MANUFACTURING TECHNOLOGY

Dr. Pradeep Kumar Karsh,

Assistant Professor, Mechanical Engineering Department, Parul
University
 CHAPTER- 3

Presses and Sheet Metal Working

 Content

2 4 6 8

1 3 5 7
Introduction Types of Classification Die
of Sheet Workpiece of Press Operations
Metal Application
Working Sheet Metal of Sheet Classification Clearance in
Processes Metal of Dies Die
Working
 Introduction press forming or sheet metal working

• Sheet metal working, also known as sheet metal fabrication, is the process of cutting,
bending, and assembling flat sheets of metal into products and structures.

• Sheet metal is simply metal formed into thin and flat pieces. It is one of the fundamental
forms used in metalworking, and can be cut and bent into a variety of different shapes.

• Thickness less than 6mm or large surface area to thickness ratio as flat, rectangular sheets of
standard size.

• The first step in any sheet metal process is to cut the correct shape and sized blank from
larger sheet.

• Die – punch combination is used for the process to impart the desired shape to the blank.
 Sheet Metal Processes

Sheet Metal
Processes

PUNCHING &
SHEARING FORMING FINISHING
BLANKING

Processes which apply Processes which cause Process that cuts holes in
the metal to undergo Processes which are
shearing forces to cut, the metal, often in the
desired shape changes used to improve the final
fracture, or separate the shape of circles or
without failure, surface characteristics.
material. excessive thinning, or squares.
cracking. This includes
bending and stretching.
1. SHEARING PROCESS

 A simple and efficient method that uses a shear machine to make long cuts in flat sheet metal.

 Shearing is performed by slicing through a piece of sheet metal with a blade that's most often
affixed to a tool or machine.
2. FORMING PROCESS

 In a sheet forming process, a thin piece of metal sheet, commonly referred to as the blank, is bent or
stretched by tools into a desired shape without excessive thinning, tearing, or wrinkling.
3. PUNCHING & BLANKING

 Blanking: The punch is used to cut and trim the sheet to create the desired shape, with the remaining material
being discarded as scrap. Blanking produces less scrap than punching.

 Punching: The punch is used to create holes or other complex shapes, with the remaining material being the
desired workpiece and the cut-off material being discarded as scrap. Punching is used in many industries,
including automobile production and household applications.
4. FINISHING OPERATION

 Sheet metal finishes refer to the different coatings or treatments applied to sheet metal surfaces to
enhance their appearance, protect them from corrosion, and improve their durability.

1. Rough Finish 5. Electroless Plating

2. Electroplating 6. Powder Coating

Finishing
. Operation
3. Bead Blasting 7. Phosphate Coating
.

4. Anodizing 8. Buff Polishing

 Sheet Metal Workpiece

Blooms Slabs Sheets

Stage Stage Stage Stage

1 3 5 7
Stage Stage Stage
2 4 6

Ingots Billets Plates Strips

The main difference between ingots, blooms, billets, slabs, plates, and sheets
is their shape, cross-section, and weight:
•Ingots: Typically rectangular in cross-section, ingots are heavier than blooms, billets, and slabs. They are
considered to be a better final product because they have better internal soundness.

•Blooms: Blooms are large, square sections with a cross-section that's usually above 155 mm x 155 mm. They are
the result of the first breakdown of an ingot.

•Billets: Billets have a round or square cross-section that's usually up to 155 mm x 155 mm. They are sometimes
called bar stock and are sold as cut-lengths or coil.

•Slabs: Slabs are flat, semi-finished, rolled ingots with a specific width and cross-dimensional section.

•Plates: Plates are products with a thickness greater than 6 mm.

•Sheets: Sheets are products with a thickness less than 6 mm and a width greater than 600 mm.

•Strips: Strips are products with a thickness less than 6 mm and a width less than 600 mm.
 Classification of Presses

Press Machine

Based on
Based on Based on
Frame and
Source of Power No. of Action
Construction
 Based on
Source of Power

Manual Mechanical Hydraulic Pneumatic

Presses Presses Presses Presses
1. Based on Source of Power

A. Manual Press: A simple, basic tool powered by a human operator. Manual presses are inexpensive to
purchase and operate. These are either hand or foot operated through levers, screws or gears. A common press
of this type is the arbor press used for assembly operations. Capacity ½ to 10 tons.

B. Mechanical presses: These presses utilize flywheel energy which is transferred to the work piece by gears,
cranks, eccentrics, or levers. 5 to 100 tons capacity.

C. Hydraulic press: Uses a hydraulic cylinder to produce compressive force, based on Pascal's law. Hydraulic
presses are known for being affordable and powerful. 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.

D. Pneumatic Presses: Also known as hydra-pneumatic presses or air over oil presses, these presses use an
air over oil intensifier cylinder to provide higher forces. 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.
 Based on
No. of Actions

Single Double Triple

Action Action Action
2. Based of Number of Action

A. 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.

B. 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.

C. 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.
 Based on
Frame and
Construction

Gap Frame Inclinable Straight Horn

Presses Frame Side Presses
Press Presses
3. Based of Frame and Construction
A. Gap Frame Press : As seen in the above figure, it has the larger frame opening part which indicates the
wide gap between ram and bed. It is also called C-Frames machines. This type of machine is beneficial for
the accommodation of large workpieces with longer beds as seen in the figure.

