PART B

SEMESTER : III SUBJECT : Press Tool Technology SUBJECT CODE : CP01 03 10

Chap
Question Marks Answers
ters

The most common classification of types of tooling are as follows :- 1) Press Tool 2) Moulds 3) Jigs & Fixtures
1 Write down the classification of tooling? 2
4) Gauges

. Press tool are special tools custom build to produce a component mainly out of sheet metal. The principle
What is press tool ? 3 operations of sheet stampings include cutting operations (Sheering, Blanking , Piercing etc) and forming
operations (Bending, Drawing, etc)

Cut off operations are those in which strip of suitable width is cut to lengthin single. preliminary operations
before cutting off include piercing, notching, and embossing .

What is cutting off Tool? 3

. It is similar to cut off operation exept the cut is in double line. this is done for components with two straight
What is parting off ? 3
surfaces and two profile surfaces. parting off produces waste.
 . A small amount of material is removed from the side of a component or strip is also called as trimming.

Define trimming? 2

Shaving removes a small amount of material arount the edges of a previously blanked stampings or piercing. A
define shaving? 3 straight , smooth edge is provided and therefor shaving frequently performed on instrument parts, watch and
clock parts and the like.

Curling tools curl the edges of drawn shell to provide strength and rigidity. The curl maybe applied over a wire
. Define curling? 2
ring for increased strength

Bulging tools expand the bottom of the previously drawn shells . The bulged bottoms of some types of coffee
Define Bulging? 2
pots are formed in bulging tools.

What do you mean by assembly tool? 2 Assembly tools assemble the parts with great speed and they are being used more and more

A piece part is the product of a die . it may be a complete product in it self or it may be only component of a
2 . Define piece part ? 2
product consisting of many and different parts

Low carbon hot rolled sheets are used for barrels, pails,farm implements ,lockers cabinets, truckbodys and
. what is hot rolled steel ? 3
other applications
 applications of pickled & oiled . Oiling protects the surfaces against [Link] and oiled sheets are used for house hold applaiances auto
3
sheets? mobile parts, toys etc

Deep drawing steel is prime quality cold rolled steel having a very low carbon content these sheet are
Define deep drawing steel sheet? 3
thoroughly anneled highly finished to deoxidized silver finish and oiled

What is meant by Cold rolled steel Cold rolled steel sheets have smooth deoxidized satin finished,which provide excellent base for paint, lacquer or
2
sheets? enamel coating.

What are precious metals ? 2 Precious alloys like gold, silver ,platinum and palladium are for laboratory equipment and electrical industry

Rarer metals like zirconium, teantulum , vanadium , tungusten and molybdenum and their alloys find their
What are rarer metals? 2
place as stock material in press working

Plastic deformation The force applied by the punch on the stock - material tends to deform it into the die
opening .When the elastic limit is exceeded by further application of force.
- the material is forced into the die oopening in the form of an embossed pad on the lower face of the material .

3 What is plastic deformation? 3

 Penetration As the load is further increased ,the punch will penetrate the material to a certain [Link] equally
thick portion of the metal is forced into the [Link] impacts a bright polished finish (cut band) on both the strip
and the blank or the [Link] optimum cutting conditions,the cut band will be 1/3rd the sheet thicness.

What is the penetration stage ? 3

Fracture I n this stage,fracture starts from both upper and lower cutting edgesAs the punch travels further,these
fractures will extend towards each other and meet to cause complete [Link] stage impacts a dull
fractured edge.

Define fracture stage? 3

 SHEARING THEORY
Shearing Theory Shearing is the method of cutting sheets or strips without forming [Link] material is stressed
i a section which lies parallel to the forces [Link] forces are applied by means of shearing blades or punch
and die.
Critical stages of shearing
Stage1 :
Plastic deformation The force applied by the punch on the stock - material tends to deform it into the die
opening .When the elastic limit is exceeded by further application of force.
- the material is forced into the die oopening in the form of an embossed pad on the lower face of the material .
-A corresponding depresion is formed onn the upper face.
This stage impacts a radius on the upper edge of the pening in the strip and on the lower edge f the punched
Explain about theory of shearing? 5
cut material (which may e blank or slug)
Stage 2:
Penetration As the load is further increased ,the punch will penetrate the aterial to a certain [Link] equally
thick portion of the metal is forced into the [Link] impacts a bright polished finish (cut band) on both the strip
and the blank or the [Link] optimum cutting conditions,the cut band will be 1/3rd the sheet thicness.
Stage 3:
Fracture I n this stage,fracture starts from both upper and lower cutting edgesAs the punch travels further,these
fractures will extend towards each other and meet to cause complete [Link] stage impacts a dull
fractured edge.

