Maharashtra State Board of Technical Education

Government Polytechnic College, Nanded

Science and Humanities Department

2023-24

Subject [14]

MPR (Subject code: -312313)

Micro-Project Topic
Title: -DETAIL STUDY OF PRESS TOOL

NISHIGANDA KARLE
Guided By
 NISHIGANDHA K
(Lect.in MANUFACTURING TECHNOLOGY)
Submitted By
Sr.No Roll Enrollment Name
. No. No.
1 633 23510220672 BULEWAR MANMATH
KAILAS
2 634 23510220682 CHIDRAWAR KEDAR
DNYANESHWAR
3 635 235110220679 DARADE DNYANESHWAR
CHANDRAKANT
4 636 GANESH DEVKAR
5
6

7
 MAHARASHTRA STATE BOARD OF TECHNICAL
EDUCATION

Certificate

This is to Verify That Mr./Mr Manmath,Kedar,Dnyaneshwar,Ganesh

of Roll No ,633,634,635,636 of second Semester of Diplomain
production engginer of

Institute GOVERNMENT POLYTECHNIC NANDED

(Code :312313) Has completed the Micro-Project Satisfactory in
course MANUFACTURING TECHNOLOGY (312313) for the
academic year 2023-2024 as prescribed in the curriculum.

Place…………………. Enrollment no:,

23510220672, 23510220682,23510220679,
Date………………….. Exam Seat No: 382391

Course Teacher Head of the Department

Principal
  Index

Sr. Topic Page

No. No.
1 Introduction 1
2 Importance 2
3 Analysis 3
4 Summary 4
5 References 5

 Work done by Group Member

Sr. Group Member Work Done in Micro-Project

No. Name
1 BULEWAR Introduction
MANMATH
KAILAS
2 CHIDRAWAR Importance
KEDAR
DNYANSHWAR
3 DARADE Analysis
DNYANESHWAR
CHANDRAKANT
4 GANESH DEVKAR Summary

5 BULEWAR References
MANMATH
KAILAS
 MPR (312313)

DETAIL STUDY OF PRESS TOOL

A press tool is a metal forming machine tool that shapes or cuts metal
by applying mechanical force. Press tools are used in various types of
presses to produce sheet metal components in large volumes. Press
tools are composed of different parts such as die, punch, stripper
plate, etc. Press tools are classified by the types of operation they
perform, such as blanking, piercing, bending, forming, forging,
trimming, etc..
Types of press tools
Press tools are commonly used in hydraulic, pneumatic, and
mechanical presses to produce the sheet metal components in large
volumes. Generally press tools are categorized by the types of
operation performed using the tool, such as blanking,
piercing, bending, forming, forging, trimming etc. The press tool will
also be specified as a blanking tool, piercing tool, bending tool etc.[1]
Classification of press tools
Blanking tool

Blanki
ng Tool

1. Blanking is a punching operation in which the entire periphery

is cut out and the cutout portion required is known as STAMP
OR BLANK.

 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.
In blanking, metal obtained after cutting is not a scrap if it is usable.

 The size of the blank depends on the size of the die.

 So the size of the die opening is equal to the blank size.
 Clearance is given to the punch.

Piercing tool

Piercing
tool
Piercing involves cutting of clean holes with a resulting scrap slug.
The operation is called die cutting and can also produce flat
components where the die, the shaped tool, is pressed into a sheet
material employing a shearing action to cut holes. This method can be
used to cut parts of different sizes and shapes in sheet metal, leather
and many other materials.
Cut off tool

Cutoff
tool
It is a shearing operation in which blanks are separated from a sheet
metal strip by cutting the opposite sides of the part in sequence.
Parting off tool
This is similar to a cutoff tool, in that a discrete part is cut from a
sheet or strip of metal along a desired geometric path. The difference
between a cutoff and a parting is that a cutoff can be nestled perfectly
on the sheet metal, due to its geometry. With cutoffs, the cutting of
sheet metal can be done over one path at a time and there is
practically no waste of material. With partings, the shape can not be
nestled precisely. Parting involves cutting the sheet metal along two
paths simultaneously. Partings waste a certain amount of material,
that can be significant.
Trimming tool
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.

