Industrial Engineering Journal

ISSN: 0970-2555
Volume : 53, Issue 2, No. 1, February : 2024
DESIGN AND ANALYSIS OF PRESS TOOL AND BRACKET BY USING SOLID WORKS
AND ANSYS

B.Thirumaleswar, CH.bhanu shiva shankar, G.Vamsi, UG-Students Department of Mechanical

Engineering, NRI Institute of Technology,Vijayawada-521212A.P, India.
Mrs.M.Blessy Raisa,Dr.E.Siva Krishna, Assistant Professor Department of Mechanical
Engineering, NRI Institute of Technology,Vijayawada-521212, A.P, India.

Abstract:
The design and analysis of press tools is a fundamental aspect of modern manufacturing. This
process involves the creation of specialized tools used in shaping and forming sheet metal or other
materials to produce precise components. The success of any manufacturing operation often hinges
on the efficiency and precision of these press tools. This abstract provides an overview of the key
steps involved in the design and analysis of press tools. It encompasses aspects such as defining
requirements, material selection, die design, tool steel selection, simulation, optimization,
manufacturing, assembly, testing, maintenance, temperature distribution, safety considerations, and
documentation. The combination of advanced design techniques and simulation technologies plays a
pivotal role in the development of press tools that are not only cost-effective but also capable of
delivering high-quality components with tight tolerances.
Keywords: Compound die,material selection,Die design,Modeling,analysis of punch

INTRODUCTION:
Press working is part of sheet metal forming in which mainly sheet metal cutting operations and
forming operations are carried out using die & punch assembly to produce sheet metal part on metal
working press equipment & support equipments. A punch is the portion of the tool attached to the
ram of the press and is inserted into the die. A die is usually the stationary portion of the tool
attached to the press bed. It has a cavity to accept the punch. The forming operations were covered in
Manufacturing Processes II, while sheet metal cutting and related forming operations will be dealt in
this subject. The sheet metal working process in general is known as cold stamping as the sheet
during working on it is always in cold state as press working operations are carried out at room
temperature. Design and thermal analysis of press tools is crucial in the manufacturing industry to
ensure efficient production processes and high-quality output. By leveraging software tools like
SolidWorks for designing and ANSYS for thermal analysis, engineers can create robust press tools
that are optimized for performance and durability. It encompasses aspects such as defining
requirements, material selection, die design, tool steel selection, simulation, optimization,
manufacturing, assembly, testing, maintenance, temperature distribution, safety considerations, and
documentation.

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ISSN: 0970-2555
Volume : 53, Issue 2, No. 1, February : 2024
PRESS WORKING TERMINOLOGY:

Fig-1:Press working Terminology.

• Bed: The bed is the lower part of the press frame that serves as a table to which a Bolster
plate is mounted.
• Bolster Plate: This is a thick plate secured to the press bed , which is used for locating and
supporting the die assembly. It is usually 5 to 12.5 cm thick.
• Die Set: It is unit assembly which incorporates a lower and upper shoe, two or more guide
parts and guide part bush.
• Die Block: It is a block or a plate which contains a die cavity.
• Lower Shoe: The lower shoe of the a die set is generally mounted on the bolster plate of a
press. The die block is mounted on the lower shoe, also the guide post are mounted on it.
• Punch : This is male component of a die assembly, which is directly or indirectly moved by
and fastened to the press ram or slide.
• Upper Shoe: This is the upper part of the die set which contains guide post bushings.
• Punch Plate : The punch plate or punch retainer fits closely over the body of the punch and
holds it in proper relative position.as shown in fig-1

PRESS OPERATIONS:
The operations done on the sheet metal can be classified into two types, cutting operations and
forming operations. In cutting operations the work piece is stressed beyond its ultimate strength. The
stress caused in the metal by the applied forces will be shearing stresses. In forming operations, the
stresses are bellow the ultimate strength of the metal. In this operation there is no cutting of the metal
but only the contour of the work piece is changed to get the desired product. The cutting operations
include: blanking, notching, piercing, perforating, trimming, shaving, slitting, lancing etc. The
forming operations include: bending, drawing, redrawing, squeezing etc.
various press operations:
Blanking:Blanking is the operation of cutting a flat shape from sheet metal. The article punched out
is called the blank and is required product of the operation. The hole and metal left behind is
discarded as waste.
Piercing: It is the cutting operation by which various shaped holes are made in sheet metal. piercing
is similar to the blanking except that in piercing hole produced is the desired product, the material
punched out from the hole being waste.
Lancing:This is a combined bending and cutting operation along a line in the work material. No
metal is cut free during a lancing operation.