cutting clearance is the gap between the side of the punch and the corresponding side of the die opening on
one side of the edge the punch is entered into the die opening

4 Define cutting clearance ? 4

1. Aid the life of the die.

Write down the importance cutting of 2. Increase the quality of the piece part.
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clearance? 3. Improve the characteristics of piece part.
4. Reduces undue stress and wear on the cutting edges of the tool.
 The optimum cutting clerance is accurate clearance given to the punch and die for the accuarte piece part or
Define optimum cutting clearance? 3
slug.
What happens if insufficient cutting
2 When cutting clearance is slightly less the condition can be identified by greater width of the cutband
clearance is provided?
The burr side is adjacent to the break . The burr side of the Blank or Slug is always towards the punch . The
burr side of the punch openining is always towards the die opening.

What is burr side? 2

Calculate the clearance for punching

Clearance = c X s X √ Tmax/10 =0.01 X 2 X √300/10 = 0.12mm/side Therefore clearance on one side =
a 2 mm sheet. Tmax is assumed to 2
0.12 mm
be 300 N/mm2

What is the formula for finding the

3 Upto 3mm sheet Thickness
Cutting Clearance?
Determine the punch and die Dimension
for the component given below. Sheet
thickness 0.5mm, stainless steel sheet,
Tmax is 400 N/mm. C=0.01

Calculate the cutting clearance.

Sheet thickness 0.5 m, stainless steel 2 Clearance = c X s X √ Tmax/10 = 0.01 X 0.5 X √ 400/10 = 0.03 mm/ side.
sheet, Tmax is 400 N/mm2 C=0.01

Define cutting force 2 Cutting force is the force which has to act on the on the stock material in order to cut out the blank or slug

L*S*Tmax L= Length of periphery to be cut in mm

S =sheet thickness mm
What is the formula for cutting force ? 2
T= shear strength in N/mm squre
 Calculate the press force required to
produce the following component. Sheet
thickness 2mm. Material is brass.

Define press force? Press force= cutting force +stripping force (stripping force=10%-20% of cutting force)

Copper 200-400 N/mm2

Brass 350-400 N/mm2
Tin 30-40 N/mm2
Give examples of shear strength
Zinc 100-120 N/mm2
Lead 20-30 N/mm2

The method reducing cutting forces is to step punch length a second method is to grind the face of the punch or
How cutting force can be reduced? Material –die
Brass
to a small shear angle with the horizontal double shear angle is preferred over single shear angle because it
balances the cutting forces acting on the punch

When the Shape of component is simple, the accuracy of the component is less and only fewer components are
5 When guide plate tool is prefered? 3
required.
Top plate- this plate also acts as top bolster or die head
Write down the elements of Guide Bottom plate- this plate is also acts as bottom bolster for base plate for die.
4
Plate Tool? punch holder- this plate holds all the punches

Importance of top and bottom plate On Top plate punch unit is rigidly and accurately held and on bottom plate die unit is rigidly and accurately
3
Guide Plate Tool? mounted.
What is the function of a punch All the punches are accurately held in this plate. this plate should be thick enough to accommodate puch
3
holder? shoulder and keep the punches perpendicular
Purpose of shank in Guide Plate
2 Shank is tool elements. this ids fixed on the top plate shank is fixed in the press ram
Tool?
 This is a fastening [Link] are used to hold the plates together the plate the size of srew s are selected
What is the purpose of screws? 2
on the basis of tool sizes.
The punch, punch holder and thrust plate is mounded on the top plate. The tool shank that locates the whole
6 What is a top plate? 4 tool centerly with the press ram is also screwed on the top plate. The top plate is made up of mild steel or cast
iron
This plate gives a cushioning effect to the die as well as provides enough room for the tool to be clamped to the
Define Bottom Plate? 4
press bed. There may be a opening in the back plate which allows the blank or slug to fall clear of the tool.
What are the main functions of a it guides the [Link] guides the [Link] it strips the strip after punching is [Link] Plate usually made
4
stripper? of mild steel.
This is one of the most important element of the tool. It is the cutting element of the tool. Punch gives the hole
Write a short note on punch? 4 size and the shape on the component. This is made out of high carbon high chromium steel material. Hardened
to 58 to 60 HRC.

