ZAINUDIN YAHYA

Office: BN-Block, Level-3, PRESSWORKING

Room-055
Email: zai@uniten.edu.my & OPERATION
Ext. No.: 2241
H/P No.: 0122669986 LECTURER : ZAINUDIN YAHYA

LECTURER : ZAINUDIN YAHYA

PRESSWORKING AND OPERATION

Definitions: A press: is a machine that is used in pressworking

Press working: is cutting, forming and drawing of
sheet metal materials using punches and dies.
Shear forces: are the forces applied to the metal
to be cut, formed or drawn.
Shear strength: is the resistance of the metal to
shear forces. In metal press working the shear forces
must be greater than the shear strength.
operations. Presses use tools called dies and punches
to perform pressworking.
PRESSES
Advantages and features of presses:
1. Unlike machine tools, presses are flexible and
multipurpose machines. This is because one press
can employ many interchangeable.

Factors of Selection of Presses

Tools (dies and punches), so a standard press can 1. Operation type

perform different types of operations (forming, 2. Size of part
shearing and punching). 3. Required power
4. Speed of operation
2. Presses are productive machines (used in mass
production) because for one stroke one part is Parts of Presses:
produced. That is why presses have found wide
applications in automotive, aircraft and appliances Frame, Bed, Ram, Ram slides, Ram drive,
industries. Flywheel, Transmission, Bolster plate,
Power source
 Presses rating:

Press rating is given in tons and it is also called

tonnage rating. It is the energy spent on the work at
each stroke. This energy is obtained from that stored
in the flywheel:

Where E- Energy, (ton-in) available at 10% slow down

from normal rpm of the flywheel.
N- rotary speed of flywheel, rpm
D- diameter of flywheel, in
W- weight of flywheel, lb

Classification of Presses C. (According to the frame type):

A. (According to the power source):

Types of frames: { inclined frame, gap frame, arch frame,
1. Manual-operated presses: for press working of straight side frame, horn frame}
thin sheets.
2. Power-operated presses: mechanical and 1. Inclined open back press:
This press has a gap frame. The press can be inclined to permit the parts to
hydraulic. slide off the back side (That is why it is called open back).

B. (According to the operation type): 2. Gap press:

It has gap or C-frame. Adv.-Excellent access to the tools, can be use fro
long and wide parts.
1. Crank or eccentric types presses (for punching and trimming)
2. Knuckle joint presses (for coining and embossing) 3. Arch Press:
3. Hydraulic presses (for drawing) It has an arch frame and used for light work.

4. Straight side press:

This is powerful because it has a vertical straight side frame which takes
the heavy loads.

5. Horn press:
The press has a heavy shaft (horn) instead of bed. It is used to presswork
cylinder parts.

Other Types of Presses

1. Press Brake:
It uses long dies to presswork long pieces. The press is suitable for small
production runs. The tools applied are very simple.
2. Turret Press:
This press consist of turrets that contain dies and punches of different sizes
and shapes. It produces holes by selecting the required punch from the
rotating the turret. (65 holes/ min)
 Features Of Hydraulic Presses

1. Adapted to drawing operation, because of the slow

uniform motion of the ram.
2. Hydraulic presses push or squeeze the work while
mechanical presses (previous types) actually strike
the work.
3. Their frames are very strong.
4. Adjustable power of the press because oil (working
fluid) can be trotted (controlled) (adv)
5. Less productive than mechanical presses because of its
slow motion (disadv)
6. Require high maintenance level (disadv)

Drive Mechanisms For Presses

1. Single crank drive: It gives harmonic motion. It reaches its

maximum speed at midstroke.
2. Eccentric drive: It gives shorter strokes than the crank
drive.
3. Rack and Gear : It gives long and length controlled strokes
4. Hydraulic drive: It gives slow powerful motion of the ram for
forming and drawing operations.
5. Knuckle joint drive: It is used for coining because of its high
load capacity.
6. Toggle drive
7. Screw drive

Feed Mechanisms of Presses PRESSWORKING OPERATIONS Cont.----------

a Shearing:
Purpose: Feed mechanisms introduce stocks to the dies
without endangering the operators hands. In addition, they
provide uniform and rapid feeding, which is important to high
production. Shearing is the process of cut along a straight line across a
strip to produce small pieces of sheet metal.
Shearing applies shearing forces that must be greater than
PRESSWORKING OPERATIONS
the ultimate strength of the metal. So the metal passes from
elastic and plastic deformation to the state of the ultimate
Presses employ tools called punches and dies. Punches are strength. At this moment fractures start to take place and
attached to the ram, so a punch together with the ram and they progress with more shearing forces.
enters the die cavity. The die is usually stationary and rests
on the press bed or a bolster plate.
 Types of Shearing:

1. Blanking : It refers to the operation of cutting out sheet

metal blanks or flat shapes from strips. The remaining
part of the strip is waste metal and called skeleton.