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Embossing: It is a process of forming a design or letters on one side of metal piece and the
impressions are visible on both sides.
Notching: This operation removes metal from either or both edges of the strip. Notching serves to
shape the outer contours of the workspace in a progressive die or to remove excess metal before a
drawing or forming operation in a progressive die.
Bending: In this operation, the material in the form of flat sheet or strip is uniformly strained around
a linear axis which lies in the neutral plane and perpendicular to the lengthwise direction.
Shaving: Shaving is a secondary operation, usually following punching, in which the surface of the
previously cut edge is finished smoothly to accurate dimensions. The excess metal is removed much
as a chip is formed with a metal-cutting tool.

PRESS MACHINE:
A Press tool is a particular type of tool that is attached to a press brake and is used to produce
a high volume of components. These types of tools are predominantly used in mechanical, pneumatic
and hydraulic presses to achieve their goals.
Fly press: A Fly Press is a machine tool used to shape sheet metal by deforming it or cutting it with
punches and dies. The punch is usually the top (male) tool and the die (female) bottom tool.
Open back inclinable press: A stamping press that has an opening at the back between the two side
members of the frame and is arranged to be inclinable to facilitate part feeding and removal by
gravity. Can be abbreviated OBI press.
Straight side single crank press:A straight side press is a machine tool designed for various
forming operations, such as stamping, punching, blanking, and deep drawing, among others. It
consists of a sturdy frame with two vertical columns on each side, providing stability and rigidity
during operation.
Double action crank press: Double acting hydraulic presses have two “sliders”one for pressing and
one for drawing. The two types of slider arrangements include an inner and outer slider type and an
upper and lower slider type.
Hydraulic press: Hydraulic presses are used in forging, molding, punching, clinching and other
operations. They can create intricate shapes while being economical with materials. They also take
up less space compared to mechanical presses.

LITERATURE REVIEW:
Gaurav.C et. al. [1] Press tool design involves selecting durable materials, such as tool steels or
carbide, to withstand stamping stresses. Types include blanking, piercing, bending, and drawing dies,
with progressive dies performing multiple operations. Considerations include achieving precise
tolerances, maintaining appropriate clearance to prevent wear, and incorporating draft angles for
smooth part removal. Efficient press tool design ensures cost-effective and accurate manufacturing
processes in industries where sheet metal components are produced.
Prabhakar Purushothaman et. al. [2] Designing a piercing tool for a special-purpose hydraulic
press involves selecting materials to withstand forces, optimizing geometry for efficient metal
penetration, and considering the unique requirements of the intended application. Analysis
encompasses structural integrity, fluid dynamics in hydraulic systems, and ensuring safety. Special
features may include adjustable depth control, rapid tool change capabilities, or automatic ejection
mechanisms.
Vinay Kumar et. al. [3] Designing a progressive press tool for an Alpha Meter component involves
a systematic approach to efficiently produce intricate parts in a single die set. Material selection is
critical for durability, considering the tool's repetitive operations. The progressive die design should
incorporate stages for blanking, forming, and assembly, minimizing waste and enhancing production

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speed. Tolerances are crucial for accurate component dimensions. Special features may include
sensors for quality control and mechanisms for part ejection.
Mr. Anil Parmar et. al. [4] The process of press tool design and manufacturing is a crucial aspect of
efficient and cost-effective production in metalworking industries. It involves material selection,
considering factors like durability and thermal resistance. The design phase includes defining tool
geometry, clearances, and features tailored to specific operations. Computer-aided design (CAD) and
simulation tools play a pivotal role in optimizing designs. Manufacturing encompasses precision
machining and heat treatment. Continuous improvement through iterative testing and analysis
ensures tool reliability. The integration of technology, adherence to tolerances, and efficient
manufacturing processes collectively contribute to the successful development and deployment of
high-performance press tools.
Vinayagamoorthi et. al. [5] The design and fabrication of multiple press tools for sheet metal
operations involve a comprehensive process to cater to various manufacturing needs. Initial stages
include material selection, considering factors like hardness and wear resistance. The design phase
integrates specific features for cutting, bending, and forming operations, utilizing computer-aided
design (CAD) tools. Precision machining techniques are employed during fabrication, with each tool
tailored for a specific sheet metal operation. Prototyping and iterative testing refine designs, ensuring
optimal performance.
Abhijit Ajabrao Tagade et. al. [6] The design and manufacturing of a compound press tool for
washers involve intricate processes to produce precise components. Material selection focuses on
durability and wear resistance. The tool design integrates features for blanking, piercing, and forming
operations in a single die set. Computer-aided design (CAD) facilitates geometric precision.
Machining techniques, such as milling and grinding, ensure accuracy during fabrication. Heat
treatment enhances tool life. The compound press tool's versatility streamlines washer production,
minimizing material waste.
Prashanth Thankachan et. al. [7] The design and analysis of a piercing tool for a specialized
hydraulic press involve careful considerations. Material selection prioritizes strength and durability
to withstand hydraulic forces. Geometric design optimization ensures efficient metal penetration
during piercing operations. Special features, such as adjustable depth control and rapid tool change
capabilities, are integrated to meet specific needs. Structural analysis evaluates the tool's integrity
under pressure. Fluid dynamics within the hydraulic system are considered for optimal performance.
Safety features and automatic ejection mechanisms may be incorporated.
Akshay.P et. al. [8] The design and force analysis of a press tool for sheet metal operations in a plate
leveler demand precision and efficiency. Material selection focuses on durability and hardness to
withstand repeated operations. The tool design incorporates features for cutting, bending, and
leveling operations, optimizing geometric parameters using computer-aided design (CAD). Force
analysis ensures that the press tool applies the required force evenly across the sheet, promoting
uniform leveling. Rigorous testing and simulation refine the design for optimal performance. The
resulting press tool streamlines plate leveling processes, ensuring accuracy, and reducing material
waste in the sheet metal manufacturing of plate levelers.The design and force analysis of a press tool
for sheet metal operations in a plate leveler demand precision and efficiency.
Suryawanshi Arvind.G et. al. [9] The design and modification of a piercing die aim to enhance tool
life and productivity in sheet metal operations. Material selection focuses on durability, and
geometric modifications optimize stress distribution. Surface coatings, such as hard coatings or
nitriding, may be applied to increase wear resistance. Redesigning the die clearance and
incorporating lubrication systems help mitigate friction and reduce wear. Additionally, strategic
changes in die geometry can improve chip evacuation and cooling. Simulation tools aid in analyzing
stress distribution and performance.

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Ferencz Peti et. al. [10] The manufacturing of bracket-type automotive parts using high-pressure die
casting technology involves several technological steps. Firstly, the alloy, often aluminum or zinc, is
melted in a furnace. The molten metal is then injected into a die cavity at high pressure, creating the
bracket's shape. Rapid cooling and solidification follow, ensuring precise part formation. Post-
casting processes, such as trimming, shot blasting, and machining, refine the part's dimensions and
surface finish. Quality control measures, including inspections and testing, guarantee adherence to
specifications.
Huiju Zhang et. al. [11] The design of a multi-station progressive die for an automobile front
bumper spotlight mounting bracket involves several key steps. Material selection focuses on
durability, considering the bracket's function and the stamping process. The die design incorporates
multiple stations for progressive operations such as blanking, forming, and piercing in a single setup.
Precision in tool geometry and clearances is crucial to meet tight tolerances. Computer-aided design
(CAD) facilitates accurate representation and simulation. Progressive stages ensure efficient material
usage, minimizing waste.
Anudeep S et. al. [12] In this paper Design and analysis procedure to develop Blanking and
bending press tool for Anchor Bracket component is discussed. Press tool manufacturing is one of
the widely emerging trends in production area. Basically sheet metal components are produced using
press tools. As the name itself suggests press tool means manufacturing the sheet metal components
by applying the predetermined force. The components manufactured using this process possess high
dimensional accuracy therefore automobile and aircraft firm depend largely on press tools. Anchor
bracket is a part which is used in brake assembly unit of automobiles.
N. Srilatha et. al. [13] With the advancement in technology, there has been an increasing use of
sheet metal components and press tools serve as one of the widely used tool for operations on sheet
metals. As the name itself suggests, it is used to produce sheet metal components of different sizes
and shapes with a predetermined force. Press tools are used for continuous mass production of
components. This leads to the requirement for the use of a tool material that possesses high strength
which would be able to withstand repeated heavy loads.
Y. V. Thokale et. al. [14] The design and development of a mounting bracket involve a systematic
process to meet specific functional and structural requirements. It begins with defining the bracket's
purpose and load-bearing capacity. Material selection is crucial, considering factors like strength and
durability. Computer-aided design (CAD) software facilitates the creation of precise 3D models,
optimizing geometry for stability. Prototyping and testing ensure the bracket meets performance
criteria. Manufacturing processes, such as stamping or machining, are employed for production.
Weiwen Jin et. al. [15] Numerical Control (NC) simulation and programming for a SinuTrain five-
axis bearing bracket involve advanced techniques to optimize machining processes. The process
begins with generating a virtual model using CAD software, simulating toolpaths and assessing
feasibility. Programming utilizes SinuTrain software to create CNC code, considering tool selection,
speeds, and feeds. Simulation ensures collision detection and validates the program virtually before
actual machining. This iterative process refines the program for efficiency and accuracy.
M Subrahmanyam et. al. [16] The design and analysis of a press tool for manufacturing a radiator
stay bracket involve critical considerations for efficiency and precision. Material selection focuses on
durability, with tool geometry tailored to the bracket's specific shape. Computer-aided design (CAD)
assists in creating a detailed 3D model, optimizing for accurate production. Finite Element Analysis
(FEA) assesses stress distribution, ensuring structural integrity under pressing forces. Tolerance and
clearance parameters are fine-tuned for precision. Iterative testing and refinement enhance the tool's
performance. The resulting press tool is optimized for the production of radiator stay brackets,
ensuring consistent quality and cost-effective manufacturing in the automotive industry.
Amit Kumar Jharbade et. al. [17] Press working is a chipless manufacturing method used to create
different sheet metal components. Another name for this procedure is cold stamping. Press is the

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name of the device that operates on presses. A press's primary components are a bed and a frame that
hold up a ram or slide. The ram's functioning mechanism is aligned with and consistent with the bed.
The die block is fastened to the bed, and the ram has the appropriate punches. As the punch
approaches and enters the die block, the ram's downward stroke creates a stamping. Press working
processes are typically carried out at room temperature, and the punch and die block assembly are
together referred to as the "die set."
N. Ramesha et. al. [18] The design and analysis of a blanking and bending press tool for
manufacturing an anchor bracket component involve a meticulous process. Material selection
emphasizes durability, considering the bracket's function. Computer-aided design (CAD) facilitates
precise tool geometry, incorporating stages for blanking and bending in a single die set. Finite
Element Analysis (FEA) assesses stress distribution, ensuring structural integrity during pressing
operations. Tolerances are fine-tuned for accuracy, and clearances are optimized to prevent wear.
Lauff, Carlye et. al. [19] The Prototyping Canvas serves as a purposeful design tool for planning
prototypes, providing a structured approach. It outlines key elements such as goals, target users, and
functionalities. The canvas includes a visual representation of the prototype, detailing user
interactions and interfaces. It aids in defining the scope, materials, and technologies required for
effective prototyping. By emphasizing user experience and design objectives, the canvas guides the
development process.
V.R. Jayasekara et. al. [20] Enhancing the productivity of D-brackets manufacturing involves
strategic measures. Firstly, adopting advanced manufacturing technologies, like automated CNC
machining, reduces production time and errors. Streamlining material handling and implementing
efficient work cell layouts optimize workflow. Utilizing high-speed stamping processes for mass
production significantly increases output. Integrating real-time monitoring and control systems
enhances process visibility, enabling quick adjustments. Continuous employee training ensures
proficiency with new technologies

SUMMARY:
The literature review on press tools and brackets highlights the significance of these
components in manufacturing processes. It encompasses studies on various types of press tools and
their applications, emphasizing efficiency, precision, and cost-effectiveness. Additionally, the review
delves into bracket design considerations, material choices, and structural analysis.

MODELING:
SolidWorks is a powerful computer-aided design (CAD) software widely used in engineering
and product design. Developed by Dassault Systèmes, it offers a user-friendly interface for creating
3D models, assemblies, and 2D drawings. SolidWorks facilitates parametric design, allowing users
to easily modify and update designs. It's utilized in various industries, from mechanical and
aerospace engineering to architecture. The software supports collaborative work, simulation, and
rendering, making it a comprehensive tool for the entire product development process.

COMMANDS IN SOLID WORKS:

Extrude: Used to create features by adding material in a specific direction, essential for forming the
base shape of components in press tools. This process results in a 3D feature based on your sketch.
Keep in mind that SolidWorks may have updates or changes, so it's advisable to refer to the specific
version's documentation or user interface for accurate instructions.
Cut Extrude:Removes material from a part, often employed to create openings or clearances in
press tool components. This command allows you to remove material from a part to create voids
or complex shapes.

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Shell: Shell Hollows out a part, useful for creating thin-walled components that are common in
press tool design. This command is useful for creating thin-walled structures or hollow parts
in your 3D model.
Draft: Adds a draft angle to faces, aiding in the ejection of parts from molds or dies. Draft is used to
make straight, vertical surfaces angled. This is useful mainly for cast parts where “Draft Angle” is
key to production capability of a part.
Fillet/Chamfer: Rounds or bevels edges, enhancing the durability of press tool components and
reducing stress concentrations. fillets and chamfers are used to ease sharp edges and corners. A
chamfer replaces the sharp change in direction with an angled slope, while a fillet makes a smooth
curve to join two surfaces.
Forming Tools:Specialized tools for creating features like punches and dies commonly used in press
tool design.The Form Tool Feature Property Manager lets you set options for inserting forming tools
in sheet metal parts.

MODELING OF PRESS TOOL BY USING SOLID WORKS SOFTWARE:

The main goal of this investigation is design and structural analysis of press tool and bracket under
the different types of materials. SolidWorks is a powerful computer-aided design (CAD) software
widely used in engineering and product design. Developed by Dassault Systèmes, it offers a user-
friendly interface for creating 3D models, assemblies, and 2D drawings.
1.Draw a rectangle using rectangle option in profile tool bar with 365mm as width and 335mm as
height. By using thickness of plate is 30mm .
2.Draw a rectangle using rectangle option in profile tool bar with 365mm as width and 335mm as
height. By using thickness of plate is 30mm and the hole was placed with 22mm diameter for the
bottom plate .
3.Draw a rectangle using rectangle option in profile tool bar with 185mm as width and 165mm as
height to create the die housing . By using thickness of plate is 45mm and the counter bore was
placed with 18mm diameter for the bottom plate .
4. Draw a rectangle using rectangle option in profile tool bar with 85mm as width and 85mm as
height to create the punch. By using thickness of punch is 60mm.the shape of the pattern is as per the
bracket for form punch .
5.Draw a rectangle using rectangle option in profile tool bar with 52mm as width and 94mm as
length for the guide post brushers. By using thickness of plate is 20mm and the hole was placed with
52mm and 32mm diameter for the brushers and they was extrude by 30mm by the extrude commend.
6.The press tool parts design is created by the SOLID WORKS software.finally we assemble the
overall parts modeling of press tool. as shown in fig-2.

Fig-2:Press tool assemble

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ANALYSIS:
SOFTEARE USED FOR ANALYSIS:
ANSYS is a powerful CFD tool commonly used for design and performance analysis. Its
integration with various engineering software, along with CAD and FEA connection modules, allows
seamless collaboration in modeling and analysis. ANSYS facilitates the import of CAD designs and
enables geometry development in the pre-processing stage for a streamlined workflow.
STEPS USED IN ANALYSIS:
1.Imported the tool design from geometry that built by the SOLID WORKS into Design Workbench
of ANSYS structural .as shown in below figure.

2.Imported the bracket from geometry that built by the SOLID WORKS into Design Workbench
of ANSYS Transient structural. as shown in below figure.

3.Material properties was taken from structural steel from the Engineering data book values are
taken. Properties of materials that are used to press tool.
4.The fixed support was fixed to the base plate for the press tool. as shown in below figure.

5.The punch displacement was set to be as -100N for the press tool. as shown in below figure.

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6.The material was taken for bracket was sheet metal was cold role cold acting (CRCA) was taken
with different types of thickness sheet was taken. as shown in below figure.