Write short note on screw and dowel

2 The screws are used to hold the die parts the together and the dowels are used to align the die parts to gather
pin?

The tool is located and clamped to the press ram by the shank. Diameter of the shank for a particular tool
. Define shank? 4 depends only on the diameter of the bore in the press ram on which it is intented to be mounted. Shanks are
standardized to suit different press.

The punches are usually fixed in with a light press fit in the punch holder. Some means to prevent the profiled
What is punch holder? 3
punches from rotating should be provided in the punch holder (a key or dowel).

The stopper is a plain cylindrical pin. the pin is mounded in the die block. The function of the stopper is to arrest
Define stopper? 3
the movement of the strip when it is fed forward to one pitch length.
 Land is important in press tool because it helps to avoid breakage of punch and die. It is also required foe
reshapning purpose

7 Importance of land in press tools? 2

The die wall below the land is relieved at an angle for the purpose of enabling the blanks or slugs to clear the
die. This is called angular clearance.

What is angular clearance? 3

Dies employing on ejector to clear the blanks will have straight walls without any angular clearance, as the
Function of ejector in press tool? 2
blanks do not get accumulated in the die.
Purpose of angular clearance in press The die wall below the land is relieved at on angle for the purpose of enabling the blanks or slugs to clear the
3
tool? die.
There are two methods of piloting in progressive dies. 1. Direct piloting : It consist of piloting in holes pierced in
What are the different methods of
8 4 that area of the strip which will become the blank. 2. Indirect piloting : It consist of piercing holes in the scrap
piloting?
area of the strip and locating by these holes at subsequent operation.
There are two types of pilots :
Retractable pilots
In many occasions especially during hand feeding, miss feeding occurs due to over shooting of the stock of strip
Write short note on the types of pilots? 4 over the stoppers.
Removable type pilots
These pilots inserted through the top bolster into the punch holder and fastened with a backup screw.

List the seven conditions that require 1. Close tolerance on holes 2. Holes too small 3. Holes too close to the edges of the blank 4. Holes in weak
3
indirect piloting? area 5. Holes spaced too closely 6. Blanks without holes 7. Projection in hole.
 Stock material conservation being a decisive factor in press working,.The designer should try out every possible
means to attain a min 60% usage of any strip, without sacrificing the accuracy of the piece part.

9 Define economy factor? 3

Shape of the blank, Production requirement, Grain Direction, burr side, Stock material.
What are the factors influence the
design of strip lay out?

Formula for finding economy factor? 2

In the rolling mills, when the sheets are rolled to the process orients the grains in the rolling direction. Standard
What is grain direction? 3 sizes of rolled strips and sheets will have the grain direction along its length. Bending the strip along the grain
direction often results in crack and fracture.

It is another decisive factor in laying the strip. In blanking operation, burr is formed on the face of the blank,
. Define burr side? 3 which comes towards the punch, whereas in piercing it appears on the faces that come directly in contact with
the die.

This is the most popular way of laying out the strip. In case the blanks are arranged in a single row and strip is
passed through the tool only once to the punch and blanks from it.

. Define single row one pass layout? 3

 . Further economy is attained by positioning the blanks in the double rows especially circular blanks workout
more economical if they are laid out in double rows.

. What is double row layout? 3

Some of the piece parts will be required to be laid out to own angular position to make the layout more economy.

What is angular layout? 2

Narrow run is used when the grain direction is important and components are layed in logitudenal direction.
Wide run
is more desirable due to the following reasons.
• Shorter advance distance of the strip feeding promotes easy
• More" blanks could be produced from a given length of strip compared
to narrow run.
• Fewer number of strips are to be handled to produce a given
number of blanks
What is Narrow run and Wide run
5
strip Lay out? Sketch ?

