I.
Introduction
Punching Machine
A punching machine is a machine tool for
punching and embossing flat sheet-materials to
produce form-features needed as mechanical
element and/or to extend static stability of a sheet
section.
Figure 1.1 Punching Machine
Principle of Operation:
The concept of punching designates a slitting
process in which a sheet is severed in one stroke.
Shapes such as round holes are created in the part,
and external contours are cut with single strokes.
A punching machine works like a hole punch
for paper. The punch presses the paper against
the support of the hole punch and finally into a
round opening. The scrap from the punching
collects in the hole punch container.
Punching works exactly the same way: the
sheet is positioned between the punch and the die.
The punch moves downward and plunges into the
die. The edges of the punch and the die move past
each other in parallel, cutting the sheet.
Figure 1.2 Principle of Operation of a Punching
Machine
Observed in detail, the punching process
proceeds in four phases. When the punch touches
the sheet, the sheet is deformed. Then it is cut.
Finally, the tension within the material is so great
that the sheet breaks along the contour of the cut.
The cut-out piece of sheet - the so-called
punching slug - is ejected downward. When the
punch travels upward again, it can happen that it
pulls the sheet along. In that case, the stripper
releases the sheet from the punch.
The higher the fraction of cut on the sheet
edge, the better the edge quality. For precise fits,
for example, preliminary holes are punched and
then the final diameter is punched out with a
slightly larger tool. The fraction of cut along such
an edge is then as high as 100%.
Static Analysis
Solid works linear static stress analysis
enables designers and engineers the power to
validate their design quickly and efficiently.
Validation is done within the Solid
works application utilizing a familiar user
interface and eliminating the need to export data
to another software package. Linear stress
analysis no longer must be delegated as a post
design process. The validation and design
become a simultaneous process instead of
sequential.
Modal Analysis
Modal analysis describes the structure in terms of
its natural frequencies, and associated mode
shapes for predicting its dynamic properties.
Basically, the procedure consisted to import solid
model of the wind turbine in the solid works
simulation/ cosmos module. Then we omit the
hidden and slight parts, apply materials properties
and boundaries conditions, and finally we
discredit the structure in finite elements.
Harmonic Analysis
Use harmonic analysis to calculate the peak
steady state response due to harmonic loads or
base excitations.
A harmonic load P is expressed as P = A sin (ωt
+ φ) where: A is the amplitude, ω is the
frequency, t is time, and φ is the phase angle.
Sample harmonic loads of different frequencies
w versus time are shown below:
Figure 1.3 Modal Analysis Diagram
Figure 1.4 Frequency Diagram
Although you can create a modal time history
study and define loads as functions of time, you
may not be interested in the transient variation of
the response with time. In such cases, you save
time and resources by solving for the steady-
state peak response at the desired operational
frequency range using harmonic analysis.
II. Related Literature
Mr.Umesh.C.Rajmane et.al. [1] Studied design
and development of the 100-ton press forging
operation. The proposed work
consisting of the modification of existence
configuration of the single layered forging press
machine into the double-forging press
configuration by performing structural analysis
and stress distribution analysis on the base platen
and on the lower die. It shows a
comparative study of the stress distribution in the
parts and the modifications of the project. An
experimental system will be
developed to achieve the established objective,
which mainly includes the examination of the
tensions in all the main parts of the
forging press.
Bhushan.V.Golechha, P.S.Kulkarni et.at. [2]
Investigated on the design optimization and
structural analysis of ten tons pneumatic
press. This work of the project concerned with the
design and analysis of the finite elements and the
structural optimization of the
ten-ton pneumatic press. The goal is to reduce the
cost and weight of pneumatic press machine
without reduction in the quality of
production. Using the best possible and available
resources in project can affect the cost and weight
of the press. One way to do
this will be to do optimize to reduce the volume
of the material used to build the complete
structure of the press machine. Here this
is considered as industrial application project
consisting of the massive optimization of a
pneumatic press. The ANSYS software
was used for the analysis of the purposes.
Malachy Sumaila et.al. [3] Carried out design and
implementation of thirty-ton hydraulic press. A
thirty-ton hydraulic press was
constructed and evaluated by testing with local Their goal was to study different frame designs of
sourced materials. The design parameters are a press machines for forging operation.
maximum load of 300 kN and has to Evaluation is determination of suitability
with stand load by piston stroke of 150 mm piston for each structure for supporting of special
diameter is 100 mm. the major component of purpose operation. FEM modal analysis is made
press consists of piston and cylinder to compare results. It is recommended
arrangement, hydraulic circuit and frame. not to use 2 column press machines for high end
Machine was tested with load condition of 10 kN operations. Four column press design with
with 2 compressive spring of 9 N/mm bottom drive was recommended.
constant each arranged between upper platen and III. Methodology
lower platen parallel and results were found IV. Analysis
satisfactory.
4.1 Design model
Akshay Vaishnav et.al. [4] By optimizing the
design of the hydraulic pressure plate through
FEA, the hydraulic press operates
under continuous load. Due to this continuous
loading, tensile as well as compressive stresses
are produced in various parts of the
machine. These stresses cause permanent
deformations in some components of the
machine. This work consists on the optimization
of a hydraulic press of four pillar and 250 tons
capacity, taking into account limitations such as
design, weight and cost. The work focuses on the
design and optimization of the top platen. The Figure 1 Isometric view of the punching
upper is most critical part of hydraulic press machine with labels
machine because it carries The punching machine is composed
cylinder. The project is based on the size of a C-frame, punching motor, die openings
optimization method and the results are validated and die shoe, shaft and shaft link and an alloy
using the finite element method with the sheet metal.

