Metal Forming
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
Sheet Metalworking Terminology
1. “Punch-and-die”
Tooling to perform cutting, bending, and drawing
2. “Stamping press”
Machine tool that performs most sheet metal
operations
3. “Stampings”
Sheet metal products
Press Machine Tool
Press machine is a metal forming
machine tool. Which is designed to form or
cut metal by applying mechanical force or
pressure.
With the help of press machine, we can form a
metal in any desired shape without removal of
chips. The presses are exclusively intended
for mass production work.
Types of Presses
Types of presses for sheet metal working
can be classified by one or a combination of
characteristics, such as
a. source of power,
b. number of slides,
c. type of frame and construction,
d. type of drive, and
e. intended applications.
Types of Presses
According to source of power
Manual Presses
These are either hand or foot operated through levers, screws or gears.
Most of manually operated presses are hand press, ball press or fly
press.
Mechanical presses
These presses utilize flywheel energy which is transferred to the work
piece by gears, cranks, eccentrics, or levers.
Hydraulic Presses
These presses provide working force through the application of fluid
pressure on a piston by means of pumps, valves, intensifiers, and
accumulators. These presses have better performance and reliability than
mechanical presses.
Pneumatic Presses
These presses utilize air cylinders to exert the required force. These are
generally smaller in size and capacity than hydraulic or mechanical
presses, and therefore find use for light duty operations only.
Types of Presses
According to source of power
Types of Presses
According to source of power
Hydraulic Power Press
Types of Presses
According to number of slides
•Single Action Presses. A single action press has one reciprocation
slide that carries the tool for the metal forming operation. The press has a
fixed bed. It is the most widely used press for operations like blanking,
coining, embossing, and drawing.
•Double Action Presses. A double action press has two slides moving
in the same direction against a fixed bed. It is more suitable for drawing
operations, especially deep drawing, than single action press.
•Triple Action Presses. A triple action press has three moving slides.
Two slides (the blank holder and the inner slide) move in the same direction
as in a double – action press and the third or lower slide moves upward
through the fixed bed in a direction opposite to that of the other two slides.
This action allows reverse – drawing, forming or bending operations against
the inner slide while both upper actions are dwelling.
Types of Presses
Double Action Presses
Types of Presses
According to Frame and Constructions
Arch – Frame Presses. These presses have their frame in the shape of an
arch. These are not common.
Gap Frame Presses. These presses have a C-shaped frame. These are
most versatile and common in use, as they provide un – obstructed access
to the dies from three sides and their backs are usually open for the ejection
of stampings and / or scrap.
Straight Side Presses. These presses are stronger since the heavy loads
can be taken in a vertical direction by the massive side frame and there is
little tendency for the punch and die alignment to be affected by the strain.
The capacity of these presses is usually greater than 10 MN.
Horn Presses. These presses generally have a heavy shaft projecting from
the machine frame instead of the usual bed. This press is used mainly on
cylindrical parts involving punching, riveting, embossing, and flanging
edges.
Types of Presses
According to Frame and Constructions
Press Working Terminology
Simple cutting Die
Press Working Terminology
Bed
The bed is lower part of press
frame that serves as a table on
which a bolster plate is mounted.
Bolster Plate
Bolster plate is a thick plate
secured to the press bed, which is
used for locating and supporting
the die assembly. Its thickness is
usually 5 to 12.5 cm.
Die Set
Die set is unit assembly which incorporates a lower and upper
shoe, two or more guide posts and guide post bushings
Press Working Terminology
Die
Die is the female part of a complete tool for producing work in a
press. It is also referred to a complete tool consisting of pair of
mating members for producing work in press
Die Block
It is the block or a plate which contains the die cavity.
Lower Shoe
The lower shoe of a die set is generally mounted on the upper
plate of a press. The die block is mounted on the lower shoe.
The guide posts are also mounted in it.
Punch
Punch is the male component of the die assembly which is
directly or indirectly moved by or fastened to the press ram or
slide.
Upper Shoe
It is the upper part of the die set which contain die post bushings.