A gang die consist of two or more similar sets of tool members so as to produce two or more number of
What is a Gang die? 3 components during as a single stock of the press ram. A gang die eliminates the cumbersome process of
double pass.
. Define notching? 2 Notching is a cutting operation of cutting off small portions from the edge of a strip or a pre blank component
 Just like notching, trimming is also on operation of cutting off material to alter the shape of the strip or blank. In
What is trimming? 4
notching, only a small area of material is cut off, whereas in trimming a larger area of material is removed.

A two pass tool requires minimum of two stops. The stop used for the first pass may have to be removed, or
. Define single row two pass method ? 3
made to disappear from the working surface so as not to interfere with the second pass.

Hardened die bushes inserted in mild steel retainer plates are commonly used in large piercing dies. Die bushes
10 Defined die bush? 3
having profiled openings should be prevented from turning by suitable means.

Separate nest blocks, even though costly, are preferred to pockets directly milled into the die set due to the
following reasons; 1. Nest blocks do not weaken the die set as the pockets do. 2. Easy to handle and can be
case hardened for heavy work. 3. For the regrinding of the die , only the nest block has to be dismantled without
disturbing the assembly of the die section in it.

What is nesting? 5

What are the applications of carbide Carbide dies are widely used to produce electrical laminations lower cost per piece compared with steel dies.
3
dies? Carbide is used as a die material for blanking, piercing, trimming, drawing and swaging operations.

. When a carbide die insert is subjected to high impact loads and internal bursting pressures, it must be
How Carbide inserts are supported? 3
supported externally by pressing or shrinking the carbide ring into a hardened steel case.
 What are the factors influence the . 1. Piece part size 2. Stock thickness 3. Intricacy of piece part contour 4. Type of tool 5. Machinery
3
design of the die block? available for manufacturing the tool
11 What is the main functions of a stripper 2 The main function of the stripper is to strip the stock material off the punches after each stroke
How stripper are catagorised? 2 Strippers are catagorised as Fixed stripper and Ttravelling stripper
What is a hook pin stripper 2 It is an alternative arrange for a cheaper version of stripping
What is the difference between Fixed and Atravelling stripper travels with the punch during every press stroke. A fixed stripper is fixed on top of the Die and is
3
travelling stripper? stationary
1. When it is necessary to clamp the strip in addition to its stripping function 2. When it is necessary to keep the punches
What are the situations where a fixed
3 engaged in stripper during entire press cycle 3. When the operator need to observe the work when the
stripper is impractical?
tool is operating
What is a spring stripper?Explain with a A spring stripper is a pressure pad [Link] are used when it is necessary or desirable to hold the stock material flat
4
neat sketch (or very nearly flat), or to provide better visibility and access when the tool is mounted in the press
When cutting punches are sharpened they become shorter. In many applications, the springs are compressed a little more
Explain the priciple of a compensating
3 and are not always desirable. A practical method to eliminate this is to install a cylindrical washer as shown in [Link]
washer
time the punches are sharpened, the washer is reduced for the amount
What is the stripping force considered for
2 Stripping force for most operations range from 10 to 20% of the cutting force
blanking and piercing ?

1. Stock material: Materials, which have high friction, 2. Surface conditions of sidewalls: A punch, which has smooth
What are the considerations for
4 finish can be stripped easily [Link] between punches: For shorter distances,more effort is required [Link] of the stock
calculating stripping force?
material to be stripped if more, force required will be more

12 What is the meaning of stop position ? 2 Stop position is the location of the actual stopping position surface against which the stock strip is halted
Registry position is the exact location in which the stock strip must be established in order that the work will be
What is registry position? 2
dimensionally correct. The registry position may or may not be the same as the stop position
This is the location of the actual stopping position surface against which the stock strip is halted, whereas Registry position
Compare between Stop position and
3 is the exact location in which the stock strip must be established in order that the work will be dimensionally correct. The
registry position
registry position may or may not be the same as the stop position
Quite a number of different stop types are in common use - for example, solid stops, pin stops, finger stops, pivoted auto
What are the different types of stoppers
3 stops etc. in addition there are many variation of each type. This diversity exists because of the wide variety of applications
used in press tools?
towhich stops must be adopted.
 The stop is the plain cylindrical pin. The stop pin is mounted in a die block. The pin is a light drive fit on the mounted hole.
What is meant by slain pin stop? 2
The mounting hole is generally made to suit a standard pin size (dowel size).
[Link] permit adjusting the height of the stop pin without removing the die block from the die shoe. [Link] allow the stop pin to
What are the three reasons for giving a be removed in order to sharpen the die with the die block fastened to the die shoe.
3
relief hole for stop pins? [Link] allow the pin to be driven down in the event of a misfeed, thus reducing the chance of damage to the die.

The stop is actuated manually. It is pushed inward until the stop shoulders contacts the front edge of the stripper. When
the stop is in close position,the nose of the stop extends into the stock channel, obstructing the stock strip. The stop is held
Explain the function of finger stoppers in closed position and the leading end of the stock strip is fed against the stop. Then the operator trips the press and
4
with the help of sketches? releases the stop. The spring returns the stop to its open position where it remains until a new stock strip is fed into the
die. In the stopper shown in the figure after the stroke the operator has to release the stopper manually

It is a spring actuated pin located at the required stopping position. over other pin stops is that they do not require
What is meant by Disappearing stop? 2
clearance in apposing die members.
What are the different types of trigger [Link] acting trigger stop & [Link] acting trigger stop
2
stoppers used in press tools?

Why pilots are used in Press tools? 2 The pilot registers the stock strip in relation with the die opening
For an average work, Ø of pilot = & of hole to be piloted - 0.05 to 0.1 mm, For close work, Ø of pilot = Ø of hole to be
What are the pilots sizes in relation to piloted - 0.03
3
piercing punches? to 0.05 mm and for accurate works Ø of pilot = Ø of hole to be piloted -0.01 to 0.02 mm However, the thick stock materials
and the stock
The most common pilot nose profile is bullet [Link] billet shape is formed by radius R which is equal to piloting
What are the different types of pilot diameter. For piloting in holes less than 6 mm the length of radius R can be increased to reduce the lateral force during
3
profiles used? piloting. Bullet nose is strong simple to make and smooth in action. The other three commonly used pilot nose profiles are:
45° conical stub nose, 30° conical stub nose and 15°angular long nose
Where 15° angular stub nose pilots are This small angle provides good mechanical [Link] are used for small pilots and for thin materials.
2
used?
In many occasions especially during hand feeding,misfeeding occurs due to over shooting of the stock strip over the
Write short note on retractable pilot 3 stoppers. This creates the problem when strip over the stoppers. This creates the problem when strip over the stoppers.
This creates the problem when obstructing smooth functioning of the tool.
Side cutter is an accurate method of stopping arrangement used mainly for thinner strips where it is difficult to
14 What is the function of a side cutter 2
accommodate the other types of stoppers.
Why heels are provided in side cutter? 2 Due to the unbalanced cutting force acting on the side cutters, the side cutters are provided with heels
[Link] is the safer method than stop pins. [Link] the danger of the deformation of margins of thinner strips by the stop pins,
when pressed against it. [Link] for small punching where it could be difficult to employ other types of stops. [Link] is
What are the advantages of side cutter? 4
economical and avoids complications in tools where the number of stages is [Link] can be avoided for punching
components with moderate accuracy.
15 Why ejectors are used in press tools? 2 Ejectors are used to push the components upwards from the die.
Shedders are used for the expulsion of the blanks from the die cavity is by making use of the knockout mechanism on the
What is the function of a shedder? 3
press. For this purpose,the tool should be of the inverted design.
The stock material is usually coated with a rust preventive solution. It is obvious that any liquid or oil deposit left on the
Why shedding pins are used in press stock material will cause the blanks to stick to face of the shedder. Spring-loaded shedding pins are employed to overcome
3
tools? this problem. Even absolutely clean and dry stock material tends to adhere to the shedder face, due to the atmospheric
pressure.
 Shedders operated by the knockout mechanism on the press are called "positive shedders".The knockout arrangement of
With the help of a neat sketch explain the the press is usually of a bump type knockout bar, mounted through slot across the press ram. The knockout bar is free to
5
function of a positive shedder. move up and down within the slot, as well as it could ride up and down together with the ram. Figure depicts the operation
of a positive shedde
Shedders backed up by compression springs,hard rubber or disc springs are called compression shedders. Such shedders
Explain what is compression shedders always tend to return the blank into the strip if employed with compression type travelling [Link] shedders
3
and its use. could be used to great advantage to produce flatter and neatly sheared blanks. They are also used if the blanks are too
large to allow the incorporation of an efficient positive knockout system
In a knockout system if the knockout rod is directly in contact with the shedder the system is known as direct knockout
shedder. As the passage of the knockout rod is through the shank, any punch which comes in line with or
near to the centre line of the shank will obstruct the knockout rod from coming in direct contact with the shedder. In such
Differenciate between direct and indirect cases an indirect knockout system should be
4
knock out system. [Link] addition to the shedder and the knockout rod, it
consists of a knockout plate and transfer pins as
shown in figure. The location and number of transfer
pins depend on the size and shape of the blank.
What is the function of Dowels in a press Dowels hold parts in perfect related alignment by absorbing side pressures and lateral thrusts. Also they facilitate quick
16 2
tool? disassembly of parts and reassembly in their exact former relationship.
There are two types of dowels in common use. [Link] dowels used in through and through hole
What are the 2 types of dowels in use? 2 applications
[Link] type dowels. These types are used where blind hole applications exists.
The fasteners are divided into two types.
What are the 2 types of fasteners used in
2 1)Threaded fasteners
tooling?
2)Non-threaded fasteners.
1. SOCKET HEAD SCREWS:
These are generally used to fasten the plate elements of a press tool like punch holder assembly to the die top and die -
stripper assembly to the die -shoe. 2.
COUNTER SUNK SCREWS:
These are used to fasten elements like nest gauges,spacers, plate stoppers etc.
Name any 4 types of threaded fasteners
4 CHEESE HEAD SCREWS:
and write they are used
These are used to fasten sheet metal elements like spring holders, leaf springs etc.
SET SCREW (Grub screw):
These are used to fasten parts, which are to be confined within a hole, like spring's etc.

Eyebolts are used for lifting heavy die sets or mould

What is the use of an eyebolt? 2
housing. It is also called as carrier bolts.
Name any 2 types of non- threaded Rivets and Cotter pins are non threaded fasteners
2
fasteners
The shank is mounted on the tool and acts as a connecting link from
17 What is the function of a shank?
press tool to the press
 There are many ways in which the shank is mounted to
the tool top. They are as follows:
1)By riveting
Write any 4 ways of mounting of shank
3 2)By press fitting
on the tool top.
3)By means of a thread
4)By making as integral part of top plate.
5)By making flange fastening.
This is a special type of shank, which permitsquick loading, and unloading of a press tool on a press. This type of shank
differs very much in design when compared with other regular shanks. A Tee coupling mechanism is made in two sections.
Explain self aligning type of shank 3
The one half, which is mounted on a tool, is a male member, whereas the other half, which is fixed to the press ram, is a
female member. They are usually case carburised and hardened.
The balancing of the cutting punches is one of the most important aspects to be considered during the punching
Why shank location is very important in a
3 operation. Unbalanced force distribution on the tool top may cause undue wear on the punch
press tool?
and die as well as on the pillars. So shank location is very important.
The position of the resultant force of all the partial cutting forces can be found applying the following methods.
What are the methods used to find the
2 1. By calculations
location of a shank
2. By polygon system (Graphical).
The rated capacity of a press is the force in MN, which
18 What is meant by capacity of a press 2
the slide will safely exert near the bottom of the slide.
Parts of a Press
PRESS BED:
The stationary and usually the horizontal part of a press that serves as a table to which a bolster plates or lower die
assembly is mounted.
PRESS SLIDES:
The common name for the reciprocating member of a press guided in the press frame and to which the punch or upper die
member is fastened. On a hydraulic press it is called the platen.
PLUNGER SLIDE:
The inner slide of a double action press upon which the punch is mounted.
BLANK HOLDER SLIDE:
What are the major parts of a press and
5 The outer slide of the double action press usually operated by toggles or cams.
explain its functions
BOLSTER PLATE:
A plate secured to the press bed for locating and supporting the tool.
PITMAN:
Connecting rods to convey power and motion from the
main shaft to the press slide.
.
CLUTCH:
A coupling used to connect or disconnect a driving
machine member such as the flywheel to or from a
driven machine member such as the main shaft.
What is shut height of a press? It is the distance from the top of the bed to the bottom of the slide with the stroke down and the adjustment up.
Die space is the area available or mounting tools in
What is die space of a Press?
the press.
According to power, presses are classified as Manual, Mechanical, Hydraulic, Pneumatic
According to source of power, what are
2
the major classification of a presses?
 With respect to the action upon the material the presses are classified as single action, double action and triple action.
A single action press has only one slide. These presses are employed for operations such as blanking, piercing, bending,
shallow drawing, forming etc.A double action press has two slides arranged one within
Breifly explain Single ation, Double action the other and moving independently of each other. The outer one serves as a blank holder and the inner one carries the
4
and Triple action Presses punch.
A triple action press has three slides, two of which are located above and one within the bed. Such presses are used for
complicated deep drawing operations.