appropriate boundary conditions. CAD modelling

was done in CREO and the ANSYS software is
4.2 Material Specification
used for FEA. The attempt was
property value units
made to limit the total deformation of less than
Elastic 2.1e+011 N/m^2
0.3 mm/m. This is done by changing the height of
Modulus
the plate.
Poisson’s 0.28 N/A
Karel Raz et.al. [5] Studied on hydraulic pressing Ratio
machine for dynamic behavior for forging Shear 7.9e+010 N/m^2
operation with 180 SPM speed. Modulus
Mass 7700 kg/m^3
Density
 Tensile 723825600 N/m^2 Acting Force
Strength
The acting force is being applied to the
Compressive N/m^2
shaft link and even in the alloy sheet metal and
Strength
die opennings. The acting force is set to 24525
Yield 620422000 N/m^2
N, which is the standard.
Strength
Thermal 1.3e-005 /K Fluid Pressure
Expansion
Coefficient Pressure is considered because if affects
Thermal 50 W/(m·K) the acting force if the pressure applied in the
Conductivity shaft.
Specific Heat 460 J/(kg·K) Gravity
Material N/A
Damping Gravity is considered when the shaft is
Ratio in static condition and during the application of
Table 1. Specification of an Alloy steel acting force.

4.3 Design Parameters 4.5 Static Analysis

Item Sub item Value

C-Frame Height (mm) 1150
Material Alloy Steel
Mounting Area (mm) 200x200
Plate
Thickness 40 approx.
(mm)
2nd mounting Volume (mm) 100x100x100
plate
Hydraulic Type Double Acting
Cylinder Cylinder
(shaft)
ODxID (mm) 30x20 Figure 2. Static Analysis-Stress 1
Motor Power (KW) 1.63 approx.
This figure shows maximum Von Mises
Shaft Link Diameter 20 Stress of 2267.936 MPa with a yield strength of
(mm) 620.422 MPa.
Thickness 10
(mm)
No. of Mesh 18
Mesh 50%-80%
Table 2. Parameters of the punching
machine

4.4 External forces to be considered

 3 5781.1 920.09 0.0010868
4 5958.6 948.33 0.0010545
5 14469 2302.7 0.00043427
Table 3. Resonant Frequencies

The following figures shows the 5 modes

of frequency of the Punching Machine in which it
shows its possible movements in different
directions.

Figure 3. Static Analysis-Strain 1

This figure shows a maximum strain of
2.460 N-m

Figure 5. Modal Analysis in Mode 1

This figure shows the lowest frequency
of 278.58 Hz and an amplitude of 6.690.