2. Piercing or punching = Cutting or enlarging a hole.

4. Shaving or sizing: the extra material from a rough-sheared

3. Nibbling: A machine called nibbler moves a punch while the (previously sheared) edges is trimmed.
sheet is fed. This operation is similar to the making of an 5. Slotting: is the cutting of elongated holes (slots).
elongated slot in a sheet of paper by the successive
punching of holes with a paper punch.
Adv.-Economical process for small production runs because
it does not employ special dies.

6. Notching: Removing pieces or various shapes from

the edges.

Difference between blanking and punching :

7. Perforating: Punching a number of holes in a sheet.

8. Slitting: Longitudinal cutting of a strip.

Importance of Clearance:
9. Lancing: Leaving a tap without removing any material.
Clearance is the gap per side between the die and punch.
Improper clearance leads to excessive deformation because
fractures between the top and bottom of the stock do not
meet.
Factors that influence the clearance definition:

With correct clearance, the material breaks suddenly so the force

1. Thickness, decreases suddenly.
2. Hardness With improper clearance the material breaks slowly so the forces do
3. Strength of the stock material. not dissipate quickly.

Calculation of punch force:

Improper clearance
Correct clearance
F = D tS
- Punch force depends on:
D- Diameter (in or mm)

Force

Force
t thickness (in)
S Shear strength (psi)
Punch travel Punch travel

b Bending and Forming:

In bending the metal experiences both compression (at the inner

Length of bend: is equal of the length of arc produced after bending:
surface) and tension (at the outer surface) at the same time.
Bending is performed in V or U shaped dies.
L = 2(r +0.4t) / 3600

Where r- Inside radius of bend, in or mm

- Angle of bend
t Thickness, in or mm

Springback and its compensation: c Drawing:

Drawing consists of pressing or stretching a flat blank or sheet over

After bending and removing the bending forces, the radius of bend
increases because the metal retains some elasticity that causes elastic
recovery (springback). The springback can be corrected by over
bending an amount such that when the bending force is removed, the
part will return to the design dimensions.
a die having the interior shape of the workpiece. During drawing,
sever tensile stresses are induced into the sheet.
Types of Drawing:
1. Single-action drawing (simple drawing): It is performed on
single-action presses (only on movement of the ram).

2. Double-action drawing: It is performed on double action presses
that have two slides one within the other (one for moving the ram
with the punch and the other for holding the blank edges using a
ring)
Advantages
1. Good surface of the part because friction with hard tool materials
is eliminated.
2. Low cost of tools
Why are hydraulic presses suitable for drawing?
1. Because of the slow action
2. Because the speed can be controlled.
3. Because of uniform squeezing pressure.
4. Because of strength of the press
Rubber Pad Forming (Guerin Process)
Instead of employing a punch, a boxlike container filled with a rubber
pad is mounted on the ram. Only male die is applied. As the ram
descends, it forces the rubber to exert forces on the plate and as a
result, the plate will flow around the die and thus forming the part.
Deep Drawing (Hydroforming or Fluid Forming)
It uses the same principle of rubber-pad forming but the differences
are:
The rubber pad has a cavity filled with a fluid. The fluid is
introduced to the cavity under pressure through a valve.
Instead of the male die, a punch is used. When the oil is
introduced to the cavity under a certain pressure, the punch
moves up pressing the plate against the rubber.
Efficient Use of Materials in Stamping: ( Refer to fig. 16.28)
It involves the principle of minimum waste . This means skeleton or
the leftover after blanking should be reduced to minimum.
Types of Material losses during stamping:
1. Waste = Skeleton or leftover after blanking
2. Scrap = Loss of materials because of mistakes (worn punches)
3. Shrinkage = Loss of material because of changes in its quality.
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