Die cushions are used to eject the component from the [Link] is fitted below the press bed and actuated by hydraulic or
What are die cushions 3
pneumatilly.
The basic principle of the mechanical slide feed is the use of feed block actuated mehanically. Strip advances the
material to exact distance required at each stroke. They have high accuracy and are suitable for use with coil stock. When
strip stock is used it is necessary to feed the strip ends into the press [Link] the stock is to be fed with the slide
Explain mechanical slide feed in Press 3
feed,stock guides should be used to overcome any tendency of the stock to buckle.A slide feed id powered by the
crankshaft of the press. The rotation of the crankshaft is transmitted to the feed through a eccentric mounted on crank
shaft.
A roll feed consists of a pair of rolls that can turn in only one direction. They exert force on the stock by means of springs.
They are rotated by means of press crankshaft. As they rotate they push the stock forward that is the function of angle of
rotation. Rolls feed are suitable for use with extremely thin material. Polished surfaces of the stock will also not be spoiled.
Roll feed eliminates manual feeding of end sections
What is roll feed roll feed ? 3
when the strip is proceeded. Double roll feeds are used
when a sizable scrap skeleton remains after the press
operation.

Why strip straightening devices are used If the strip is bend as in roll feed it is difficult to feed in to the tool. So it must be strightened fefore enytering the Die. For
3
in pressing operations? this reaon straightening devices are used
What are the different types of dieset Rear pillar, Diagonal pillar, Centrepillar and 4 Pillar diesets are the commonly used diesets
19 2
used in Press tools?
[Link] life is increased.
[Link] can be installed in the press in the minimum
amount of time because they are self contained units.
What are the advantages of using a
4 [Link] is facilitated. There is no possibility of loss of
dieset in a press tool?
loose parts.
[Link] designed tools can be sharpened without
removal of cutting members.
 Ten elements of die-set information must be
known before a die set can be ordered:
[Link] or manufacture
[Link]
[Link]
What are the information needed to [Link]
5
select a proper dieset [Link] of the die holder
[Link] of punch holder
[Link] and lengths of bushings
[Link] of guide posts
[Link] diameter
10Grade of precision
A. Top plate :
B. Guide bushings
Explain the parts of adie set 3
C. Guide pillar
D. Bottom plate
Why guide bushes and pillars are needed To make a proper alignment between punch and die, guide pillar and bushes are required
2
in a dieset?
What are the materials used for each Top and bottom plate : MS, Guide Bush and pillar : Case hardened steels : E230
3
elements of a Die set?
When very big diesets are required or for special operations on a components, Non standard diesets are manufactured
When non standard diesets are used? 2
When the tool is in closed condition,the distance between the top of the top plate to the bottom of the bottom plate is
What is shut height of a press tool? 3
termed as the shut height of the tool.
A blanking is an operation in which a blank is produced by shearing the entire perifery by cutting theentire periphery
20 Define blanking 2
What is piercing tool 2 It is a Tool by which holes of any size and shapes can be produced on blanks
The basic operation of a cutoff tool consists in severingstrips into short lengths to produce blanks. The line of cut may be
straight or curve, and holes and notches or both may be applied in previous operations.
Explain cut off operation 3
The cutoff tools are used for producing blanks having straight, parallel sides because they are less expensive to build than
blanking tools.
Compound tool is a presstool in which 2 or more cutting operations are done simultaneously in a single stroke to produce
What is a compound tool 2
a component
Combination tool is a presstool in which 1 or more cutting operations and non cutting operations are done simultaneously
what is a combination tool 2
in a single stroke to produce a component
Coining has two major advantages.
What are the advantages of a coining
3 1)Ornate detail can be produced with excellent surface finish.
operation?
2)Tolerances can be held to very closer values.
Coining is the operation of pressing material in a die so that it flows into space in the detail of the die face. Coining differs
Differenciate between Coining and
3 from embossing. In coining the metal flows, whereas in embossing the metal does not change in thickness to a great
embossing
extent.
 Broaching may be considered to be a series of shaving operation performed one after the other by the same tool. A broach
is provided with a number of teeth,each of which cuts a chip as the broach traverses the surfaces to be finished. Internal
broaches finish holes;
surface or slab broaches finish outside [Link] conditions make broaching necessary:
[Link] are too thick for shaving. A considerable metal must be removed from the edge of the thick blanks; a series of
shaving tools would be required to produce smooth finish. It would then be more economical to use a broaching tool.
[Link] considerable metal must be removed. This occurs when ridges or other shapes are required in the edge of the
blank such shapes directly because the cutting edge would be weak and subjected to breakage