RESULTS:
ANALYSIS FOR THE TOOL:
In this section, the simulation results for the press tool model are analyzed. With a purpose to study
the influences of maximum shear stress and total deformation of a model was created by using
ANSYS simulation software. The punch displacement was set to be as -100N for the press tool for
the x-axis direction. The simulation of the mode has been run with all the given data.

(a)Maximum shear stress

\
(b)Displacement

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(c)Total deformation
The maximum shear stress reached 3.8447e+14 Pa. The values then decrease gradually to a
minimum of 0 Pa. Each value corresponds to a specific time point in your analysis. the structure
experienced a maximum deformation of 100.38 meters, and as time passed, it gradually returned to
its original state, reaching no deformation after 0 minutes.

ANALYSIS FOR THE BRACKET:

In this section, the simulation results of the Bracket model are analyzed. With a purpose to
study the influences of major strain and equivalent stress used for bracket a model was created by
using ANSYS simulation software. The different type of thickness of bracket was taken as
1mm,2mm,&3mm as been taken.
i.1mm thickness of bracket:

(a)Major strain for 1mm (b)Equivalent stress for 1mm

Major Strain" in engineering percentage. It starts at 30.000 and decreases gradually over subsequent
values until reaching 0.000. The maximum strain is 15.954, and the minimum is –0.007. The
"Equivalent Stress" is given in MegaPascals (MPa), and the provided values range from 384.624 to
11.469. This stress represents the combined effect of different types of stresses on a material.
ii.2mm thickness of bracket:

(a)Equivalent stress for 2mm (b)Major strain for 2mm

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iii.3mm thickness of bracket:

(a)Major strain for 3mm (b) Equivalent stress for 3mm

Table-1:Different types of thickness of bracket and equivalent stress and major strain:
S.NO THICKNESS MATERIAL EQUIVALENT MAJOR
OF SELECTION STRESS STRAIN
BRACKET
Min Max Min Max
1 1mm CRCA 11.469 384.624 -0.007 15.954
2 2mm CRCA 0.756 362.778 0.0002 12.527
3 3mm CRCA 6. 3 - 2
237 96.164 0.578 1.964
The results to assess factors like stress distribution, deformation, and safety factors for each bracket
thickness. Identify the thickness that meets design criteria with optimal performance.as shown in
table-1.

DISCUSSION:
A press tool and bracket involves several key considerations.For the press tool, you'll need
to focus on factors like material selection, die design, and the type of press operation (e.g., blanking,
piercing). Ensuring proper clearances, incorporating features for tool life improvement, and
considering material flow are crucial aspects.
In bracket design, structural integrity, load-bearing capacity, and material selection are pivotal.
Utilize Finite Element Analysis (FEA) for stress analysis to ensure the bracket meets required safety
factors. Also, consider manufacturing processes, such as casting or machining, to achieve the desired
geometry.

CONCLUSION:
press tool and bracket involves several steps. In SolidWorks, you'd start by creating
detailed 3D models for both components, considering material properties and manufacturing
processes.For the press tool, focus on features like punch and die shapes, clearance, and alignment.
In ANSYS, perform a structural analysis to ensure it can withstand the expected loads during
operation. Similarly, design the bracket in SolidWorks, considering its function, load-bearing
capacity, and attachment points. ANSYS can then be used to simulate structural, thermal, or dynamic
analyses based on the bracket's application. Throughout this process, iteration and refinement are
crucial. SolidWorks and ANSYS provide a powerful combination for designing, simulating, and
optimizing mechanical components.

FUTURE SCOPE:
Designing a press tool and bracket using SolidWorks involves creating detailed 3D models,
considering material properties, and ensuring functionality. ANSYS can be employed for structural

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analysis to assess factors like stress and deformation.Future scope could involve incorporating
advanced materials, optimizing designs for additive manufacturing, or exploring automation in the
manufacturing process. Integration of IoT for real-time monitoring and predictive maintenance could
enhance efficiency and reduce downtime. Continuous improvement in design methodologies and
software capabilities will also shape the future of such projects.

REFERENCES
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with Special Purpose Hydraulic PressAmerican Journal of Mechanical and Industrial Engineering
2016; 1(3): 31-37
(3) Vinay Kumar A, D Ramegowda,design of progressive press tool for an alpha meter
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