Press
Punch Plate
Working Terminology
The punch plate or punch retainer fits closely over the body of
the punch and holds it in proper relative position.
Back Up Plate
It is also called pressure plate. It is placed so that the intensity of
pressure does not become excessive on punch holder. The plate
distributes the pressure over a wide area and intensity of
pressure on the punch holder is reduced to avoid crushing.
Stripper
Stripper is a plate which is used to strip the metal strip from a
cutting or non-cutting punch or die. It may also guide the strip.
Knock Out
Knock out mechanism is used to remove the workpiece from a
die. It is connected to and operated by the press ram.
Pitman
Pitman is a connecting rod which is used to transmit the motion
from the main drive shaft to the press slide.
Three Major Categories of
Sheet Metal Processes
1. Cutting
Shearing to separate large sheets; or cut part
perimeters or make holes in sheets
2. Bending
Straining sheet around a straight axis
3. Drawing
Forming of sheet into convex or concave shapes
Three Major Categories of
Sheet Metal Processes
1. Cutting
Shearing between two sharp cutting edges
Cutting
Shearing, Blanking, and Punching
Three principal operations in press working that
cut sheet metal:
Shearing
Blanking
Punching
Cutting
Shearing
Cutting
Blanking and Punching
Shearing
1) Before contact
2) Pushing in to the work - plastic deformation
3) Create cut surface
4) Create shear plane - Fracture
Cutting
Shearing with punch
Cutting
Shearing with punch
Shearing
Plastic Deformation
Plastic Shearing
Fracture
Burr Fracture
Angle
Punch-Die Clearance
• Reliable Operation of the Blanking Tools
• Quality and Type of Cutting Edges
• Life of punch and die (wear)
• Tool Forces
• Typically, 4 to 8 % of the sheet thickness
• Small clearance needs large force
• Large clearance will lead to more scrap
Cutting
Clearance in Sheet Metal Cutting
Effect of Clearance
Effect of Clearance
Effect of Clearance
Effect of Clearance
Effect of Clearance
Shearing Force
Types of Dies
1. Based on Types of Press Operations
i. Cutting Dies Examples. blanking dies, piercing
dies, perforating dies, notching dies, trimming dies,
shaving dies and nibbling dies
ii. Bending Dies Examples. V-Bending dies, U-
Bending, Wipe/Edge Bending, Rotary Bending
iii. Drawing Dies Examples. drawing, redrawing,
ironing, reducing, and bulging dies
2. Based on Methods of Operation
i. Progressive Dies
ii. Compound Dies
iii. Combination Dies
iv. Transfer Dies
v. Inverted Dies
Types of Dies
1. Based on Types of Press Operations
i. Cutting Dies Examples. blanking dies, piercing dies, perforating dies,
notching dies, trimming dies, shaving dies and nibbling dies
Types of Dies
1. Based on Types of Press Operations
i. Cutting Dies Examples. blanking dies, piercing dies, perforating dies,
notching dies, trimming dies, shaving dies and nibbling dies
Types of Dies
1. Based on Types of Press Operations
Bending Dies Examples. Bending dies, drawing dies and squeezing dies
Types of Dies
1. Based on Types of Press Operations
Bending Dies Examples. Bending dies, drawing dies and squeezing dies
Types of Dies
1. Based on Types of Press Operations
Bending Dies Examples. Bending dies, drawing dies and squeezing dies
Types of Dies
1. Based on Types of Press Operations
Drawing Dies Examples. drawing, redrawing, ironing, reducing, and bulging
dies
Cutting Dies
Blanking Dies
Cutting Dies
Hole Punching Dies
Compound Dies
Blank and punching Dies
Compound Dies
Blank and punching Dies
Compound Dies
Blank and punching Dies
Combination Dies
Blanking and Forming Dies
Combination Dies
Blanking and Forming Dies
Progressive Dies
Progressive Dies
Multi
Station
Multi
Transfer Dies
Station
• Q.1 Estimate the force required for punching a 25-
mm Diameter hole through a 3.2-mm thick annealed
titanium alloy Ti-6Al-4V sheet at room temperature.
Sol. UTS = 1000 MPa