B. Inclinable Frame Press: It is known as inclinable frame press because of the flexibility of the frame. As
seen in the figure, the frame is tilted back up to some angle. It’s also known as the open back inclinable
press since its rear is open to allow scrap to depart.
3. Based of Frame and Construction
C. Straight Side Press : Two vertical stiff frames make up this press machine. These are positioned on two sides of
the base and are designed to absorb the ram’s essential stress. The machine can handle heavy work, but sheet metal
cannot be fed from the side due to the existence of side frames.

D. Horning Press: It is made out of a vertical frame with an overhanging top that faces the front. The ram control
and driving mechanism are housed in the overhanging part. The frame has a horn-shaped front face that serves as a
work table.
Press Tool Terminology
 Press Tool Terminology
 Shank : It is used to locate the press tool in
press for alignment purpose.
 Punch Back up Plate : This plate prevents
the hardened punches penetrating into top
plate.
 Punch Holder: This plate is used to
accommodate the punches of press tool.
 Punches : To perform cutting and non cutting
operations either plain or profiled punches are
used.
 Die Plate: Die plate will have similar profile
of the component where cutting dies usually
have holes with land and angular clearance
and non cutting dies will have profiles.
 Press Tool Terminology
 Die Back Plate: This plate prevents the
hardened Die inserts penetrating into bottom
plate.
 Guide Pillar & Guide Bush : Used for
alignment between top and bottom halves of
the press tools.
 Bottom plate: It is used to hold bottom half of
the press tool with press slide.
 Stripper plate: it is used to strip off the
component from punches.
 1.
Simple Die

4. Types 2.
Combination Progressive
Die of Die Die

3.
Compound
Die
1. Simple Die

• Simple dies are also known as single operation dies as a single operation is performed for each stroke of the die
press.

• These are generally used for very simple operations listed under cutting or forming dies.
2. Progressive Die

• These dies are used to perform multiple cutting operations in a single stroke, but at different stages.
• The punched-out sheet moves from one stage to the next until all the operations are completed.
• Progressive dies are used in the automotive and electronic sectors.
3. Compound Die

• These dies combine two or more cutting operations, such as blanking and piercing, in a single stroke.

• These dies allow simultaneous cutting of internal as well as external part features in a single stroke in some cases.

• Compound dies are more efficient than single operation dies.

4. Combination Die
• In a combination die two or more operations will be performed simultaneously.

• Two or more operations such as bending, drawing, extruding, may be combined on the component with various
cutting operations like blanking, piercing, and cut off takes place.

• It can perform a cutting and non cutting operations in a single die.

 Different cutting actions in dies

Trimming
Perforating

Notching
Shaving

Coining
Punching
Lancing

Blanking

Drawing
 Different cutting actions in dies
1. Blanking: Blanking is the operation of cutting a flat shape from sheet metal. The product punched out is
called the “blank” and the required product of the operation the hole and the metal left behind is discarded as
waste.

2. Punching or Piercing: It is a cutting operation by which various shaped holes are made in sheet metal.
Punching is similar to blanking except that in punching, the hole is the desired product. The material punched
out from the hole being waste.
 Different cutting actions in dies
3. Notching: This is cutting operation by which metal pieces are cut from the edge of the sheet , strip or blank.

4. Perforating: This is a process by which multiple holes are very small and close together are cut in a flat sheet
metal.

5. Trimming: This operation consists of cutting unwanted excess of material from the periphery of a previously
formed component.
 Different cutting actions in dies
6. Shaving: The edge of a blanked part are generally rough, uneven and un square. Accurate dimensions of the
part are obtained by removing a thin strip of metal along the edges.

7. Coining: Coining is a type of stamping procedure used to punch circular holes through a material (usually
metal). The cut is made via pressurized force clamping a punch and die. This process can result in highly intricate
or precise product features.

Coining Operation
Shaving Operation
 Different cutting actions in dies
8. Lancing: This is a cutting operation in which a hole is partially cut and then one side is bent down to form a
sort of tab. Since no metal is actually removed and there will be no scrap.

9. Drawing: Drawing is a method of pulling material to a designated length, resulting in a thinner, longer work
piece. Products such as tubing, bars, or wires are often fabricated through drawing.

Drawing
Clearance on blanking and punching operation
Clearance on blanking and punching operation
Problem 1: Calculate the punch size in mm, for a circular blanking operation for which
details:
Size of blank 25 mm
Thickness of the sheet 2 mm
Radial clearance between
Punch and die 0.06 mm
Die allowance 0.05 mm

Solution:
 Shear on Punch
 In sheet metal working, shear on a punch refers to the angle at which the working face of a punch is
ground off so that it's no longer parallel to the horizontal plane.

 The shear angle distorts the material being cut and reduces the maximum force required.
The punching force required in a blanking operation of mild
steel sheet is 500 kN. If, the diameter of blank is increased by
20% and thickness is reduced by 4%, then punching force will
be: