Press Tool Theory - 1

PRESS TOOL THEORY –I
GOVT. TOOL ROOM AND TRAINING CENTRE

KARNATAKA
REFERENCE NOTES
PRESS TOOL THEORY -I
FOR
: DIPLOMA IN TOOL AND DIE MAKING
GOVT. TOOL ROOM AND TRAINING CENTRE Page 1 of 144

INDEX
SL.NO TITLE PAGE NO
1 INTRODUCTION TO PRESS TOOL 6 - 10

2 PRESS TOOL OPERATIONS 11 - 22
3 ELEMENTS OF PRESS TOOL 23 - 38
4 THEORY OF SHEARING 39 - 42
5 CUTTING CLEARENCE 43 - 51
6 CUTTING FORCE 52 - 57
7 STRIP LAYOUT 58 - 67
8 PUNCHES 68 - 72
9 DIE BLOCKS 73 - 81
10 STOPPER 82 - 87
11 STRIPPER 88 - 96
12 PILOTS 97 - 104
13 CENTRE OF PRESSURE 105 – 108
14. FITS. 109 - 112
15 DIE SETS 113 - 122
16 PROGRESSIVE TOOL 123 - 132
17 COMPOUND TOOL 133- 142
QUESTION BANK 143-159

PRESS TOOL THEORY – I

Contact Hrs. /Week: 4 Contact Hrs. / Semester: 64
SPECIFIC INSTRUCTIONAL OBJECTIVES:

1. INTRODUTION TO TOOLING.
- Introduction
- Purpose, applications and advantages
- Types
2. TYPES OF PRESS TOOLS.

- Basic description of different types of press tools, their applications
3. ELEMENTS OF A PRESS TOOL.

- Different parts of a press tool
- Materials, functions and their importance
4. THEORY OF SHEARING.
- Shearing action on metal
- Plastic deformation
- Penetration
- Fracture
5. CUTTING CLEARANCE.
- Necessity of clearance
- Calculation of clearance
- Effects of insufficient, sufficient and optimum clearance
- Misalignment between punch and die
- Land and angular clearance
- Problems
6. CUTTING FORCE.
- Calculation of cutting force
- Methods of reducing the cutting force
7. STRIP LAYOUT.
- Unit stock and stock strip
- Types of strip layout

- Economic strip layout

- Problems
8. & 9PUNCH AND DIE.

- Introduction
- Basic requirement of a die
- Types of dies - solid and split type
- Types of punches
- Classification of punches
- Mounting of punches
- Materials for punches and dies
- Heat treatment methods
- Methods of manufacture of punch and die
10 STRIPPER.
- Functions
- Types and applications
11STOPPER.
- Functions
12 PILOT.
- Functions
13 CENTRE OF PRESSURE.
- Meaning
- Importance in design
- Calculation of COP by analytical and graphical methods
14 . DIE SETS.
- Elements of a die set

- Types of die sets
- Accuracy and manufacture
- Applications of different types

15. FITS.
- Importance of Fits in press tool.
- Fits between all the elements- Pillar/Bush, Pillar/Bottom plate, Bush/ Top
Plate, punches/ plates, pilots/plates, pilots/pierced hole
16. PROGRESSIVE DIES.

- Introduction
- Pitch and pitch punch
- Advantages and disadvantages
- Classification
- Design considerations
17. COMPOUND DIES.

- Introduction
- Applications
- Construction
- Comparison with a progressive die
QUESTION BANK 143-153
REFERANCE BOOKS:
1. Tool and die maker by Mahajan

2. Design fundamentals by Pacquin
3. Tool design by Donaldson
4. Tool engineering & design by G H Nagpal
5. Basic die design by Osterguard
6. Advanced die design by Osterguard

HISTORY
BRIEF HISTORY OF PRESS TOOLS

Sheet metal operations have been in existence since 8000 B.C. 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. Due to its long history, sheet
metalworking is, unfortunately, often seen as archaic and uninteresting.
That metal sheets can be transformed with the aid of robust machines intendancy
consumer products with tight tolerances is inconceivable to many. Yet, sheet metal operations
are used for producing both structural components and durable consumer goods. Nowadays,
sheet metal parts are widely present in different daily life products. During the past decades,
scientific research in the field of sheet metal operations has been booming and international
conferences on different sheet metal topics attract numerous attendants. Both industry and the
academic community recognize the importance of continuing improvement in sheet metal
operations. Application 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.
Advantages High strength, Good dimensional accuracy, Good surface finish, relatively low
cost, for large quantities, economical mass production operations are available.
The most common end uses for sheet metal have been electronic enclosures, such as
personal computer housings or casings; roofing and roof drainage equipment; air conditioning
ducts and stovepipes; sheet metal flooring and siding; awnings, canopies, cornices, and soffits;
culverts, flumes, and irrigation pipes; and other or unspecified uses. These categories cover a
myriad of products used by every industry, including aircraft manufacture (air cowls); building
construction (siding, stove hoods, and gutters); heating, ventilation, and air conditioning
(HVAC) applications (ducts, furnace flues); mineral processing (coal chutes); highway
construction (guardrails); agriculture (irrigation pipes); business machines (computer casings);
shipbuilding (ship ventilators); postal delivery (mailboxes); and food preparation (vats and
bins). Market Survey According to industry statistics from Dun and Bradstreet, there were an
estimated 5,917 establishments engaged in manufacturing sheet metal work for buildings (not
including fabrication work done by construction contractors at the place of construction) in 2010
with revenues of more than $10.7 billion employing 115,83,800 workers. States with the highest
concentration of establishments in these Sheet metal product sales are expected to account
for 51.3% of industry revenue in 2012. Sheet metal products are used in virtually all phases of
building construction and have many uses in improvements and repairs for existing structures.
Sheet metal is used to install and maintain heating, ventilation and air-conditioning duct
systems; roofs; siding; rain gutters; downspouts; and skylights. Some products manufactured
in this segment include awnings, canopies, casings, chutes, ducts, furnace casings, gutters
and ventilators Sheet metal demand is forecast to cross $20 billion by 2017, following annual
gains of over five percent from 2011. Cost Estimation Capacity: 900 MT/ Annum Mild Steel
Sheet Products: 600 MT/ Annum MS Scraps: 300 MT/Annum

Unit 1: INTRODUCTION TO PRESS TOOLS
Most of the industries products are produced in mass. The idea of producing products in mass is mainly
to meet the requirement of the consumer, to maintain consistent quality and to make the product cost
effective.
Press tool are one of the devices, which are going to meet the entire above mentioned
requirement all most all products like television, tape recorder, radio, refrigerator, car, watch etc.
consists number of components made of either plastic or sheet metal. Press tool are used to produce
the sheet metal components.
PRESS TOOLS:
Press tool is a device in which the sheet metal components are produced in large volume with
stipulated time, when this is used in a press these press tools are develop to increases the productivity
of the components both by quality and quantity. Press tools are special tools custom built to produce
a component mainly out of sheet metal. Press tool is of stampings including cutting operations
(shearing, blanking, piercing, etc.) non-cutting operations (bending, drawing, etc.) & hybrid
operations. (Both cutting & non-cutting)
ADVANTAGES
Sheet metal items such as automobile parts, mobile parts, components of aircrafts, computer
components, parts of business machines, household appliances, sheet metal parts of electronic
equipment’s, even medical & surgical components etc., precision parts required for homological
industry etc. are manufactured by press tools.
1. Mass production –Press tool are used to produce components in large scale
2. Components are Identical- all the components produced from a Press tools are similar.
3. Less component Cost- The components produced from a Press tools are lesser in cost.

4. Accuracy of components is high- The components produced from a Press tools will have good
accuracy.
5. Less labor cost - The components can be produced from a Press tools by a semiskilled labor.
DISADVANTAGES
1.Tool design & manufacturing cost is more.
2.ToolMaintenance cost is high.
3. Raw material cost is high.
4. Highly skilled manpower is required to design & manufacturing of Tool.
The word tooling refers to the hardware necessary to produce a particular product. The most common
classification of tooling is as follows:
DIFFERENT TYPES OF TOOLS

1. Sheet metal press working tools –Press tools
2. Moulds Tools for plastic molding and die-casting Tools for aluminum alloys.
3. Forging tools for hot and cold forging.
4. Jigs and fixtures for guiding the tool and holding the work piece.
5. Gauges and measuring instruments.
Cutting tools such as drills, reamers, milling cutters broaches, taps, etc.

UNIT 1: PRESS TOOL OPERATIONS
PRESS TOOL OPERATIONS:

The press tool operations are classified as below depending on type of functions,

CUTTING OPERATIONS.
Blanking:
Blanking is a process of producing flat

stampings. The entire periphery is cut and cut
out piece is called the blank or a component, In
blanking metal remained after cutting is called
scrap or slug.
 When a component is produced with one single punch and die where the entire outer profile is
cut in a single stroke the tool is called a blanking tool.
 Blanking is the operation of cutting flat shapes from sheet metal.
 The outer area of metal remaining after a blanking operation is generally discarded as waste.
 Size of blank or product is the size of the die & clearance is given on punch.
 It is a metal cutting operation.
Piercing:
It is the operation of making hole in the stamping. Here also

the entire Periphery is cut and cut piece is waste. This operation
consists of simple hole punching from the components this is
different from blanking here components becomes strip for
piercing and the materials removed is called scarp or slug,
piercing operation is most of the cases accompanied by a
blanking operation either before, after are at the same time.
GOVT. TOOL ROOM AND TRAINING CENTRE Page 10 of

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Cut - off:
Cut off operation separates the work material along a straight line in a single cut. No scrap is produced
in cutting off operation. The process of cutting off is similar to shearing in a shearing machine.cutting
off or cut off operation separates the work materials from the strip along a straight axis in a single line
cut in this operation utilization of strip is 100%.
Parting - off:
The parting off operation separates the work material along a straight line in a double line cut. The
piece, which is removed by the punch, is a scrap. In this operation part will be separated from the main
strip by double line cutting it produces scrap also therefore, it is not economic as cutting off operation,
but the accuracy of the component is more compare to cutting off some times this operation is also
adopted in a progressive tool to separate the component in a final stage.

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Notching:
This operation removes the metal from either one or both the edges of the strip, notching
serves to shapes the out contours of the work piece in a progressive die or to remove
excess metal before drawing or forming operation in a progressive die.
Trimming:
It is the operation of cutting the edges of the drawn
components, which are wavy and irregular. When cups and
shells are drawn from flat sheet metal the edge is left wavy
and irregular, due to uneven flow of metal. Shown is
flanged shell, as well as the trimmed ring removed from
around the edge.
While a small amount of Material is removed from
the side of a component in trimming tool.
A -- COMPONENT BEFORE TRIMMING

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B -- COMPONENT AFTER TRIMMING

Shaving:
It is operation of removing a chip from around
the edges of a previously blanked stampings to
get finished edges and accurate dimensions.
Shaving is a secondary
operation usually done to finish the previously pierced or blanked profiles to accurate dimension,
the excess metal is removed in the form of small chips of metal cutting tool, there is very less or no
clearance(zero) is provided between punch and die, this operation is used to produced precession
components.
Perforating:
If more number of holes are pierced, it is called

perforating.
Lancing:
It is a combination of bending and cutting

operation along a line in the work material. No metal
is cut free during lancing operation.
Dinking:

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To cut paper, leather, cloth, rubber and other

soft materials a dinking tool is used. The cutting
edges penetrate the material and cut (like knives).
Broaching:
It is similar to shaving operation; in this a tool

having a series teeth profile removes metal from the
edges of the blanked component.
Extrusion:
This is a special process to manufacture collapsible tubes, shells etc. The blank, which is loaded in the
die, is forged upward or downward under high pressure between punch and die.
A-COMPONENT BEFORE EXTRUSION B- COMPONENT AFTER EXTRUSION
Planishing:
Planishing tool is used to straighten, blanked
components. Very fine serration points penetrate
all around the surface of the component.

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Embossing:
The embossing tool is used to press letters and numbers
into a sheet metal or on pre drawn piece part or stampings.
Usually the punch will have the raised form and the die will
have the corresponding cavity.

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Swaging:
The operation of swaging sometimes
called necking is exactly the opposite of
bulging. When a work piece is swaged
a portion is reduced in size and this
causes the part to become longer than
it was before swaging.
PROGRESSIVE TOOL:
In a progressive tool strip is moved in stages from station to station, different operations
both cutting & non-cutting like piercing, notching, coining, lancing, blanking, bending etc. are
performed on it at each station except idle stage. A complete strip is removed to the final
stage for getting a finished Component.

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Compound Tool
A common characteristic of compound dies is the inverted construction. The blanking die is on
the upper die shoe and blanking punching on the lower half. The pierced slugs pass through
the lower die shoe. In the Compound Tool only cutting operations are done, in this tool 2 or
more cutting operations are done in a SINGLE STAGE (Station)for getting a finished
Component. A strip will not be moved to stage by stage for getting a finished Component as
the component produced in single stage.

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Side cam tool: Side cam transforms vertical motion from the press ram into horizontal or angular
motion in the tool
Horning: Horn tools are provided with an arbor or horn over which parts are placed for secondary
operations.
Combination tool: In combination tool two or more operations such as forming, drawing,
extruding, embossing may be combined on the component with various cutting operations like blanking,
piercing, broaching and cut off in the single stage (STATION)

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UNIT 3: ELEMENTS OF PRESS TOOL
ELEMENTS OF PRESS TOOL
Press tool is an assembly of different parts to produce sheets metal components rapidly
or in mass, different elements (parts) of press tool are mentioned below.

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ELEMENTS OF PRESS TOOL
ASSEMBLY OF A PROGRESSIVE PRESS TOOL

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MATERIALS USED IN PRESS TOOLS

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TOP PLATE
The assembly including the punch holder plate, punch back plate and punches are
mounted on the top plate, the shank which locates the tool in the center of press ram is also
screwed in the top plate. The top plate is made up of mild steel or cast iron. This plate should
be thick enough to prevent bending. Top plate is a top most plate of a press tool used to hold
the top of a punch unit contains punches, punch plate punch back plate etc., all these units
are held together with the help of dowels and Allen screws, the main purpose of using dowels
pins are for alignment of different parts, minimum two dowels are used for the alignment
purpose both dowels are heavier different in diameter for fool proofing , Allen screws are
used for the Purpose of clamping the parts, usually four Allen screws of same size are used
number may be increased.
If the tool size is large, Allen screws is will be free in the top plate, punch back plate and
in a punch plate with threads, counter bores are made in the top plate to positioned the

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counter head of Allen screws. The size of the top plate is (L x B) depending upon number of
operation or number of stages. In a particular press tool the material is soft (St42), no
hardening is required. Top plate provides accommodation for guide bushes also, the bushes
generally fitted by H7/h6 fit in the top plates.
BOTTOM PLATE
Bottom plate is a bottom part of press tool it is fixed to the die unit it is also called as base plate it
holds the entire die elements like die, stripper plate, guide plates etc. generally two dowels pins of
different sizes located diagonally opposite in the plate and four Allen screws are used to hold the die,
Allen screws increases for the larger die unit in bottom plate profiles are made free to freely fall up
slugs and components it has 2or4 holes to fix guide pillars by H7/g6 fit.
This gives a constraining effect to the die as well as provide enough room for the tool to be clamped
to the press bed. The opening in the base plate allows the blank or slug to fall free off the tool, they

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should meet the following requirements

 The opening should not weaken the support of the die.
 The blank should fall clear off the die without any abstraction.
 The contour of the opening should be made as simple as possible.
The opening should not weaken the die plate.
PUNCH BACK PLATE
Punch back plate is provided at the top of the punch plate (Back plate) to avoid the impression of the
punches on the top plate it is a hardened plate having thickness of 8to12mm, the punch while performing

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the cutting operation the punches will exert upper thrust, so the punches should be backed up by
hardened plate to prevent it from digging in the soft top plate. Punch back plate is made up of case
hardened steel IS Code 17Mn1Cr95 hardness up to 40-45HRC or it is made up of OHNSIS
CodeT110W2Cr1 hardness up to 50-52HRC
PUNCH HOLDER PLATE
Punch plates are to hold punches to the right position to have a proper relation of a die the

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profiles are made in the punch plate to fix the punches according to the design of the different punches.
the material of a punch plate is Mild steel IS Code St42.
The punches are usually fixed by light press fit in the punch holder H7/k6 some means to prevent the
profile punches should be provided in the punch holder plate hence it is made up of st-42 material.
PUNCH
The basic elements of press tool are punch they are made up of good quality of alloy steel or HCHCr.IS
Code T215Cr12, punches are hardened up to 60-62 HRC. The punch is generally termed as male element

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of the press tool and clamped at the top half of the tool, punch is a important element of the press tool. On
cutting punches are made up of OHNS, IS Code T110W2Cr95 and hardened up to 50-56 HRC.
STRIPPER PLATE

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While performing the cutting operations the punch penetrating the stock material and enters into the
die before it should be guided by means of stripper, as a result of this blank or slug is punched into the
die on completion with draws from the die but the stock material sticks tightly around the punch the strip
cannot be moved forward unless the punch to facilitate the removal of the strip from the punch another
plate is mounted on the top of the die with the help of screws and dowels this plate does not allow the
strip to move with punch. this strips out or removes the stock material which sticks tightly around the
punch and so it is called stripper plate. Stripper plate is made up of St42 material and kept soft for fixed
strippers, and OHNS for floating stripper and hardened up to 50-52 HRC.

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STRIP GUIDE PLATE.
Strip guide are used to guide the strip for different operations for different stages in a tool, strip guides
are fitted in between the stripper plate above the die plate it is fitted in bottom half of the press tool.
Strip guides make a way to strip movement. Strip guides are made up of case hardening steel and
hardened up to 40-45HRC.
End Stopper:
End Stoppers are stopping agents for the strips in press tools, they are fitted on the die plate to stop the
strip feeding at required position for the operations to perform on the strip. They are mounted on holes
provided for the end stopper away from the opening. The end stoppers are made up of OHNS hardened
up to 50-54HRC

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DIE PLATE
The basic element of the press tool is die plate; they are made up of good quality alloy steel or HCHCr.
they are hardened to 60-62 HRC. The die is generally termed as female elements of the press tool and
clamped at the bottom half of press tool using screws and dowels. The profile required for the components
are machined on the Die, the accuracy of the component depends on the manufacturing of die. The die
plate plays important role in press tool for getting/manufacturing the required component

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STAGE STOPPER
STAGE STOPPER is also called as finger stopper in progressive tools for manual feeding
finger stops locate the strip for each station except for final station. It is made up of OHNS
(IS CODE-) T110 W2 Cr1 material with 50-54HRC.
PITCH PUNCH (END NOTCHING PUNCH)
Pitch punches wear against cut off strip edges these are also known as notching stops. At a pitch punch
cuts the strip to the exact width desired and to a length equal to the ONE feed distance or pitch punch

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length is slightly greater than the feed advance so that no scrap can remain. These are made up of HCHCr
with hardness up to 60-62HRC.
GUIDE BUSH & GUIDE PILLAR.
GUIDE BUSH
These are mounted on the top plate which provides smooth

sliding contacts between pillars and top half. They are
made up of 17mn1Cr95 material with 56-58 HRC. The
containing surface of pillars and guide bushes have H7/h6
precession sliding fit whereas the fitted portion of the bush
with top plate have H7/h6 tolerance.
GUIDE PILLAR
These are cylindrical pins known as Guide pins or Guide

pillars these provides 0 means of alignment to die sets they
are made up of 17mn1Cr95 material with 58-60 HRC and
are ground one end of the pillar is press fitted in bottom
plate with H7/p6fit. The other portion which is sufficient
long provides guide for top half and having precision
sliding fit H7/h6 with the guide bush at top plate for easy
sliding & alignment.

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SHANK
It is element which connects between the press tool and

press ram the shank is screwed in top plate and clamped to
the press ram .it is made out of mild steel the diameter and
length of shank depends on the force required for the press
tool. the major function of shank is to locate the press tool
on the press ram. Shank is made up of St42 material and
kept soft.
PILOTS
These are also called as true gauges. the functions of pilots are to position the stock strip
accurately and bring the strip to proper registry for successive stations when the strip stop
allows a slight amount of over feeding, they bring strip to the registry position, a pilots than
blocks the strip in to registry position in a direction away from the strip stop. It is made up of
OHNS (IS CODE-) T110 W2 Cr1 material with 50-54HRC.
SCREWS
Screws are the clamping elements which are used to clamps the plates of top half and bottom half and
also some punches. screws used in blanking and piercing dies should be located diagonally across
from each other and as far apart as possible to increase location accuracy.

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UNIT 4: THEORY OF SHEARING
DOWELS
Dowels are the aligning elements where the plates are aligned and clamped dowels are cylindrical pins
which are hardened and ground accurately to fit into the holes by means of H7/m6 fits. all dowels
should be located at a distance ranging from 1.5 to 2 times.

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The result of the force imposed on the stock material by the working of the blanking or piercing
dies is a shearing action. This shearing action may be considered in three stages, which are very
important to the die maker because of their direct relationship to the dimensional qualities and
appearance of the piece parts. They are also related to the effective working and life of the die.
1. Plastic deformation:
The pressure applied by the punch on the stock material tends

to deform it into the die opening when the elastic limit is exceeded
by further loading, a portion of the material will be forced into the
die opening in the form of an embossed on the lower face of the
material and will result in a corresponding depression on its upper
face. This stage imparts a radius on the upper edge of the punched
out material. This is called the stage of “plastic deformation
2. Penetration stage:
As the load is further increased, the punch will penetrate
the material to a certain depth and force an equally thick portion
of metal into the die. This stage imparts a bright polished finish
or burnished surface (cut band or burnished land) on both the
strip and the blank or slug. On optimum cutting conditions the cut
band will be 1/3rd of the sheet thickness.
This is “penetration stage”.
3. Fracture stage:

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In this stage, fracture will start from both upper and lower
cutting edges. As the punch travels further, these fractures
will extend towards each other and eventually meet,
causing complete separation. This stage imparts a dull
fractured edge. This is the “fracture stage”. There will be a
small burr as a result of fracture, known as TENSILE
BURR, the amount of burr depends on the quality or
sharpness of cutting edges of punch & die
Figure shows the characteristic appearance of the edges of the produced by blanking and
piercing operations in details. The edge radius appears more when using soft materials.
The highly Burnished Land or Cut Band is the result of the material being forced against the walls
of the punch and die and rubbing during the final stages of plastic deformation. The sum of the
edge radius depth, and the burnished depth is referred to as penetration, i.e. the distance the
punch penetrates into the stock material before fracture occurs. Penetration decreases. For this
reason, harder materials have less deformation and burnished area or cut band.
The remaining portion of the cut is the fractured area, or break. The angle of the fractured area is
the breakout angle or slug is towards the punch, and the burr side of the work material is toward the die
opening.

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Note- Cut edge characteristic features of Punched Hole (a) & scrap (b-slug)

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UNIT 5: CUTTING CLEARANCE
Cutting clearance:
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, when the punch is entered into the die opening. It is expressed in
the amount of clearance per side.

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Importance Of Cutting Clearance:

Proper cutting clearance is necessary to:
1. Improves &Increases the life of the die.
2. Increase the quality of the component.
3. Improve the cut edge characteristics of the component.
4. Reduces the undue stress and wear on the cutting edges of the tool.
Optimum Cutting Clearance:
Fig shows the blank or slug made under optimum cutting conditions. The edge radius (die roll-roll
over) is the result of initial plastic deformation, which occurred during the first stage of plastic
deformation action.
Highly burnished cut band results from the second stage (penetration) of shear action. The width of
the cut band is approximately 1/3 rd. of the thickness of stock material. The balance of the cut is the
break, which results from the third stage (fracture) of the shearing action.
Excessive Cutting Clearance:

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In this the large gap between the punch and die cutting edges allows the stock material to react to the
initial pressure on a manner approaching that of forming rather than cutting. Therefore, the edge radius
becomes larger and the cut band becomes smaller
Insufficient Cutting Clearance:
When the cutting clearance is slightly less the condition can be identified by greater width of the
cut band. Because of steeper angle between the punch and die cut edges the resistance of the stock
material to fracture is increased. In case of excessive clearance, the burr results from dragging of the
material. While insufficient clearance compressive forces cause the burr.
MIS ALINGMENT OF PUNCH & DIE
When the cutting clearance is uneven the condition can be identified by uneven width of the cut

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band by the sides, the edge radius becomes uneven at the sides, Because of lesser and more angle
between the punch and die cut edges the resistance of the stock material to fracture is increased. In
case of the misalignment of punch & die excessive burr & lesser burr results from dragging &
shearing of the material. While insufficient clearance compressive forces cause the burr.
Burr Side:
The burr side is the adjacent to the break. The burr side is also called because of a noticeable burr
condition develops it will occur in this side. Burr should be practically non- existence if the cutting
clearance between the punch and die is correct and if the cutting edges are sharp.
The burr side of the blank or slug is always towards the punch (die starts shearing) the burr side of
the punched opening is always towards the die opening.
Determination of punch and die size:
For Piercing:
Piercing punch = Piercing hole size.
Die = Piercing hole size + total clearance.
For Blanking:
Blanking punch = Blanking size - total clearance.
Die = Blanking size.
For finding the cutting clearance following formula to be used.

Cutting Clearance = 0.01x t x fs, mm/side
fs= shear strength of the material t= sheet thickness
Problems:
1. Calculate the clearance for punching a 2mm sheet shear strength of the material
assumed to be 30kg/mm2.

= 0.01 X 2 X  30

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= 0.02 X  30/1
= 0.12 mm/side
Therefore, clearance on one side = 0.12 mm
2. Determine the punch and die dimension for the component given below. Sheet thickness 0.5mm,
stainless steel sheet, is 40 kg/mm2.
= 0.01 X 0.5 X 40
= 0.03 mm/side
Therefore, clearance on one side = 0.03 mm.

Blanking punch:
 Blanking die dimension is the same as that of component dimension.

 Piercing punch size is the same size of the pierced hole
Piercing Die:
1. Determine the punch and die dimension for the component given below. Sheet thickness

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2mm MS, shear strength is 40kg/mm2.
= 0.01 X 2.0 X  40
= 0.126= 0.13 mm/side
= 0.13 mm/side
 Blanking die dimension is the same as that of component dimensions.
 Piercing punch size is same as component size.
Piercing Die size = component size + clearance

= 10.00 + 0.26 = 10.26mm

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LAND:
The inner walls of a die opening are not usually

made straight through as the blanks or slugs tend to
get jammed inside, which may result undue stress
build up. This may lead to the breakage of the punch
and die.
To avoid such situation, the die walls are kept
straight only to a certain amount from the cutting
edge. The straight wall is called “THE LAND”.
 An amount of 3mm land for stock thickness up to 3mm.

 For thicker materials equal to their sheet thickness.
ANGULAR CLEARANCE OR ANGULAR
RELIEF:
Generally, soft materials require greater angular
clearance than hard materials. Soft thicker materials
above 3mm require more angular clearance. An angular
Clearance of 1.5°per side will meet the usual
requirements.
In special cases, the angular clearance extends from
top to bottom of the die wall completely eliminating the
land.
Dies employing an ejector to clear the blanks will

have straight walls without any angular clearance, as
the blanks do not get accumulated in the die.

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UNIT 6: CUTTING FORCE
CUTTING FORCE OR SHEAR FORCE :

“Cutting force is the force which has to on the stock material in order to cut out the blank or
slug”. It is expressed in tons. This determines the capacity of the press to be used for particular tool.
The cutting force is also determining the cut length area for straight cuts are performed in the shearing
and some cut off operations, the area to be cut is found by multiplying the length of cut by stock
thickness.
Formula for calculating the cutting force:
Cutting force =Kx L x fs x t
1000
K = Constant value 1.33
L = Total cut Length or material to be cut in ‘mm’.
t = Sheet thickness in ‘mm’
fs = Shear strength in Kg/mm2, (taken from the table)
Add 20% safety for the Cutting force

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The fig. Represents the typical load curve of cutting force of blanking or piercing
punch.
Formula to calculate the press force:

Press force = Cutting force + stripping force
(Stripping force = 15% - 30% of cutting force)
The following table gives the shear strength of different materials.

MATERIAL Shear strength in Kg/mm2
Steel with 0.1% carbon 24 – 30

Steel with 0.2% carbon content (deep draw steel) 32 - 40
Steel with 0.3% carbon 36- 42
Steel with 0.4% carbon 45 - 56
Silicon steel 45 - 55
Stainless steel 35 – 45
Copper 20 – 40
Brass 35– 40
Bronze 36 – 45
German silver (2 - 20% Ni, 45 - 75% Cu) 30 – 32
Tin 3–4
Zinc 10 – 12
Lead 2–3

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Aluminum 99% pure 2– 12

Aluminum manganese alloy 15 – 32
Aluminum silicon alloy 12 – 25
Paper & card board 2–5
Hard board 7–9
MATERIAL Shear strength in Kg/mm2

Laminated paper or rosin impregnated paper 10 – 14
Laminated fabrics 9 – 12
Mica 5–2
Plywood 20 – 40
Leather 1
Soft rubber 1
Hard rubber 2–6
Celluloid 4 -6
CUTTING FORCE CALICULATION

Example:
Calculate the press force required t produce the following component.
Given Data-Sheet thickness 2mm. Material is brass.
Cutting force =K x L x fs x t
1000
= 1.33x120 x 2 x 40
1000
= 12768
1000
= 12.76 tons
Safety 20% 12.76x20=2.5 =
100 12.76+2.5 =15.26 tonsThat is equal to 16 TONS
Note- Cutting force calculations to be done for different components…………

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METHODS OF REDUCING THE CUTTING FORCE:

It sometimes becomes necessary to reduce the cutting force to prevent press over loading
1. The use of Stepped punches will reduce the shear force..
2, To grind the small shear angle on face of the punch or die will reduces the shear force 3,
To grind the concave or convex surface on face of the punch or die will reduces the shear
force
DIFFERENT METHODS TO REDUCE SHEAR FORCE
1. The use of Stepped punches.
A minimum of a sheet thickness can be varied in punch length and cutting force will be applied in
progressive way reducing the shear force/cutting force

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SINGLE SIDE SHEAR ANGLE ON PUNCH & DIE

A minimum of 1 degree to 3 degrees’ max angle can be given and cutting force will be applied in
progressive way in a same punch/die by reducing the shear force/cutting force

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CONCAVE & CONVAX SURFACE ON PUNCH FACE

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UNIT 7: STRIP LAYOUT
STRIP LAYOUT:
The strip layout is defined as an imaginary plan of producing a sheet metal component in an
economical way in which all details are indicated clearly, details such as no of stages, feed directions,
different operations performed, strip width, pitch, scrap value stopper position & pitch, pilots placed
& sheet thickness.
A strip layout represents the sequence of the logical, workable operations, which is to say a
sequence of ideas. If this sequence of operations has error, the error will be surely emerging in a tryout
of the press.
Strip Layout for blanking tools:

 Blanking tools produce blanks entirely from the strip or unit stock.
 Blanking is a most efficient and popular way of producing intricate and closely tolerated
blanks.

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UTILIZATION FACTOR: (ECONOMY)--KW

The designer should try out every possible means to attain a good percentage of utilization strips,
without sacrificing the accuracy of the piece part.
UTILIZATION FACTOR (KW)= Area of the blank x No of rows x 100

Strip Width x pitch
A minimum utilization of 60% should be aimed. The position of the blank in the strip decides the
utilization factor

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Factors to be considered while designing the layout are: -

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1. Shape & Size of the blank.

2. Production requirement.
3. Grain direction.
4. Burr side.
5. Stock material.
Shape & Size of the blank:

 The contour of the blank, decides the position of the strip.
 Some of the blanks are laid at an angle.
Production Requirement:
If production requirement is less, then material conservation is necessary. This must not increase
the tool cost. Gang die may be suitable for the mass production.
Grain Direction:
 The grains are found in the sheets when they are rolled.
 Bending the strip along the grain direction results in crack and fracture.
Burr Side:
 It is a decisive factor in laying the strip.
 In blanking, burr is found on the punch.
 In piercing, burr is found on the die.
Stock Material:
 Every means is necessary to conserve the stock material.
 A double pass layout would justify the cost of stock material conserved.
Single Row One Pass layout:

Here the blanks are arranged in a single row and the strip is passed through the tool only once to
the punch and blanks from it.
Blanks having at least two Straight parallel sides:
Here the strip width should be equal to the distance between two parallel sides. The blanks are

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produced by cut off or parting off operation.

Blanks having Irregular Counters:
Factors considered for best method of positioning a blank in the strip.
1. Contour.
2. Minimum material wastage.
3. Less tool cost.
4. No scrap strips to handle, which renders the production faster.
5. Accuracy in strip width.
6. Accuracy of the blank.
7. Flatness.
Strip layout for Cut Off and Parting Off:
 Cut off and parting are the operations, which shear the strip across the entire width either, in
straight or curved lines.
 The difference is cut off punch cut s only one edge producing no scrap where as parting
punch cuts two opposite edges producing the scrap.
FORMULA TO CALCULATE
SCRAP BRIDGE, PITCH & STRIP WIDTH
FOR SINGLE PASS-
SCRAP BRIDGE = 1.5 x SHEET THICKNESS
PITCH = 1 x SCRAP BRIDGE + COMPONENT LENGTH STRIP WIDTH
= 2 x SCRAP BRIDGE + COMPONENT WIDTH FOR DOUBLE PASS-

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STRIP WIDTH = 3 x SCRAP BRIDGE + 2 x COMPONENT WIDTH
ELEMENTS OF STRIP LAYOUT
Different layouts:
There are two ways of laying the strip, Narrow run and wide run. Wide run is generally desirable
due to,
 Shorter advance distance of the strip promotes easy feeding.
 More blanks can be produced from a given length of strip.
Narrow run is used when the grain direction of the piece part is important.
Single row two pass method:

A two-pass tool requires minimum of two stops. The stops used for the first pass have to be
removed. Or made to disappear from the working surface so as not to interfere with the second pass.
For double pass the front and back scrap as well as the scrap bridge should be wider than those for
single pass (about 50-100). Two pass layouts are justified only when the wastage is considered and
the stock material is costly.
Double row layout:

Further economy can be attained by double rows. Strips for double row layout will be wider and
require the back and front scrap to be more than usual amount.
Gang die:
It consists of two or more similar sets of tool members so as to produce two or more number of
components during the single stroke of press ram. Gang die is the most economical means of mass
production of stampings. But still gang dies are not recommended for very complex work.
Angular layouts:
Some of the piece parts will be require to be laid out to an angular position to make the layout more
economical.

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Different types of strip layout: - PRODUCTS

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UNIT 8 : PUNCHES
PUNCH:
Punch is the male member of a press tool There are three categories of punches:
Cutting punches. ------- Material HCHCr –T215Cr12 - HARDNESS—60-62HRC

Non – cutting punches. -- Material OHNS–T110W2Cr1 - HARDNESS—50-54HRC
Hybrid punches. ------ Material HCHCr –T215Cr12 - HARDNESS—60-62HRC
CUTTING PUNCHES:
These punches perform operations like
blanking, piercing, notching, trimming etc.
NON - CUTTING PUNCHES:

These punches perform operations like
bending, forming, drawing, extruding etc.
HYBRID PUNCHES:
These punches perform both cutting and

non-cutting operations, like shear and form,
punch-trim etc.

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PUNCH GROUPS:
There are two groups of punches:
Segregated punches.
Self mounted punches, which are positioned and
retained by means of self-contained screws and
dowels.
Integrated punches.
Punches depend on other component such as punch
plate, to locate and position them.
TYPES OF PUNCHES:
1) Plain punches
 Rectangular in cross section.
 These are self-mounting
straight punches.
Advantages:
 Material saving.
 Machine time saving.

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 Easy mounting.
2) Pedestal punches
 They are also called as broad based punches.
 Load distribution qualities are excellent.
 Used for heavy-duty work.
3) Pedestal offset punches

 Base is offset.
 Reason for offsetting
 Space consideration for other components.
 Machining and grinding accessibility.
Disadvantages:
Non-uniform distribution of forces.
4) BOSSED PUNCHES
 Punches made with positioning
boss.
5) FLANGED PUNCHES
 Punches having a flange with boss.
 Allows the possibility of providing
clamping screws.
6) HEADLESS PUNCHES
 Plain punch, which does not contain
dowels.
 Positioning is done by opening
provided on the punch plate.
 Fastening is done by means of
screws.
7) STEPHEAD PUNCHES
(SHOULDERED PUNCHES)
 Punches fitted in punch plate without
screws and dowels.
8) BEVELED HEAD PUNCHES
 Punches are made to angular sitting.
 Bevel angle is made to 30-45deg.
 Beveled portion may be machined or

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pinned.
9) CLAMPED PUNCHES
 A headless punch except the
manner in which it clamped.
10) FLOATING PUNCHES
 Punches made loose in the punch plate.
 Well guided in the stripper plate.
 Alignment of the stripper to the die plate
is maintained precisely.
PERFORATORS:
 Punches of dia 2.5mm or below.
 Punches whose working contour are other than
round.
Commonly used perforators:
Step head perforator:
Consists of stepped head shank and point diameter.
Step head shank less:

Similar to step head perforator. Shank dia is more than point diameter.
Pyramid perforator:
It is used when there is a disparity between point dia and shank.
Bevel head perforator:
Consists of bevel seating
Headless perforator:
Does not have a shoulder. A whistle notch is milled on the shank for fastening.
Slug ejector perforator:
To prevent slug pulling, air pressure or spring pins are commonly used.
Quilled perforator:
Slender perforators are quilled, to prevent buckling.
Healed Punches

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UNIT 9: DIE BLOCKS
These types of punches give support to the cutting edges as only one edge will cut the material the
chances of punch deflection to other end will be avoided by the heel provided. The punches are
called end notching punch or side cutters
This is also called as Side cutter; Side cutters an accurate method of stopping arrangement used
mainly for thinner strips where it is difficult to accommodate the other type of stoppers.
FACTORS INFLUENCE THE DESIGN OF A DIE BLOCK:

1. Piece part size
2. Stock thickness
3. Type of tool
4. Profile of the piece part contour
5. Accuracy
6. Production requirement
7. Machinery available for manufacturing the tool

SOLID DIES:
1. Made up of Alloy Tool Steel (HCHCr) or non-shrinking tool steels

2. Hardened & tempered to 54-62hrc

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CONSIDERATIONS OF SOLID DIES:
1. Critical nature of the Dimensions involved

2. Extreme Pressures & Wear conditions while Shearing
3. Sheet thickness
4. Press force
5. Strength & Life of the Die:
6. Sufficient wall thickness at the weakest points
7. Sufficient Die thickness according to the Severity of the specific operations.
DIES THICKNESS:
DIES THICKNESS:
The thickness of the die is calculated by the formula: -

3√Shear force in kg. (Cube root of CUTTING FORCE IN Kg)
Expressed in tons
Example If the Cutting force is 16 Tons
16 Tons converted to Kgs= 16x1000 3√16000Kg = 25.2MM
Note +25% safety

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SPLIT or SECTIONAL DIE

BLOCKS:
These are the dies having more than One
Section.
1. Made up of Alloy Tool Steel
(HCHCr) or non-shrinking tool steels
2. Hardened & tempered to 54-62hrc

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SPLIT DIES ASSEMBLY

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Locating & Clamping of Die Sections:

Considerations:
 Tilting Due to Downward Thrust.
 Lateral Displacement due to Lateral Thrust created by the Punching Action.
Methods:
 For Thin Stock materials, Dowels and Screws.
 As the Stock material thickness increases, Need of Nesting arises.
NESTING:
METHODS OF NESTING:
 Nesting in Die set pockets.
 Nesting in Retainer Plate, which is of Mild steel.

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 Nesting in the above methods incorporating Liners.

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NESTING IN DIE SET with LINERS:

NEST BLOCKS
Advantages:
 They do not weaken the die set.
 Can be easily hardened for heavy work.
 Can be easily ground, when Die needs to regrind. As the Whole assembly of Die Sections
are ground together.
Disadvantage:
Costly compared to pocket milled Die set type nesting, as the separate nest block has to be
machined & clamped to the die set.

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DIE INSERT:
CARBIDE DIES:
Die Material: Tungsten Carbide.
Applications:
 Blanking, Piercing, Trimming, Forming, Drawing, and swaging operation.
 Where production rates are high.
 Parts having Close tolerances.

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DESIGN PRINCIPLE:
 Draw radii or approach angles.
 Punch & die clearance.
 Relief
All remains the same as that of the steel dies.

Supporting of Carbide Dies inserts:
Inserts must be supported externally by pressing or shrinking them into a Hardened steel case.

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UNIT 10: STOPPERS

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Relationship between stop position & registry position:
 The work is located by the stop and is registered by the pilots.

 The Relationship between stop position & registry position depends upon the function
of the stop. if a stop acts a true gauge, stop position & registry position are one end
the same. If stop function as an approximation gauge, the stop position doesn’t
coincide with the registry position. It can be said generally that if the stock strip is
piloted, it is necessary for the stop to act only as an approximation gauge, allowing
the strip to be overfed. If a stock strip is not piloted the stop then function as a true
gauge.
Stopper Categories:
Primary:
Primary stop is the first stop in the die, which act as true gauges, registering the stock
strip.
This locates stock position to coincide with the registry position.
Secondary:

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The stops in between are secondary stops. The secondary stop acts as an approximation
gauge, therefore allows the overfeed when installed.
Final:
The final stop is the last stop in the die. It may or may not register the stock strip, when mounting
them locate the stopping position as required.

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A clearance hole for the pin should be provided in the die shoe for
three reasons:
 To permit adjusting the height of the stop pin without removing the die block from the die
shoe.
 To allow the stop pin to be removed in order to sharpen the die with the die block fastened
to the die shoe.
 To allow the pin to be driven down in the event of a miss-feed, thus reducing the chance of
damage to the die
Headed pin stop:

It frequently occurs that a stop must be located close to the die opening. In such cases the use of
plain pin stop is prohibited because the proximity of the mounting hole to the die opening will make
the die weak. For such an application a headed pin stop may be employed. The mounting hole can
be located at the safe distance from the die opening.

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Finger stopper (STAGE STOPPER)

The stop is actuated manually. It is pushed inward until the stop shoulder 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 in closed position and the leading end of the stock strip is
fed against the stop. Then operator trips the press and releases the stop. The spring returns the stop
to its open position where its remains until a new stock strip are fed into the die.
Pusher Stops:

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UNIT 11: STRIPPERS
These stops are special types of finger stop. They serve a dual purpose as both stops and
pushers–the spring forces inward where it obstructs the stock strip channel. In operation the leading
end of the stock strip is fed against the pusher stop. After the press cycle, the stop is manually pulled
outward, permitting the strip to advance the next stop. When released, the stop in effect becomes a
pusher.
Trigger stoppers:
For the fast productions mostly trigger stopper are used. They are also called as automatic stoppers.
They are of two types
1. Front acting &
2. Side acting.
In general, the working mechanism is same in both but one is mounted in the front end of the tool
& other one at the side of the tool. The lever shaped trigger stop fits freely in the slot milled in the
guide plate. One sidewall of the slot is provided with the taper angle, which gives the necessary
movement to the trigger. An inclined set spring set at the other end of the trigger.

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STRIPPER CATEGORIES AND TYPES:

Stripper can be classified into 2 groups,
 Fixed stripper, (BOX STRIPPER)
 Traveling stripper. (FLOATING STRIPPER)
Fixed stripper is easier to make than the traveling strippers. Fewer components are required in the
construction of fixed strippers when compared to the equivalent traveling stripper. Therefore, the fixed
strippers are economically desirable as far as the die construction cost is concerned, mechanically,
fixed stripper are solid in performance. This is an advantage where the stripping force is necessary.
But, in some situations a fixed stripper may be impracticable. i.e.
1. When it is necessary to clamp the strip in addition to its stripping function.
2. When it is necessary to keep the punches engaged in the stripper during the entire press
cycle.
3. A traveling stripper permits the operator to observe the work while the tool is operating.
Box Stripper:
A typical box stripper is shown below made up of mild steel St42, this is always kept soft. The
tunnel dimensions are as fallows tunnel is the space (way) to strip movement
The tunnel width “X” can be determined as

X=W+F W = Stock strip width at maximum tolerance.
F= Desired horizontal feeding distance.
For the average progressive die, assuming there are no other specific requirement, Clearance F
may be 0.3 per 100mm tunnel length.
Tunnel height H=S+G, G is the required vertical feeding clearance, G may be= 0.5s for flat work
cutting dies with short tunnel length. Or it may be several times larger than the ‘S’

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PRESSURE PAD STRIPPERS:

Pressure pad strippers hold the material during cutting and strips it from the punch in the
upward stroke. They may be actuated by the spring, rubber or hydraulically.
SPRING STRIPPERS:
Spring stripper is a pressure pad stripper. They are used when it is necessary or desirable
to hold the stock material flat (or very nearly flat), or to provide better visibility and access
when the tool is mounted on the press. Inverted dies have stationary punches & therefore

144
require traveling pressure pad strippers. Pressure pad strippers are also used for push back
applications.
Stripper Plate
NON CLAMPING SPRING STRIPPER:
These kinds of strippers are used when the material is not to be clamped. There will be
clearance between the stock strip and the strip for obtaining good flatness, clearance within
0.05 to 0.4mm is recommended. The pilot registers the stock strip. In most cases, spring
strippers are an effective device for producing good flat piece parts.