Trimm
ing Tool.........
Shaving tool
Shaving removes a small amount of material around the edges of a
previously blanked stampings or piercing. A straight, smooth edge is
provided and therefore shaving is frequently performed on instrument
parts, watch and clock parts and the like. Shaving is accomplished in
shaving tools especially designed for the purpose. it is also required
proper die clearance
Forming tool
Forming is the operation of deforming a part in curved profile.
Forming tools apply more complex forms to work pieces. The line of
bend is curved instead of straight, and the metal is subjected to plastic
flow or deformation.
Drawing tool
Drawing tools transform flat sheets of metal into cups, shells or other
drawn shapes by subjecting the material to severe plastic deformation.
Shown in fig is a rather deep shell that has been drawn from a flat
sheet. It is an axial elongation through the application of axial force.

Drawing
Tool
This type of Press tool is used to perform only one particular
operation therefore classified under stage tools.
Progressive tool
A progressive tool differs from a stage tool in the following respect:
in a progressive tool, the final component is obtained by progressing
the sheet metal or strip in more than one stage. At each stage, the tool
will progressively shape the component towards its final shape, with
the final stage normally being cutting-off.
Compound tool
The compound tool differs from progressive and stage tools by the
arrangement of the punch and die. It is an inverted tool where
blanking and piercing takes place in a single stage and also the
blanking punch will act as the piercing die. That means punch will be
to the bottom side of the tool and piercing punches to top side of the
tool. The burr forms only one side.
Combination tool
In a combination tool, two or more operations such as bending and
trimming will be performed simultaneously. 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 takes place- it can perform a cutting and non-
cutting operations in a single tool.
General press tool construction
The general press tool construction will have the following elements:

 Shank: It is used as a part for installing the Press tool die in the
slide of the press machine with proper alignment.
 Top Plate: It is used to hold top half of the press tool with press
slide. It is also called Bolster Plate.
 Punch Back Plate : This plate prevents the hardened punches
penetrating into top plate. It is also called Pressure Plate or Backup
plate.
 Punch Holder: This plate is used to accommodate the punches of
press tool.
 Punches : To perform cutting and non cutting operations either
plain or profiled punches are used.
 Die Plate: Die plate will have similar profile of the component
where cutting dies usually have holes with land and angular
clearance and non cutting dies will have profiles.
 Die Back Plate:This plate prevents the hardened Die inserts
penetrating into bottom plate.
 Guide Pillar & Guide Bush : Used for alignment between top and
bottom halves of the press tools.
 Bottom plate:It is used to hold bottom half of the press tool with
press slide.
 Stripper plate: it is used to strip off the component from punches.
 Strip guides: It is used to guide the strip into the press tool to
perform the operation.
 Press tool
Cutting force in press tool
In general, cutting force can be calculated using the formula: CF =L x
T x ζmax
Cutting force will be in Newton (N) Where, L = Cut length in mm,
(perimeter of profile to be cut) Ex: 40 mm square to be cut will have
cut length of 160 mm
T = Sheet metal thickness in mm,
max = Maximum shear strength of sheet metal in MPa
Stripping force
Stripping force is the force required to eject the strip from the
punches, which helps the strip to go forward for the next operation
Stripping force will be usually 10 to 20 % of cutting force (CF)
Press force
The Press force is the cutting force added to the stripping force: Press
Force = Cutting force + Stripping force
Fits in press tools

 Punch holder and Punches =H7/k6

 Punch and Stripper = H7/k6
 Guide Pillar and Guide bush = H7/g6
 Guide bush and Top plate = H7/p6
 Guide pillar and bottom plate = H7/p6
 Dowel and plate = H7/m6
 Dowel holes = H7/m6

References

1. Cyril Donaldson, George H LeCain, V C Goold, Tool

design 3rd edition, Tata McGraw-Hill Education, New Delhi.
2. Press tools, BSI British Standards, retrieved 2023-10-05

Press Tools: The Complete Guide A Press tool is a particular type of

tool that is attached to a press brakeand 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.
  WORKING PRINCIPLE OF PRESS TOOL

A press tool, commonly known as a die, plays a crucial role in sheet

metal stamping processes. It enables the production of sheet metal
components or stamped parts from flat metal sheets. Here are the key
components and principles involved:
1. Ram (Slide): The ram is the moving component of the press. It
transfers mechanical or hydraulic force from the flywheel or hydraulic
system to the press tool for sheet metal stamping.
2. Shank: The shank serves as a part for installing the top die in the slide
of the press machine.
3. Punch Holder (Upper Shoe): The upper shoe contains guideposts and
provides support for the entire upper section of the die set (which
generally includes the punch and punch plate).
4. Die Holder (Lower Shoe): This is the lower part of the die set,
containing guideposts. The whole lower section typically includes the
die and stripper, and it is mounted on the lower shoe.
5. Back-Up Plate: Also known as the punch backplate or pressure plate,
the backup plate prevents excessive pressure on the punch holder.
6. Punch Plate (Punch Retainer): The punch plate holds the punch in its
proper relative position.
7. Punch: The main component of the die assembly, the punch is directly
or indirectly moved by the press ram. The punch and die work
together to create stamped parts.
8. Bed: The bed is the lower part of the press frame, serving as a table to
which a bolster plate is mounted.
9. Bolster Plate: This thick plate secures to the bed and supports and
locates the die set.
10. Die: The die is the female part of the die block or press tool. It
shapes the given workpiece in the press.
11. Stripper: A stripper is used to strip the metal strip from a punch
or die.
12. Guidepost & Guide Post Bushing: These components guide the
die set, maintaining alignment during operation. Proper lubrication
 and positioning improve tool operation and contribute to producing
quality products.
13. Shut Height: The distance between the top of the bed and the
bottom of the slide, considering stroke adjustments.
14. Stroke: The distance of ram movement from its up position to its
down position.
In summary, the press tool’s working principle involves loading the
material, clamping it down, and pressing a punch or die into the
material to create the desired shape. Whether it’s forming, cutting, or
bending, press tools are essential for efficient sheet metal processing.
 ADVANTAGES OF PRESS TOOL
1. High Precision: Press tools are designed with precision,
ensuring accurate and consistent results during sheet metal
stamping. The controlled movement of the ram and die ensures
tight tolerances.
2. Efficiency: Press tools operate at high speeds, allowing for rapid
production of stamped parts. This efficiency is crucial for mass
production in industries like automotive, electronics, and
appliances.
3. Cost-Effective: Once the press tool is set up, it can produce a
large number of identical parts without significant labor costs.
This cost-effectiveness makes it ideal for high-volume
manufacturing.
4. Versatility: Press tools can perform various operations,
including blanking, piercing, bending, and forming. By
changing the die, manufacturers can create different shapes and
sizes.
5. Reduced Material Waste: The precise cutting and shaping
capabilities of press tools minimize material waste. This is
essential for optimizing material usage and reducing overall
costs.
6. Consistent Quality: Since press tools maintain uniform pressure
and movement, the quality of stamped parts remains consistent.
This is crucial for meeting industry standards and customer
expectation.
  DISADVATAGES OF PRESS TOOL
1. Initial Setup Cost: Developing and configuring press tools can be
expensive. The design, fabrication, and installation of dies require
significant investment upfront.
2. Limited Flexibility: Press tools are optimized for specific operations
(such as blanking, piercing, or bending). Changing the tool for a
different operation can be time-consuming and costly.
3. Maintenance and Repair: Regular maintenance is essential to keep
press tools in optimal condition. Wear and tear, damage, and
alignment issues can affect performance. Repairs can disrupt
production schedules.
4. High Volume Requirement: Press tools are most cost-effective when
used for high-volume production. For small-scale or custom
manufacturing, the initial investment may not be justified.
5. Material Constraints: Press tools work best with flat sheet metal.
Complex shapes or irregular materials may not be suitable for
stamping using standard press tool
  APPLICATION OF PRESS TOOL
1. Automotive Industry:
o Press tools are widely used for manufacturing automotive components
such as body panels, brackets, and engine parts.
o Blanking, piercing, and forming operations create precise shapes for
car doors, hoods, fenders, and chassis components.
2. Aerospace Industry:
o Aircraft manufacturing relies on press tools for producing structural
parts like wing panels, fuselage sections, and landing gear
components.
o High precision and consistent quality are crucial for safety and
performance.
3. Electronics and Appliances:
o Press tools create intricate shapes for electronic enclosures,
connectors, and appliance housings.
o The stamping process ensures uniformity and tight tolerances.
4. Food Processing Industry:
o Press tools are used to manufacture food packaging containers, lids,
and closures.
o Blanking and forming operations produce aluminum or steel cans,
ensuring airtight seals.
5. Textile Industry:
o Press tools cut patterns for textile machinery parts, zippers, and
buttons.
o Precision cutting and shaping enhance garment production.
  IMPORTANCE OF PRESS TOOL

1. Efficient Production:
o Press tools enable rapid and efficient production of sheet metal
components.
o They streamline the manufacturing process, allowing for high-speed
stamping and consistent output.
2. Precision and Consistency:
o Well-designed press tools ensure precise shaping and forming of sheet
metal.
o Consistent quality is crucial for meeting industry standards and
customer expectations.
3. Cost-Effectiveness:
o Once set up, press tools can produce a large number of identical parts
without significant labor costs.
o This cost-effectiveness is essential for mass production.
4. Versatility:
o Press tools can perform various operations, including blanking,
piercing, bending, and forming.
o By changing the die, manufacturers can create different shapes and
sizes.
5. Reduced Material Waste:
o The precise cutting and shaping capabilities of press tools minimize
material waste.
o Optimizing material usage contributes to cost savings.
6. Safety and Automation:
o Properly operated press tools enhance workplace safety by
minimizing direct contact with sharp edges and heavy machinery.
o They can be integrated into automated production lines, reducing
manual labor.
  OPERATION OF PRESS TOOL
Certainly! Press tools play a crucial role in sheet metal stamping
processes. Let’s delve into the details of press tool operations:
1. Blanking: A blanking press tool cuts out the outer profile of a metal
sheet, creating a flat piece of material. This operation is commonly
used to produce parts like washers, gaskets, and electrical contacts.
2. Piercing: In piercing, the press tool creates holes or openings in the
sheet metal. These holes can be of various shapes and sizes,
depending on the design requirements.
3. Bending: The bending operation involves shaping the metal sheet by
applying force to deform it along a straight line. It results in bent or
folded components, such as brackets, flanges, and angles.
4. Drawing: Drawing press tools pull the sheet metal into a die cavity to
form complex shapes. This process is commonly used for creating
cylindrical or cup-like parts, such as beverage cans or automotive
components.
5. Cutting Off: A cut-off press tool trims excess material from the edges
of the sheet, separating the desired part from the rest of the
material. Think of it as precision cutting.
6. Parting Off: Parting off tools separate a continuous strip of material
into individual pieces. This operation is useful for producing items
like key blanks or small stamped components.
7. Embossing: Embossing press tools create raised or sunken patterns on
the surface of the sheet metal. These patterns can be decorative or
functional.
8. Coining: Coining press tools compress the metal sheet to create
intricate designs or features. This operation is often used for minting
coins or adding logos to metal parts.
9. Notching: Notching tools remove small portions of material from the
edge of the sheet, creating specific cutouts or grooves.
10. Trimming: Trimming press tools precisely cut excess material
from the edges of a formed part, ensuring clean and accurate edges.