Figure 4. Static Analysis-Displacement 1

This figure shows a maximum
displacement of 35.398mm.

4.6 Modal Analysis

The modal analysis studies the properties
of Punching Machine Assembly to determine the
response of the assembly through vibration.
This is the list of frequencies when
determining the mode shapes of structures:
Mode Frequency Frequency Period Figure 6. Modal Analysis in Mode 2
No. (Rad/sec) (Hertz) (Seconds) This figure shows a frequency of 280.6
1 1750.4 278.58 0.0035897 Hz and an amplitude of 6.684
2 1763 280.6 0.0035638
 Figure 7. Modal Analysis in Mode 3 Figure 9. Modal Analysis in Mode 5
This figure shows a frequency of 920.09 This figure shows the maximum
Hz and an amplitude of 10.570. frequency of 2302.7 Hz and an amplitude of
7.535.

Figure 8. Modal Analysis in Mode 4

This figure shows a frequency of 948.33
Hz and an amplitude of 10.972.

Figure 10. Frequency vs. Mode No.

This figure shows that the frequency is
gradually increasing from mode 1 to mode 5. The
minimum and maximum frequency of 278.58 Hz
and 2302.7 Hz, respectively.

4.7 Harmonic Analysis

The Harmonic Response Analysis is used
to determine the response of the Punching
Machine Assembly when there is an external load
of 24525 N and gravity.

Figure 11. Harmonic Analysis-Linear Dynamic

Displacement
This figure shows a frequency of 277.462 Figure 13. Response Graph-Frequency vs.
Hz and a displacement of 261.841 mm if Linear Amplitude
Dynamic Displacement is observed. This figure shows that the maximum
amplitude (261.841) is attained at 277.462 Hz
from node 2.

Figure 12. Harmonic Analysis-Linear Dynamic

Nodal Stress
This figure shows a frequency of 277.604
Hz and a VONDC of 23102.322 MPa if Linear
Dynamic Nodal Stress is observed.

Figure 14. Response Graph-Frequency vs.

Mode No.
This figure shows that the frequency is
gradually increasing from mode 1 to mode 5. The
minimum and maximum frequency of 278.58 Hz
and 2302.7, respectively.
VI.
Figure 15. Response Graph-Frequency vs.
Stress
This figure shows that the maximum Von
Mises Directional Component Stress (23102.322
MPa) is attained at 277.604 Hz from node 1.
3 which is 10.570; Mode 4 that is 10.972; and
Mode 5 composed of 7.535; and the lowest
frequency is 278.58 Hz and the highest is
2302.7 Hz. The value of the highest
frequency obtained in the harmonic analysis
is 2310 Hz.
Conclusion
The project carried out by as will
make impressing mark in the field of small-
scale industries. It is very usefully for the
workshop to carry out the punching
operations easily on our machine. Therefore,
the students learned how to design and to
determine the metal punching machines’
static, modal, and harmonic reaction using
the SOLIDWORKS application. It can also
calculate the frequencies, amplitude, stress,
strain, and displacement of our mechanism.
Based on the results gathered in the
simulation of the machine, the use of alloy
steel is good for punching a metal sheet and
it is recommended by the students as the
material for metal punching machine because
it cannot be destroyed by the vibration easily.

V. Results and Discussion

VII. References
Students emulate through different
conditions using 3 different analyzes for the
Punching Machine. Static analysis, Modal
Analysis and Harmonic Analysis are the three
analyzes. The stresses and deformation are
measured by static analysis. This consists of
a series of amplitudes in modal analysis,
showing different free vibrations that give a
frequency value. Finally, the harmonic
analysis analyzes a structure's steady state
behavior under cyclic loads.
It shows that the maximum
displacement is 35.398 mm in static analysis,
the maximum strain is 2.460 N-m and the
maximum Von Mises Stress is 2267.936 MPa
with a yield strength of 620.422 MPa. The 5
amplitudes in modal analysis are: Mode 1
which is in 6.690; Mode 2 that is 6.684; Mode