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COMPENSATING WASHER:
When cutting punches are sharpened they become
shorter. In many applications, the springs are
compressed a little more and are not always desirable.
A practical method to eliminate this is to install the
cylindrical washer as shown in the figure. Each time
the punches are sharpened the washer is reduced for
the amount
SPRING AROUND THE STRIPPER BOLTS:

Such a construction is shown figure. This construction has desirable features and
undesirable features
Desirable features are

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 The bolt retains the stripper at center of spring pressure

 The bolt acts to confine the spring in location so that the double spring pocket can
be eliminated
STRIPPER BOLT SUSPENSION:
Bolt hole is drilled larger than shoulder diameter A. (clearance hole is provided). When the die
fully closed and the stripper bolt is at its maximum travel position E must be sufficient to assure
adequate punch grinding life (E is about 6mm).
Normally, a space G Should exists between the end of the stripper bolt and the stripper (G =
0.5mm).
To ensure stripping a spring stripper should over travel a distance S, when the stripper is at its
extended position. The over travel is between 0.1 for every light work to 1.5 for heavy work. In any case
each time the punch is sharpened, the over travel increases. This should be corrected from time to time
by inserting the compensator under striper bolt head as shown.
GUIDE STRIPPERS:

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Two typical stripper guide pins arrangements are shown in figure. The drawings are self-
explanatory.
STRIPPING FORCE:
Stripping force for most operations range from 10 to 20% of the cutting force. If the die has
more than one punch the stripping force for that die is the sum of stripping force required for
each punch.
Stripping Force for the Blanking and Piercing:
The following factor affects stripping force,
1. Stock material: Material, which has high friction, value and material, which tend to cling, are
more difficult to strip.
2. Surface condition of sidewalls: A punch, which has smooth finish on its side, wall strip more
easily than punch, which is not as smooth.
3. Area of the stock material to be stripped: Figure shows two-piece parts one larger than
other. The thickness and the type of stock material. The pierced opening is the same size in
both parts. The cutting is the same for both the parts. But the larger piece part requires the
greater stripping effort.
The larger area of the stock material surrounding the punch is stronger and causes the material to

144
cling more tightly to the punches.
THE TYPICAL VIEW OF FIXED STRIPPER & FLOATING STRIPPER

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UNIT 12: PILOTS
PILOTS:
Pilots play a vital role in the operation on multiple-station dies, and many press lines troubles can be
traced to their faulty design. In applying pilots, the following factors should always be considered:
1. They must be strong enough so repeated shock will not cause fracture.
2. Slender pilots must be sufficiently guided and supported to prevent bending, which can
cause faulty strip positioning.
3. Provision should be made for quick and easy removal of the pilots for punch sharpening.
PURPOSE OF PILOT:
The pilot positions the stock strip relation with die opening. This is termed as registering the
stock strip in the required position. Usually the stock strip is over fed than the actual pitch length. The

144
max over feeding of the strip is about 0.1mm.
When the press is tripped the pilot comes down and engages the pierced hole thus dragging the
strip back into the registry position stock strip is fed by mechanical means pilot action is the same
principal. However, the direction in which the feeding is qualified is normally reversed. Instead of being
over feed the stock is under fed.
PILOT SIZE:
The accuracy with which the work can be registered depends upon the proper location and the
diameter of pilot, the pilot should be close sliding fit to the die opening after piercing. There will be
clearance given between cutting punch & corresponding die hole but there will be only sliding fit
between pilot & the corresponding die hole.
Example – Pierced hole Ø8.00 then pilot will beØ7.98 –Ø7.99 & die hole will be Ø8.02 The
following will indicate the pilot diameter;
For an average work Ø of pilot = (Ø of hole to be piloted-0.03 to 0.05mm) For

close work Ø of pilot = (Ø of hole to be piloted-0.02to 0.03mm) For
an accurate work Ø of pilot = (Ø of hole to be piloted – 0.01to 0.02mm)
However, the thick stock materials & the stock materials like aluminum and copper need often
bigger tolerances between the pilot and the pierced hole.
PILOT LENGTH:
Registering the strip must be complete before the cutting punches come and engage the strip.
Therefore, the pilot must be 10mm longer than the punches. If the pilots are too short they cannot
perform their function
This creates serious consequences ranging from spoiled work to damaged pilots. Care must be
taken while setting the stroke of the press so throes pilots clear the stock strip without obstructing the
future feeding of the strip in any case the piloting length should be extended beyond the punch face
equal to the sheet thickness.
PILOT OPENING IN THE DIE:

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The opening of the pilot in the die should not be too large. If so, the stock strip may tend to draw into
the opening. In case of the thin material pilot may not displace the material into registry position but may
instead draw the material on one side therefore it is advisable to have the die opening Ø as pilot
dia+0.02mm, Weaker pilots are guided in the stripper.
PILOT OPENING IN DIE SHOE:

Through hole is provided in the die shoe for the pilot so that slugs produced during miss feed are
cleared. It also helps in clearing the accumulated burrs dislodged from the pierced hole.
 Step headed shank less
 Step head shank type
 Step head pyramid type
 Beveled head
 Headless whistle notched
PILOT NOSE PROFILE:

The main function of the pilot nose profile is to allow smooth riding of the pilot into the stock strip.
The most commonly used nose profiles are described below:
BULLET NOSE:
The most common pilot nose profile is bullet nose. The bullet shape is formed by radius ‘R’, which
is equal to piloting diameter. For piloting in holes less than 6mm the length of radius R can be
increased to reduce the lateral force during piloting. Bullet nose is strong simple to make and smooth
in action.
The other three commonly used pilot nose profiles are:
1.45º conical stub nose
2.30º conical stub nose
3.16º angular long nose
45º CONICAL STUB NOSE PILOT:
The profile is used when a shorter nose profile is desired. 45º cone increased the relative
lateral forces hence not recommended for delicate pilots used for piloting thin soft material.
30º CONICAL STUB NOSE PROFILE:

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This is same as the above pilot except the nose angle is30º this is a compromise between
the 45º stub nose pilot and the conventional bullet nose
15º ANGULAR NOSE:
This small angle provides good mechanical advantages. they are used for small pilots and for thin
materials.
PILOT NOSE PROFILE

144

144
INDIRECT PILOTING:
Indirect piloting consists of piercing hole in the scrap area of the strip and locating in these holes at
subsequent operations direct piloting is the preferred method but certain blank condition require
indirect piloting, as will be explained.
IN DIRECT PILOTING PART CONDITION:
There are seven conditions that required in indirect piloting. Close tolerance on hole: Pilots can
enlarge holes in pulling a heavy strip to position.

144

144

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UNIT 13: CENTRE OF PRESSURE
Centre of pressure (Location of a Shank on a Tool):

The point of pressure where at which the all the forces acts, it is the resultant position at
which all the applied forces meet. In the press tool different operations are done with different
profiles of components, thus the forces of different pressure will be applied by a various types
of punches hence center of pressure is most important for considering the die life of the tool.
The shank is clamped at the point where Centre of pressure meets, so this is also called as
Location of a Shank
IMPORTANCE OF CENTRE OF PRESSURE

 Balancing of the punches is the most important aspect during punching operation.
 Un balanced force on the tool may lead to undue wear on punch and die as well as pillars.
 The resultant forces of all cutting forces acting on many punches should pass
through the shank center.
 This is called as center of pressure or COP
The position of the resultant forces of all partially cutting forces can be found
by the following methods
 By calculation.
 By polygon system (graphical)
By Calculation:

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1) No all the lines in component.

2) Length of each lines in mm
3) Distance from X axis.
4) Distance from Y axis.
5) Line length multiplied by Distance from X axis.
6) Line length multiplied by Distance from Y axis.
7) Total of L x X & L x Y
8) L x X & L x Y = COP IN X AXIS & COP IN Y AXIS
9) Total of L
By Calculation:

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By Polygon System:
Polygon system:
To find the line of the action of resultant then follow the reference below:
1. Draw the forces to scale in a straight line.
2. Draw the arrowheads at the ending points of each force as shown.
3. Draw two more lines at 450 angle from the starting and finishing points of the total length of
the forces so as to form an equilateral triangle and call the intersecting point as pole.
4. Draw the lines from each arrowhead joining the pole point and call them as pole beams.
5. Draw the forces to scale at the given distance.
6. Draw the lines parallel to the pole beams, cutting force line graphically.
7. The line of action of the action of the resultant goes through that point where those two-

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UNIT 14: FITS IN PRESS TOOLS ASSEMBLY
pole beams intersect.
Fits
When two parts are to be assembled the relation resulting from the difference between their
sizes before assembly is called a fit. The fit signifies the range of tightness or looseness which
may result from the application of a specific combination of allowances and tolerances in the
design of mating parts.

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UNIT 15: DIE SETS
Fit is the relation between two mating parts, this is also depending the function of the
elements. The maintaining of proper fits between related elements in press tools will effects all
the below points effectively. Different types of Fits in Press tools
Importance of Fits in press tool

1. Improves tool Life.
2. Improves Component
dimensional accuracy
3. Reduction of wear & tear
4. Improves cut edge characteristics
5. Improves rate of production
6. Minimizes tool maintenance
Colour Codifications for Fits
Generally, it is advised to have color codifications in design depending upon the type
of fits followed between two mating parts.
Type of fit H7/m6 H7/p6 H7/k6 H7/h6

Color BLUE GREEN ORANGE MEGENTA
DIE SET:
These are the ready tools like drills reamers cutters etc., readily available in the market
to accommodate speedy work in manufacturing process of the PRESS TOOLS. The
assembly of A) Top plate B) Guide bush. C) Guide pillar D) Bottom plate. Is known as DIE

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SET
ADVANTAGES OF USING STANDRED DIE SETS
 This reduces the time of manufacturing press tools.

 The accuracy of the die sets is more as they are made from SPM and skilled
persons. The cost of die sets is less.
 They are available in size of 50mm X 50mm to 1mtr X 1mtr.as per requirements
The following elements are considered before selecting the die set.
1. Make or manufacture,
2. Type,
3. Size,
4. Material,
5. Thickness of the die holder,
6. Type & length of the bushing,
7. Thickness of the punch holder,
8. Length of guidepost,
9. Shank diameter,
10. Grade of precision.
A. Top plate B. Guide bush C. Guide pillar D. Bottom plate
DIE SET COMPONENTS:
A. Top plate. B. Guide bush. Guide pillar. D. Bottom plate.

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TOP PLATE:
The upper working member of the die set is called the top plate. The upper surface of the top plate
is bears against the underside of the press ram. The top half or Punch components are fixed
(fastened) to the lower finished surface of the top plate. The top plate is generally made out of MS.

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PUNCH SHANK:
The punch shank projects above the top plate and it

align the center the die with the center line of press. In
operation the shank is securely clamp to the press ram
and it drives the punch portion of the die, rising and
lowering the die.
For semi steel die sets, the punch shank is cast
integrally with the body of the top plate and it is then
machined. To supplement their holding power of the
shank, cap screws are often inserted upward to engage
tapped in the press ram.
BOTTOM PLATE:
The bottom plate is the lower working member of

the die sets. Usually the bottom plate is made thicker
than the top plate to observe the load & shocks then
compensates the weakening effect of the slug and
blank holes, which must be machined through it.
Generally, bottom plate is made up of MS or cast iron.
GUIDE PILLAR:
Guide pillars are precision-ground pins which are press fitted into accurately bored holes in the
bottom plate. They align punch & die components with the high degree of accuracy. Most GUIDE
PILLARS are made up of tool steel hardened up to 58-60HRC
Guide pillars are used for precision die sets are chromium plated to provide high degree of
accuracy of resistance to wear. The addition of chromium reduces wear up to 50%.
They are specified at least 20-25MM shorter than the shut height.

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REMOVABLE GUIDE PILLAR:

Pillars may be removed for die sharpening,
especially in large dies. In first kind of removable pillar
have an axial hole machined through them are tapered
at one end to engage a taper pin.
In second type of removable pillar, the taper pin is

advanced for locking by means of a socket cap screw.
In third type of removable pillar a socket head cap

screw is engaged in retaining cap to clamp the pillar to the
bushing.
NON STICKING GUIDE PILLARS:

In initial engagement the jamming of top plate and bottom plate is problem to avoid this kind
of problem non-sticking pillars are used. Sticking occurs until the bushings have engaged the
pillars sufficiently for complete alignment.

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GUIDE BUSHS:

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Guide bushes are engaged with the guide pillars for

aligning to the top plate with the bottom plate. Most
bushings are made up of tool steel hardened up to 56-
58HRC they are also available in bronze.
There are two types:
1. Plain bushing are simple sleeves, pressed into the top plate.
2. Shouldered bushings are turned down at one end and they are
pressed into the top plate against the shoulder thus formed.
PILLAR ARRANGEMENT:
Different Ways of positioning the pillars in a die set.
A. Two pillars are applied at the back of the die sets. This is most commonly used two pillar
arrangement.