What are the different types of bending 'U' Bending , 'V' Bending and ' L' Bending Tools are the different types of bending tools.
2
tools?
Name 4 types of forming tools 3 Bending tool, Coining tool, Embossing tool and Drawing tool
Differenciate between Drawing and Deep Drawing tools are used for producing shallow drawn cups where the cup height is less than the diameter. Deep drawing
3
drawing tools tools are used to produce cups having heights more than its [Link] gas cylinder body.
Trimming tools cut away portions of formed or drawn work pieces that have become wavy and irregular. This condition
Why trimming tools are used? 3 occurs because of un even flow of metal during forming operations. Trimming removes this unwanted portion to produce
square edges and accurate contours.
Shaving tools are used for removing a small amount of metal from around the cut surface of the blank or [Link] order to
improve the surface. A properly shaved blank has a straight, smooth edge and it is held to a very accurate side. Many
Explain the principle of shaving tool
instruments, business machine, and other parts are shaved to provide better functioning and
longer wear.
A curling tool forms the material at the edge of a work piece into a circular shape or hollow ring. Flat blanks may be curled;
a common application is a hinge formed of two plates, each of , which is curled at one side for the engagement of the
Why curling tools are used? 3 hinge pin. More often, curling
is applied to edges of the open ends of the cups and shells to provide stiffness and smooth, rounded edges. Most pans
used for cooking and baking foods are curled.
To cut paper, leather, cloth, rubber and other soft materials a dinking tool is used. The cutting edges penetrates the
What is the function of a dinking tool? 3 material and cuts it (like knives). The dinking punch digs into the base plate. The base plate is made of wood, fiber, or hard
rubber. The dinking tool can be used to cut the inner and outer shapes of component
This is a continues bending and cutting operation along a line in the work material. No metal is cut free during the lancing
What is lancing tool? 3
operation. Example mosquito coil stand.
Planishing tool is used to straighten blanked components.
Why planishing tools are used? 3 Very fine serration points penetrate all over the surface of the component in order to release stress and straighten the
component
In a progressive tool the strip is moved instages from station to station. Different operations are performed on it and at
each station except at idle ones applied to provide room for components. A complete work piece is removed from the strip
at the final [Link] the operations described previously may be performed in progressive tools. For example, a single die
of this type may do piercing at the first station, rimming at the second station, bending at third, forming at the fourth etc. a
explain the working principle of a
5 progressive tool may thus be consideredas a series of different tools placed side by side with the strip passing through
progressive tool with supporting sketches
each [Link] analogy has some merit although it does not give
a true picture of the extremely close inter relationshipbetween the various stations.

Embossing is the shallow forming operation in which the work piece material is stretched over a male die and made to
With the help of a neat sketch explain the
conform to a male die surface by a mating female die surface. The finished product will
working principle of an embossing tool.
have depressed detail on the other.
 If more [Link] holes are pierced, it is called perforating [Link] process of piercing a series of holes in a given blank or
What is a perforating tool? 3
workpiece is known as perforating.
Assembly tools assemble two or more parts together by press fitting riveting, stacking or other [Link] are
What is the function of an assembly tool? 2
assembled very quickly and relationship between parts can be maintained closely.