Type of press frame refers to the physical construction of the
press
 Frame design is important regarding size of work, how it is fed,
stiffness of the machine etc.
 The frame of a press is fabricated by casting or welding heavy
steel plates
 Based on type of frame, presses have further two types
(i) Gap Frame Presses
(ii) Straight-Sided Presses
15 6/26/22
(1) Classification By Type of Frame
(i) GAP FRAME PRESSES:

 The gap frame press has the general configuration of letter ‘C’
(also called C-frame press)
 Some of these presses have an open back
 This allows feeding strip from front to back
 Some of these presses have inclinable frame
 This allows the parts to fall through the open back by gravity
 Such presses are called open-back inclinable (OBI) presses
 The press brake is a gap frame press with a very wide bed
 Turret presses are suited for a sequence of cutting operations
16 6/26/22
 C-Frame Press
This press is used for relatively small workpieces
Most commonly used
Provides access to the dies from three directions

17 6/26/22
 Parts of a C-Frame Press

Components of a typical mechanical drive C-frame press

18 6/26/22
 Parts of a C-Frame Press

19 6/26/22
 Parts of a C-Frame Press

BED:
 Rectangular in shape
 The center is open to allow finished parts or scrap to fall
through due to gravity

BOLSTER PLATE:
 Fastened to the to the top of the bed
 Die set is fastened to it
 2 to 5 inch thick

20 6/26/22
PARTS OF AN OBI PRESS
RAM:
Also called the slide
Oscillates and provides the motion which moves
the punch holder through its stroke

KNOCKOUT:
Mechanisms that are used to eject workpieces from
the die set
PARTS OF AN OBI PRESS
PITMAN ARM:
Connecting link between the ram and the crank or
main shaft
FLYWHEEL:
Has mass enough so that energy provided by a
motor is stored

It provides intermittent forces to the ram without

appreciable loss of power
 Schematic illustration of a press brake. It has a very wide bed. It is generally
used for bending operations to be performed as a sequence.

23 6/26/22
 (1) Classification By Type of Frame
(ii) STRAIGHT-SIDED PRESSES:
 Box-like construction
 Much larger than C-frame presses
 Have straight columns at both ends of the bed
 Are open at front and rear
 Used for large and heavier work (higher
tonnage)

24 6/26/22
 Straight-Sided Presses

25 6/26/22
 (2) Classification By Source of Power
(i) MECHANICAL PRESSES:
 Use a flywheel-driven system to obtain ram movement
 The heavy flywheel absorbs energy from the motor continually
 Delivers its stored energy to the workpiece intermittently
 Drive mechanisms: crank, cam, knuckle joint, toggle, screw

(ii) HYDRAULIC PRESSES:

 Use a large cylinder and piston coupled to a hydraulic pump
 The tonnage capacity depends upon the cross-sectional area of the
piston and the pressure developed by the pump

(iii) MANUALLY OPERATED PRESSES:

 Generally foot-operated

26
Used for very light work 6/26/22
 20-38

Types of drives for sheet-metal mechanical presses: (a) eccentric,

(b) crankshaft, and (c) knuckle joint

27 6/26/22
 (3) Classification By The Number of
Slides Incorporated
 The number of rams or slides in a press is called the ‘action’

 Single-action press has one ram or slide

 Double-action press has two rams or slides, generally one inside

the other

 Triple-action press has three slides

 Multiple-action presses are usually specified for the drawing of

more complex parts

 Single-action presses are used for the simpler operations

28 6/26/22
 Die Sets
Punches and dies are mounted on standard die sets

The guide pins (guide posts) provide alignment

between die holder (shoe) and punch holder (shoe)

The guide bushings are mounted in the punch

holder and slide over the guide pins

The flange provides a means of clamping the die

shoe to bolster plate

29 6/26/22
 Basic Components of Standard Die Set

A typical two-post standardized die set and its components

30 6/26/22
 Basic Components of Standard Die Set

31 6/26/22
 Basic Components of Standard Die Set

32 6/26/22
 Standard Die-Set Styles

33 6/26/22
 Press Tonnage
 The tonnage of a press is the force that the press ram is able to
exert safely

 The tonnage of a hydraulic press is the piston area multiplied

by the oil pressure in the cylinder

 The tonnage is varied by changing the oil pressure

 The tonnage of a mechanical press is approximately equal to

the shear strength of the crankshaft metal multiplied by the
area of crankshaft bearings
34 6/26/22
 Stroke
 The stroke of a press is the reciprocating motion of a press slide

 Usually specified as the number of inches between the terminal

points of the motion

 The stroke is constant on a mechanical press

 The stroke is adjustable on a hydraulic press

DIE SPACE: It is area available for mounting dies in the press

35 6/26/22
 Shut Height
 The shut height of a press is the distance from the top of the
bed (or to the top of the bolster plate) to the bottom of the slide
indicating the maximum die height that can be accommodated

 The shut height of a particular die set is the distance from top
of the punch shoe to the bottom of the die shoe when the die is
in its closed position (excluding the shank)

 The shut height of the die must be equal or less than the shut
height of the press

36 6/26/22
 Die Sets and Related Terminology

37 6/26/22
 Questions??

38 6/26/22
 References
• Fundamentals of Modern Manufacturing ; Materials,
Processes, And Systems, 3rd Ed. By Mikell P. Groover;
John Wiley And Sons

 Tool Design, 2nd Ed. By H. W. Pollack, Prentice Hall Inc.

 Tool Design, 3rd Edition By C. Donaldson, G. H. Lecain, V.

C. Goold

• Manufacturing Engineering And Technology, 5th Ed. By S.

Kalpakjian, S. R Schmid; Pearson Education
39 6/26/22