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B. Pillars are applied at the sides force feeding strip from front to back.
C. The pillars are arranged diagonally.
D. Four pillars are used the foregoing are standard pillar arrangement as listed in die set catalogue.
Types of DIE SETS
A- REAR PILLAR DIE SET
The pillars are fixed at the rear end of the plates these die sets are used where
lesser force is applied in the tools specially for bending tools single stage tools &
smaller size components manufacturing tools. The visibility of strip movement is clear
in this type of DIE SETS.

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b. CENTRE PILLAR DIE SET
The pillars are fixed at the center of the plates these die sets are used where medium force
is applied in the tools especially for compound tools, single stage tools & combination
components manufacturing tools. These die sets are also used for secondary operation work. The
of movement strip is generally front to back or back to front in this type of DIE SETS.
FACTORS-TWO PILLAR DIE SETS:
Most tools are provided with two guide pillars applied at the back of the die set because this type
gives maximum visibility and accessibility since it is open on three sides.
There are three most distinct types of back/rear pillar or caterpillar die sets.
1. Regular: This type is employed with average proportions.
2. Long: This type is used for dies, which are long and narrow.
3. Reverse: This type is used for dies, which are relatively longer in measurement from front to
back than their measurement from side to side.
DIAGONALPILLAR DIE SET:

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The pillars are fixed at the diagonal corners of the plates, these die sets are used where
much more force & heavy force are applied in the tools especially for multi stage tools, heavy
force required tools & progressive components manufacturing tools. The of movement strip is
generally left to right in this type of DIE SETS.
FOUR PILLAR DIE SET:
The pillars are fixed at the all four corners of the plates, these die sets are used where
heavy force are applied in the tools especially for multi stage progressive tools, heavy force
required draw tools & progressive components with different operations. The of movement
strip is generally left to right or front to back in this type of DIE SETS.

144
Shut Height-The distance between top surface of the top plate to the bottom surface of the
bottom plate at the closed condition is called as Shut Height
Day Light-The distance between bottom surface of the top plate to the top surface of
the bottom plate at the closed condition is called as Day Light.

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DISET SET-FOOL PROOFING:
The Die set are provided with different diameter pillars, dimension A and B Thus, the top
plate cannot be reversed on the bottom plate for the purpose of fool proofing.

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UNIT 16: PROGRESSIVE TOOL
PROGRESSIVE TOOL:
In a progressive tool strip is moved in stages from station to station. Different operations are
performed on it at each station except idle stage. A complete strip is removed at the final stage.
Progressive tool may be considered as series of tools placed side by side with the strip passing through
each successively. Before designing the tool, the piece part may be studied carefully. This is to plan
the operation to be carried out in different stations. For this process strip lay out is made.
The strip lay out carries the following information.
1. Feed direction.
2. Pitch maintained.
3. Position of stopper.
4. Width of the strip.
5. Scrap bridge/Side scrap
6. Different operations.
7. Pilot position & type of pilots
8. Total no of stages.
The method employed in laying out the strip influences the economic success. The strip lay
out is such that maximum area of strip is utilized for the production of the stamping.
The tool shown in figure the finish part is produced through three stations. The strip is stopped
at the first station by the auxiliary stopper, and 2 holes are pierced.
In second station the pilot enters into the holes. In third station the piece part is blanked and
pierced component is obtained.

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DIFFERENT TYPES OF PROGRESSIVE TOOL
1. Progressive Blanking Tool

2. Progressive Cut off Part off Tool
3. Progressive Draw/Form Tool and trimming
4. Progressive Cut & Carry Tool

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Progressive Blanking Tool This is a metalworking method that can encompass

punching, coining, bending and several other ways of modifying Sheet metal raw material,
combined with an automatic feeding system to transform in to required components in large
scale final stage accompanied by blanking operation.
Progressive Cut off Part off Tool The feeding system pushes a strip of metal (as it unrolls
from a coil) through all of the stations of a progressive die. Each station performs one or more
operations until a finished part is made. The final station is a cutoff operation, which separates
the finished part from the carrying web. The carrying web, along with metal that is punched
away in previous operations, is treated as scrap metal. Both are cut away, knocked down (or
out of the dies) and then ejected from the die set, and in mass production are often transferred
to scrap bins via underground scrap material conveyor belts.
The progressive die is placed into a reciprocating stamping press. As the press moves up,
the top die moves with it, which allows the material to feed. When the press moves down,
the die closes and performs the stamping operation. With each stroke of the press, a
completed part is removed from the die by part off operation.
Since additional work is done in each "station" of the die, it is important that the strip be
advanced very precisely so that it aligns within a few hundredth of an as it moves from station
to station. Bullet shaped or conical "pilots" enter previously pierced round holes in the strip
to assure this alignment since the feeding mechanism usually cannot provide the necessary
precision in feed length.
Progressive Draw/Form Tool and trimming Progressive Tools can also be produce
components of drawn or form shapes, these tools transfer from flat sheet metal in to different
forms. The components in final stage are trimmed to get the finished component.
Progressive Cut & Carry Tool The components produced from these Progressive Tools are
remains as an integral part of the strip even after the final stage, hence these tools are called
as Progressive Cut & Carry Tool. The components are removed by manually or by external
method of removing agents.

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PROGRESSIVE DIE DESIGN:

Selection of progressive die:
Following factors are considered for the selection of progressive die.
1. Stock material thickness overall size of the die.

2. Number of station.
3. Total press tonnage.
4. Quick change die and flexible manufacturing requirement exits.
5. Press level and condition. Problems with worn bearings that can damage precision
tooling
These are tools that transfer the components from one station to the next with the use of
mechanical "fingers". For mass production of stamped parts which do require complicated
in-press operations, it is always advisable to use a progressive press. One of the advantages
of this type of press is the production cycle time. Depending upon the part, productions can
easily run well over 800 parts/minute. One of the disadvantages of this type of press is that
it is not suitable for high precision deep drawing which is when the depth of the stamping
exceeds the diameter of the part. When necessary, this process is performed upon a transfer
press, which run at slower speeds, and rely on the mechanical fingers to hold the component
in place during the entire forming cycle. In the case of the progressive press, only part of the
forming cycle can be guided by spring- loaded sleeves or similar, which result in concentricity
and ovality issues and non-uniform material thickness. Other disadvantages of progressive
presses compared to transfer presses are: increased raw material input required to transfer
parts, tools are much more expensive because they are made in blocks with very little
independent regulation per station; impossibility to perform processes in the press that
require the part leave the strip (example beading, necking, flange curling, thread rolling,
rotary stamping etc.).
The dies are usually made of tool steel to withstand the high shock loading involved, retain
the necessary sharp cutting edge, and resist the abrasive forces involved.
The cost is determined by the number of features, which determine what tooling will need to

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be used. It is advised to keep the features as simple as possible to keep the cost of tooling
to a minimum. Features that are close together produce a problem because it may not
provide enough clearance for the punch, which could result in another station. It can also be
problematic to have narrow cuts and protrusions.
An excellent example of the product of a progressive die is the lid of a beverage can.
The pull tab is made in one progressive stamping process and the lid & assembly is made in
another, the pull tab simultaneously feeding at a right angle into the lid & assembly process.
Also various car brake calipers have plates that are bent into shape, possibly cut too using
these methods.
STRIP LAYOUT CONSIDARATION FOR PROGRESIVE TOOLS:
The following guidelines are used for designing the progressive tools.
 The solid margin around the die is 1.2 times the sheet thickness.
 Margin between 2 blanks, strip edges should be adequate.
 The shank should be loaded at the center of the press.
 Scrap disposal should be provided.
 For precision pilots must be provided.
 The tonnage, table area, ram face area must bead
equate.
PILOTS:
 The blanking punch is fitted with pilot for
accurate centralization of the piercing hole.
 Pilots can be spring loaded with a grub
screw for adjusting the spring
compression.
Generally, the trigger stopper of blanking tool with pilots is
adjusted in such a way that the strip is fed about 0.1mm more
than the pitch. This allows the strip to move freely towards left
as the pilot centralizes the pierced holes.

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FOUR STAGE TOOL FOR WASHER:
In this tool the strip fed is stopped by auxiliary stopper in first stage. In second stage a hole is
pierced. IN next stage piloting is done, and in fourth stage the punch blank the strip & piece part is
obtained. In this tool the punches should be spaced widely to provide healthy margin.

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If the work piece has got no holes’ additional pilot holes can be provided to utilize the strip area.
The additional holes are also provided in the case where the accuracy requirements are high, or
the holes are very smaller in diameter.
In such cases the pilots are provided on the scrap bridge or where the adequate space is
available accept blanking area.

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PITCH PUNCH:
They are installed in the first position of the tool. this eliminates extra stops and simplifies both
construction and operation of the tool. Usually the pitch punch is located along the front edge of stock
strip, because of the fact that the strip is usually meant to gauge of the tool
A PITCH PUNCH is a punch, which trims the side of the stock material, providing a shoulder.
This shoulder is stopped against a hardened insert provided in the spacer. In small tools the spacer may
be fully hardened to avoid the insert. The width of the pitch punch is equal to the pitch. The allowance
for side cutting depends upon the type and thickness of the stock material.
The size of the pitch punch will be more than the pitch by 0.05-0.1 for the purpose of registry
the strip with the pilot known as OVER FEED ALLOWANCE (OFA). But in case of tools without
pilot, the pitch punch is made equal to the pitch. The stop position and registry position will be the
same.
Due to the unbalanced cutting force acting on the side of the punch, the pitch punch is provided with
heels. The undercut provided on the pitch punch eliminates the difficulties of feeding due to thorn
formation. Thorns are small projection, which occurs at the side of the strips due to the punch wear
out. In side cutting there is a tendency of the slugs being coming up with the punch, causing difficulties
in further punching. Slug pushers are used to avoid this. A standard pitch punch shape is shown below

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THE ADVANTAGES OF PITCH PUNCH:

1. It is a safer method than stop pin
2. Avoids the danger of the deformation of margins of thinner strips by the stop pins, when
pressed against it.
3. Preferred for small punching where it could be difficult to employ other types of stops.
4. It is economical and avoids complications in tools where numbers of stages are more.
5. Pilots can be avoided for punching components with moderate accuracy.
6. The movement of strip will be accurate.

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UNIT 17: COMPOUND TOOL

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Construction of Compound Tool:

In this type of tool, the arrangement of die and punch is reversed and the punch is mounted on
the die shoe with the knockout pins and the combined pressure pad and the stripper. This type of die
is known as inverted die.
The inverted die has the advantages that the cutting edges are kept clear of chips by the operation
of the stripper and ejector.
A common characteristic of compound dies is the inverted construction. The blanking die is on
the upper die shoe and blanking die on the lower half. The pierced slugs pass through holes in the
lower blanking punch (die shoe) & bottom plate. The spring loaded stripper mounted on the bottom
plate guides the strip with the help of guide pins. It also removes the strip form the bottom blanking
punch the component has to be collected manually or by air blowing. The blanking die mounted on
the top plate houses an ejector (shedder) which ejects the component from the die block after
blanking. The ejector guides the piercing punch also which again held on to the top plate. The ejector
is closely guided in the inverted die and is actuated either by springs or knock out rod.
CONSTRUCTION OF COMPOUND TOOL: Open & closed condition

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EJECTORS AND SHEDDERS:

In conventional drop through type blanking tools, the punch forces the blanking to the die. The blank will be
retaining within the die cavity till the subsequent blanks push it pass the land. Then it falls down through the
opening in the die shoe and subsequently through the opening in the press bed.
Shedders and ejectors are used when it is not possible to remove the blanks in the conventional method
due to the following reasons.
1. Size of the blank does not allow it to conveniently pass through the opening in the press bed.
2. Counter of the blank is such that it tends to stick and get distorted during its travel through the die
cavity.
3. Opening in the press bed fitted with die cushion, which will interfere with the piece part disposal.
4. Close tolerance specified for the flatness of the blank.
5. Tools of Inverted nature.
EJECTORS:
 In the conventional position, die is the lower member of the tool.
 If the expulsion of the blank is achieved by forcing it upwards, the action is known as “ejection”. The
element of the tool, which ejects the blank, is called as “ejector”.

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 Ejectors may be actuated by compression springs, rubber, pneumatic devices or hydraulic devices.
 Ejectors if used with spring stripper always return the blank into the spring due to the simultaneous
stripping and ejecting action.
 In some progressive tools, the blanking station is provided with an ejector to return the blank into the
strip to be carried forward to the next station for further operations, known as the cut and carry method.
SHEDDERS:
Another way to accomplish the expulsion of the blank from the die cavity is by making use of the knock out
mechanism on the press. For this purpose, the tool should be of the inverted design.
In inverted tools, Die becomes the upper member of the tool, being clamped to the press ram. The expulsion
of the blank is achieved by forcing them downwards. This action is generally known as “shedding” and the
element of the tool, which sheds the blanks, is known as the “shedder”.
COMPRESSION SHEDDERS:
 Shedders hacked up by compression springs; hard rubbers or disc springs called compression shedders.
Such shedders always tend to return the blank in to the strip if employed with compression type traveling
stripper.
 Compression shedders 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 knock out system.
SHEDDER PINS:
 The stock material is usually coated with rust preventive solution.
 It is obvious that any liquid or oil deposit left on the stock material will cause the blank to stick to the
face of the shedder.
 Spring loaded shedding pins are employed to overcome this problem. Even absolutely clean and dry
stock material tends to adhere to the shedders, due to the atmosphere pressure.
Therefore, regardless of the conditions of the stock, the illustration of shedding has to be considered to be
absolutely necessary.
Shedding pins will be more effective if applied to one side of shedder face rather than in the center.

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KNOCKOUTS:
Positive knockouts are classified in to two groups
 Direct knockouts
 Indirect knockouts
DIRECT KNOCKOUT:
In a knock out system if the knock out rod is directly in contact with the shedder the system is known as
direct knock out system.

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Shedders and Knockouts:
Positive Shedders:
Positives shedder is shedder, which is not actuated by springs or other compression media. Fig
below illustrates the basic positive shedder actuated by means of a knockout rod. This type of
assembly is used for inverted type dies. The flanges are an integral part of the shedder; act as
keepers, retaining the shedders within the die cavity this type of knock out is called as direct knock
out system.

144
In this fig the transfer pins are assembled by pinning them in the pin plate.
In view A the pin plate and knockout rod are also fitted together and secured by pining. This method
is for light duty, where the knockout forces are evenly distributed and balanced in relation to the
shedder counter. The knockout assembly shown in view B is stringer, since knockout rod is welded to
pin plate.
In this fig the knockout rod is pined to the assembly to the shedder. A collar ring is assembled to
the knockout rod by means of a cross pin. The collar acts as a stopper limiting the protrusion distance
of the shedder.

144

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BURR SIDE RELATION IN COMPOUND TOOLS
Components produced by these dies have only one burr side, the burr side of openings pierced
within the component will agree with the burr side of the blanked outer contour of the component.
This characteristic burr side effect can be major consideration which influences to the decision to
build new compound tool in order to produce a given component.
The factors which apply to burr side location are-
 The burr side of a blank or of a slug is always towards its respective punch.
 The burr side of a pierced opening is always towards its respective die opening.
Therefore, the burr side on the outer periphery of the blank will be towards the blanking punch.
Since the pierce-die opening is contained in the blanking punch, the burr side of the pierced opening
in the blank will also be towards the blanking punch.
The burr side effect as related to compound tools is shown in the below fig.

144
PRESS TOOL QUESTIONIERS

1. What is a tool?
Anything which is necessary to make a product is called tools.
2. What are the classification of tools?
Press tools, Molds, Jigs and fixtures, Cutting and assembly tools, gauges and measuring
instruments.
3. What is a press tool?
Press tool is a custom built tool in which we make sheet components that not readily available in
the market.
4. What do you mean by stampings?
The sheet metal which makes with the help of press tool is called stampings.
5. Name the different types of rolling?
Hot rolling, cold rolling.
6. What is Stock materials?
Sheet metal from which stampings made is called stock material.
7. What are the press tool operations? Cutting, non-cutting and combination of both.
8. What is strip?
Each piece of sheet metal called strip.
9. What do you mean Blanking?
In this operation, cut out material will be the component remaining is scrap.
10. What is piercing?
Process of making opening on sheet metal is called piercing. The cut out material will be waste.
11. What is called cutting off?
Material is going to cut in a single line, there won’t be any waste.
12. What is parting off?
Double line cutting material in between the line will be waste.
13. Describe about a side cam tool?
14. Transforms vertical motion of the press ram into horizontal motion of the tool. It is used for side
piercing.

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14. What is perforating? Making no. of holes at a time.

15. What is dinking?
Press tool cutting operation for soft materials like paper, leather, wood etc.
16. What is trimming?
Removing large amount of material from the edge of the piece part.
17. What do you understand shaving?
Removing small amount of material from the previously blanked part.
18. What is broaching?
Series of teeth profile removes metal from blanked part.
19. Describe bending?
Bending can be explained as shaping of material around straight line axis. Result is a new plane which
is at an angle to the mother plane.
20. What is lancing?
Combination of cutting and bending.
21. What is forming?
Press tool non cutting operations in which material is formed into different shapes.
22. What do you mean drawing?
Process of making cup or vessel is called drawing.
23. What is curling?
Rolling the edge of sheet metals.
24.Define bulging?
Internal forming operation to expand portions. 25.Name the common medias of bulging? rubber,
urethane, oil etc.
26. What is swaging?
Opposite of bilge. External forming operation also called as necking.
27. What is extrusion?
Operation to produce collapsible tubes, shell etc.
28. Define coining?
Making depression and corresponding projection won’t be there.
29. What is an assembly tool?

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Assembling of two or more parts by riveting, press fitting etc.

30. Describe flaring, lugging, collar drawing?
Making collar so that no. of threads can be provided.
31. What is Planishing ?
Flattening of material is called Planishing.
32. What is progressive tool?
Multi stage tool in which perform work at number of stations.
33. What is compound tool?
All cutting features of the component perform at one stroke of the ram.
34. What do you mean by combination tool?
Small press operated in large one. Blank and form very small parts.
35. What is notching?
Small amount of material cuts from the edge of the component.
36. What do you understand by sub press tool?
Small press operated in large one, blank and form very small parts.
37. What is lowering?
Combination of cutting and forming.
38. What is shearing?
Method of cutting sheets without forming chips.
39. What are the stages of shearing? Plastic
deformation, penetration, fracture.
40. Result of plastic penetration stages is? Cut band
41. Result of plastic deformation stage is? Edge radius or roll over.
42. Result of fracture stages is? Break edge.
43. Name the types of shear load? Internal and external loads.
44. What are the types of external shear load?
Compressive load and tensile load.
45. Define tensile load?
Force acting on opposite direction in same axis.
46. What is shear load?

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Load which is acting on same direction but not in same axis.

47. What is compressive load?
Forces acting on same direction in same axis.
48. Name the types of force based on speed? Impact force (quick force)
magnetic force
49. Describe about stress?
Load acting on a material per unit area.
50. Formula of stress? load /area
51. What is cutting force?
The force which acts on sheet metal to cut the blank.
52. Formula of cutting force? Fc
= LSTmax
L: Length of periphery to cut in mm.
S: sheet thickness in mm
TMax: shear strength in n/mm^2
53. Shear strength is …. % of tensile strength. 80%
54. Equation to calculate press force? Press force = cutting force + stripping force
55. Normal stripping force is? 10 to 20 % of cutting force.
56. What are the methods to reduce cutting force? Using stepped punch.
Grind the face of the punch or die to a small sheared angle
57. For blanking shear angle will be on? Die.
58. For piercing shear angle will be on? Punch
59. Briefly explain the capacity of the press?
Maximum amount of force can be given on the press. It is determined by KN or TONS.
60. What is the shear strength? Ability of material to resist shear stress.
61. 1 TON =……. Kgf 1kgf.
62. What is reason of drill breakage? Due to torsion and compression
63. U channel and angle iron made by …... process Extrusion
64. 1N =... kgf
9.8 kgf

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65. What do you meant by cutting clearance ?

Gap between the side of the punch and corresponding side of the die in single side.
66. Cutting clearance is expressed as ...? Mm /side
67. Result of optimum cutting clearance will be ... ?
Maximum cut band.
68. Result of excessive cutting clearance will be ... ?
Maximum edge radius.
69. Result of insufficient cutting clearance will be .. ?
Maximum break edge.
70. Punch determines. .. ?
Piercing size
71. Die determines ... ?
Blanking
72. Calculation of cutting clearance?
Sheet metal up to 3mm = C*S* root of (TMAX/10)
Sheet metal more than 3 mm=(1.5*s) *(s-0.015) * root of (TM ax /10)
73. What is called land?
To avoid jamming of material inside the die, we give straight portion of certain amount from the
cutting edge. That is called land.
74. For sheet metal S up to 3 mm = land will be ..... ?
3mm
75. For sheet metal more than 3 mm = land will be .. ?
Sheet thickness.
76. Usually, angular clearance is provided in .... Degree?
1.5 degree /side.
77. Generally, soft material requires . Angular clearance?
more.
78. What are the types of guide plate tool?
Open guide plate tool

Stripper guide plate tool

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79. Name the basic elements of tool? Punch and Die.

80. Punch and die materials?
Good quality alloy steel (HCHCr ,D2).
81. Hardness of punch? 58-60 HRC.
82. Hardness of die? 60-62 HRC.
83. Stripper plate material? MS or medium carbon steel
84. Thrust plate material? OHNS.\
85. Hardness of thrust plate? 45-48 HRC
86. Top plate and bottom plate material ?
MS or Cast iron.
87. Screws are to ……… the parts ?
hold
88. Dowels are to .............. the parts?
align
89. Name the types of cold rolled stock materials used?
Hard, Three quarter hard, Half hard, Quarter hard, Soft, Dead soft.
90. What is the specialty of hard sheet metal?
Cannot bend.
91. What is the specialty of 3 quarter hard material?
Can bend 60 degrees across the grain.
92. Specialty of half hard material? Can
bend 90 degrees across the grain.
93. Quarter hard material?
Can bend 180 degrees across and 90 degrees along the grain direction.
94. Soft material?
Can bend 180 degrees across and along.
95. Dead soft material?
Can be formed into different shapes.
96. What is strip lay out?
A layout which gives sequence of works and operations.

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97. What are the factors effecting a strip layout?

Shape of the blank, production requirement, grain direction, burr side, stock material.
98. Formula of economic factor?
(area of the blank*no. of rows) / (pitch*scrap width)
99. What is pitch?
Distance between two consecutive operations.
100. What is scrap bridge?
Portion of the material remaining between two adjacent openings.
101. Scrap bridge nearer to the operator called .... scrap?
Front scrap
102. Scrap bridge away from the operator called .... scrap?
Back scrap
103. What are the types of strip layout?
Single row layout, double row, gang dies and angular.
104. Name the types of single raw layout? Narrow run, wide run
105. List about the types of punches?
Cutting punch, non-cutting punch and hybrid punch.
106. What are the groups of punches? Segregated punches and integrated punches.
107. What is segregated punch? Self-mounted by screwing etc.
108. What are the integrated punches? Mounting with the help of punch plate etc.
109. For beveled head punch bevel angle is ... ?
30 to 45 degree
110. What is perforator?
Punch of diameter 2mm and below.
111. What is bucking force?
Maximum force a punch can withstand without bucking.
112. Formula for buckling force? Fb = (ii2EI)/LP2
113. Modulus of elasticity of Steel?
200 to 220 GN/M2
114. Unit of moment of Inertia?

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Mm4
115. The ultimate condition of buckling force is ......... ?
Buckling force =cutting force require for the operation =shear force on the punch
116. Material of solid die?
Non shrinking tool steel.
117. Die bushes are inserted in …...?
mid steel retainer plate.
118. Dies having more than one section called .... ?
Split dies
119. Material of carbide dies?
Tungsten carbide
120. What is the function of stopper?
Arrest the movement of the strip for one pitch length after each stroke.
121. Fundamental principles of stopper?
Stop position and registry position.
122. What is stop position?
Actual position of the stopper.
123. Describe registry position?
Exact position where strip has to be established.
124. Types of strippers?
Fixed and travelling
125. Function of stripper?
Strip the stock material off the punches after each stroke.
126. Tunnel width formula?
X=w+f
w = stock strip width at maximum tolerance
f = desired horizontal feeding clearance

127. Hook pins are made from ............. ?
Cold drawn steel rod
128. Gauge thickness for the material up to 1.5 mm is ..... ?

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3mm
129. Gauge thickness for the material more than 1.5 mm is .... ?
Sheet thickness +1.5 mm
130. Prevention of wrong loading can be done by. .. ?
Fool proofing
1. Press tool is used for producing sheet metal components.

2. Press tools are mainly manufacture for high rate of component production.
3. Press tool operations are of 3 types.
4. Classifications of press tool operations are cutting , non-cutting , hybrid.
5. Blanking is a type of cutting operation.
6. Blanking is producing a flat piece part from sheet metal. 7.Blanking these process entire is cut
external profile of the shape.
8. Blanking cut piece is called as blank.
9. Blanking piece part of ready for assembly then it is called component.
10. Blanking piece part that is removed from strip is always the work piece and remaining strip is
called skeleton.
11. Internal profile of the component is shape that to be cut is called piercing.
12. Piercing operation material cut from the sheet is scrap. It is called slug.
13. cut off is separating the piece part from the parent material.
14. In cut off the material is cut in a straight line no scrap is produced in operation.
15. Part off cutting operation is another name of parting.
16. Part off operation the removed material by the punch is called scrap.
17. Cut off and part off usually occurs in the final stage of progressive tool.
18. Notching operation removes are all small amount of materials from either or both edges of
the strip or blank.
19. Shaving is a secondary and finishing operation.
20. Shaving is a small amount of material is removed around the edge of the component.
21. The excess metal is removed as small as chip.
22. Shaving is formed similar to material cutting tool.
23. Shaving allowance of approximately 0.2 to 0.3mm of material.
24. Trimming is a secondary operation.
25. Trimming is used to remove the excess metal.
26. Trimming operation provides a smooth edge and the outer contour will be neat.

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27. Broaching operation Are similar to shaving operation.

28. One after the other by the same tool called broach.
29. Side cam converts the up and down motion of press ram.
30. Side cam required in the nature of the work.
31. Dinking operation is performed on non- metal sheets.
32. Bending operation is one of the Non-cutting Operation.
33. Bending is shaping the material around the straight axis.
34. Forming is similar to bending operation.
35. Drawing is parent material subject to several plastic deformations.
36. Drawing dies transform flat are metal in to Cups, shells.
37. Horn dies are provided with an arbor or over.
38. Curling dies curved the edges of drawn shells.
39. Swaging’s another name is necking.
40. Coining is process of performing cold metal in a tool.
41. Planishing are planning operation.
42. Coining is also called as cold forming.
43. Lancing is the hybrid operation.
44. Lancing is combined operation of cutting and non-cutting like
cutting and bending along a line in the work material.
45. No metal is cut free during a lancing operation.
46. Lancing punch is deserved to cut on two or three sides and bend along
fourth axis.
47. Lancing is very important press operation.
48. Lancing operation two or three sides shearing and one side bending
or forming.
49. Lancing is widely used to lock the part of the other for proper
assembly.
50. Lowering is a hybrid operation.
51. Lowering is a passage with flat sloping profile with one sides
opening.
52. Lou ring allows light and air to enter.
53. Lou ring keeps rain water out is a difficult operation.
54. In Lou ring operation only one side will be cut.

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55. Bending extends completely across the material.

56. One or more bends may be involved in bending dies.
57. Bending is large and important class of press tool.
58. Bending sheet material flows in the tool is always Uniform. Its
thickness remains and changed.
59. Forming is a non-cutting operation.
60. In forming operation line bending is a long curved axis instead of a
straight line.
61. In forming the metal flow is not uniform.
62. Forming dies applied more complex forms to the work piece.
63. Drawing is a non-cutting operation.
64. Drawing is ferrite Material is objected sever deformation.
65. Horning is a non-cutting operation.
66. Horning dies are provided with arbor.
67. Horning hard dies may also be used for piercing holes inside of
shells.
68. Curling is a non-cutting operation.
69. Curling dies have curled edges of drawn shells.
70. coil over the wire ring for increased.
71. Bulging is a non-cutting operation.
72. Bulging dies expands the bottom of the previously drawn shells.
73. The bulged bottoms of the same type of coffee parts are formed in
bulging dies.
74. Swaging is a non-cutting operation.
75. In swaging operation, the drawn shells or tubes are reduced in their
diameters.
76. Swaging is also called as necking operation.
77. Extruding is a non-cutting operation.
78. Extruding is a special process to manufacture collapsible tubes
shells.
79. The blank is also called as billet.
80. The amount of clearance between punch and die determines the wall

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thickness.
81. Flanging is a non-cutting operation.
82. Flanging is a process of forming upward protrusive in a piece called
flanking.
83. Flanging will be done stage tool as progressive tool.
84. Flanging are pre-piercing or direct flanging with hybrid punches.
85. Dimpling is a non-cutting operation.
88. Dimpling is forming dies which produce conical flange.
89. Coining is a non-cutting operation.
90. Coining is a process of performing cold metal in a tool.
91. Ironing is a non-cutting operation.
92. Ironing is an operation in which the wall thickness of the drawn shells or
bend component.
93. Embossing is a non- cutting operation.
94. There are two types of planning.
95. Stamping is a non-cutting operation.
96. Stamping is an operation that it produces the profile on the sheet metal
are component.
97. Stamping maybe projected or depressed on the components.
98. Example for stamping is number plates of vehicles.
1. Base Plate is also called as die shoe or bolster plate.

2. Bottom plate is made of mild steel.
3. Die plate is a Female part of press tool.
4. Die plate are made of HcHcr material for non-cutting operation.
5. Die plate are hardened and tempered to 60-62HRC.
6. Die plate for non- cutting operations are made from OHNS
material and hardened up to 55-58HRC.
7. Die plate provides external shape to the component.
8. In cutting press tool the thickness always depends on shear force
required for operation.
9. Die plate is the cube root of the total shear force.

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10. Punch is a male member of press tool.

11. Punches are made of HcHcr material for cutting operation.
13. Punches are made of OHNS material for non- cutting operations.
Punches Provides internal shape of the component in non- cutting
operation.
14. Stripper plate is made of MS material.
15. Stripper plates are usually kept in soft condition.
16. Stripper also guides the strip.
17. Punch holder plate is made of MS material.
18. The punch is usually inserted with a light key fit H7/K6.
19. Punch back plate is made of case hardened steel.
20. Punch back plate is also called as punch retainer plate.
21. Top plate is a soft plate made of MS material.
22. The top plate is clamped to top unit of the press tool.
23. Guide plates are thin plates mounted on the die plate for guiding
strip.
24. Guide plates are normally made of MS material.
25. Guide plate for medium production press tool is made of
OHNS material.
26. Stage stoppers will have sliding in slot made in these guide
plate.
27. Guide pillars are also known as Guide pins.
28. Guide pillars provide `o’means of alignment to the die set.
29. Guide pillars are made of 17Mn1Cr95 material.
30. Pillars and bushes have H7/h6 fit.
31. Bushes and top plate have H7/j5 fit.
32. Pillars and bottom plate have h7/p6 fit.
33. Guide bush are generally fixed in top plate.

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34. Guide bush are made of 17Mn1Cr95 material.

35. Shank is made of MS material.
36. Pilots are generally cylindrical parts.
37. Pilots are made of OHNS material.
39. Direct pilots are mounted on the cutting face of the punch.
Indirect pilots are placed outside the boundary of the component.
40. Stoppers are made of OHNS material.
41. Stoppers are used to stop the strip.
42. Dowels are case hardened cylindrical ground standard pins.
43. Taper dowel pins are normally used in machine tool.
44. Screws are used to hold the tool parts.
45. The result of the force is imposed on the stock material.
46. Shearing action occurs in three stages.
47. The stock material is placed on the die.
48. The punch is driven towards the die.
49. The punch contacts the stock material and exerts the pressure on
it.
50. The elastic limit of the stock material exceeded is known as
plastic deformation.
51. The radius is formed on the top edge of the hole and the
bottom.
52. The radius is often referred as roll over.
53. Magnitude depends upon the ductility of the stock material.
54. The driving force of the punch is continuous.
55. Penetration is the actual cutting portion.
56. The punch causing a corresponding bright bond or
burnished area.
57. The cut edges meets exactly at breaking lines.

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58. The punch enters the die opening.

59. The edge radius appears more than using soft material.
60. The remaining cut portion is the fracture area or break.
61. Burr is the projection which appears during fracture.
62. Cutting clearance is the intentional gap provided between the
punch and die.
63. The optimum clearance must often be determined.
64. The amount of cutting clearance to decrease.
65. The burr side of a blank or slug.
66. Cutting clearance given is sufficient then burnished area or cut.
67. Sheet thickness and the piece part separating from the stock
material.
68. The cut band or the burnished area will be less than 1/3.
69. The material thickness and tensile burr will be more if the cutting
clearance.
70. This is the actual shift between the punch and die.
71. The actual shift between punch and die results in insufficient
cutting clearance.
REFERANCE BOOKS:
 Tool and die maker by Mahajan

 Design fundamentals by Pacquin
 Tool design by Donaldson
 Basic die design by Osterguard
 Advanced die design by Osterguard
 Fundamentals of Tool Design by SME
 Press Tools and Press Work by Waller

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PRESS TOOL THEORY –I

GOVT. TOOL ROOM AND TRAINING CENTRE

GOVT. TOOL ROOM AND TRAINING CENTRE Page 1 of 144

SL.NO TITLE PAGE NO

1 INTRODUCTION TO PRESS TOOL 6 - 10

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PRESS TOOL THEORY – I

SPECIFIC INSTRUCTIONAL OBJECTIVES:

2. TYPES OF PRESS TOOLS.

3. ELEMENTS OF A PRESS TOOL.

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- Economic strip layout

8. & 9PUNCH AND DIE.

- Elements of a die set

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16. PROGRESSIVE DIES.

17. COMPOUND DIES.

QUESTION BANK 143-153

1. Tool and die maker by Mahajan

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BRIEF HISTORY OF PRESS TOOLS

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Unit 1: INTRODUCTION TO PRESS TOOLS

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DIFFERENT TYPES OF TOOLS

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UNIT 1: PRESS TOOL OPERATIONS

PRESS TOOL OPERATIONS:

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Blanking is a process of producing flat

It is the operation of making hole in the stamping. Here also

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A -- COMPONENT BEFORE TRIMMING

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B -- COMPONENT AFTER TRIMMING

If more number of holes are pierced, it is called

It is a combination of bending and cutting

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To cut paper, leather, cloth, rubber and other

It is similar to shaving operation; in this a tool

A-COMPONENT BEFORE EXTRUSION B- COMPONENT AFTER EXTRUSION

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UNIT 3: ELEMENTS OF PRESS TOOL

ELEMENTS OF PRESS TOOL

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ELEMENTS OF PRESS TOOL

ASSEMBLY OF A PROGRESSIVE PRESS TOOL

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MATERIALS USED IN PRESS TOOLS

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