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PRESSING PROCESSES
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Pressing process
Definition of pressing process
It is the process by which the sheet metal is pressed
(pierced, blanked, bent, formed) to get the required shape
and size
2 WHEELER FRAME
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Why Sheet metal & Pressing process
Ease of manufacture & less
process complexity
Thin sections can be
produced as low as 0.2mm
High productivity.
Cost effective.
Can be easily fabricated by
using joining technology.
Superior strength and good
aesthetics if painted / plated/
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Types of Pressing operation
Cutting operation
(Normally a chip less operation)
1.Shearing 8.Perforating
2.Blanking 9.Dinking
3.Piercing 10.Shaving
4.Notching 11.Fine blanking
5.Trimming 12.Lancing
6.Parting off 13.Louvering
7.Cutting off 14.Broaching
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Types of Pressing operation
Forming operation
15.Bending 23.Swaging
16.Forming 24.Seaming
17.Flanging 25.Hemming
18.Embossing 26.Planishing
19.Flaring 27.Extrusion
20.Collar drawing 28.Coining
21.Curling 29.Rolling
22.Bulging 30.Drawing
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CUTTING OPERATIONS
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Shearing
It is a method of cutting sheets or stocks without forming
chips
The material is stressed in a section which lies parallel to
the forces applied by SLITTING or SHEARING blades
SHEARING
SLITTING
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Shearing
Normal cutting Blanking
(Shearing)
Chips
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Blanking
• Blanking is a process producing flat stampings.
• The entire periphery is cut and the cut-out by a single
punch & die
• The cut out piece is a blank or stamping.
• The tool used is called as blanking tool
Blanking
punch
Punch
Sheet
Scrap
Die
Output
product
Blanking
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Piercing
• Piercing is a process of making hole in the stamping.
• Entire periphery is cut-out by a single punch & die
• The cutout piece (Slug) is a waste. The tool used is called
piercing tool
Process - 1 Process - 2
Piercing Piercing operation Blanking operation
punch
Blanking
punch
Input
raw material
Scrap
Required
Scrap part
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Notching
This operation removes a small amount of material from the
edges of the strip or a blank.
Notching serves to shape
the outer contours of the
work piece in a progressive
tool or to remove excess metal
before a drawing or forming
operation in a progressive tool
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Notching examples
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Trimming
It is a shearing operation which
removes the excess unwanted material
from a drawn part.
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Trimming
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Parting off
• The parting off operation separates the work material
along a straight line in a double line cut.
• The piece removed by the punch is scrap.
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Parting off
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Cutting off
A cut off operation separates
the work material in a single
cut line.
No scrap is produced in cutting
off operation. The process of
cutting off is similar to shearing
in a shearing machine.
Cutoff lines may be straight,
curved, or jagged.
Why cutting off operation ?
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Cutting off
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Cutting off
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Typical parting off die
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Comparison
Cutting off Parting off
Slug
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Typical cutting off die
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Perforating
Similar to piercing operation carried-out
on full width of sheets or parts with rows
of punches and dies arranged in a line
or in a staggered / profiled manner
Various types of
perforated sheets
Perforated
paper(Stamps)
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Perforating
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Nibbling
Punching a series of small overlapping slits or holes along a
path to cutout a larger contoured shape.
This eliminates the need for a custom punch and die but will
require secondary operations to improve the accuracy and
finish of the feature
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Dinking
Dinking
Punch
Sheet metal
Bottom support
(Soft material)
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Dinking
It can be used to cut-out parts of various shapes
from soft materials
Dinking tool
Material to be cut
Soft support
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Dinking application
Shaving
Shaving finishes a previously cut edge by shearing off a
small amount from the previovs cut edge.
finish (smoothness).
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Shaving
From Die-roll side (in progressive tools)
Before After
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Shaving
From Burr side (In Stage tools)
(a)
Before
Fracture
cross-section Burr
Cut band
Radius
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Nest/locator
Die
Shaved part
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Fine Blanking
After a typical blanking
operation, the edge of the blank
has two distinct portions. The
smooth portion and the rough
portion
The rougher portion, flatness,
edge squareness and edge
condition are undesirable for
parts having like gear teeth, cam
faces, drive chains etc.
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Fine Blanking
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What is Fine Blanking?
In Fine blanking, a ‘V’-ring(2)
compresses the metal while
the punch(3) shears the metal
against a counter-pressure (4)
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Lancing
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Louvering
Louvering is an operation
involving shearing and
forming in a single stroke
No scrap is generated in
this process
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Louvering
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Broaching
A cutting operation carried-out on presses to create keys
/ key ways or splines using Broaches.
Broached parts
Broaches
Unlike other press operations broaching creates chips
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Broaching
Types of Broaching machines
Vertical Horizontal
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Broaching done on Arbor Press
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Broaching
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Broaching
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FORMING OPERATIONS
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Bending
It is the deforming of metal in
a straight line with very little
change in thickness.
Bending
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16) Forming
It is similar to bending
except the line of bend
is along the curved axis
instead of a straight line.
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Flanging
It is an operation that
creates a 90° bend
A flange can be straight or
curved.
A stretch flange bends
inward, and a shrink flange
bulges out.
Why Flanging operation ?
It strengthens edge of the
part
Fuel tank inner
Also facilitate location/guide
for next assembly parts
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Embossing
Embossing compresses
sheet metal against a
patterned die in order to
create a raised surface
In embossing the upper and
lower die shapes match
No thickness variation in
part
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Embossing
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Flaring or Lugging
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Collar Drawing
• Flanging or collar drawing is a process in which a collar
is formed so that more number of threads can be
provided.
• The collar wall can also be used for as rivet when two
sheets are to be fastened together.
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Collar Drawing
C draw.
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Curling or Beading
A common operation used to shape
the rim is curling.
Curling turns the edge of the rim on
itself.
The curling process may take two or
more steps to create the final curved Fender part
edge.
Why Curling operation ?
It adds stiffness at the edge and
Curling
improves the appearance of the part
and for safe handling.
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Curling
Curling and coiling-up is done by the pressure of the
punch face with a semi-round recess.
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Swaging or Necking
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Swaging or Necking
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Seaming
Seaming joins the edges of
sheets of metal together by
folding them over one another
A seam is essentially two
interlocking hemming
operations.
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Hemming
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Hemming
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Planishing
Usually a blanked part is slightly cup
shaped
It is used to straighten the blanked
component.
Very fine serration points penetrate
on top and bottom of the part.
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Planishing
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Extrusion
A process used to manufacture pipes or profiles out of
steel or aluminum.
Extrusion
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Extrusion
A compression forming process in which the work metal
is forced to flow through a die opening to produce a
desired cross-sectional shape.
Continuous extrusion
Forward extrusion
Backward extrusion
Combined extrusion
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Extrusion
Extrusion
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Coining
To create different
impressions on the faces of the
part
Coining
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Rolling
It is a pressing operation .
The metal sheet is deformed
continuously in a linear manner
by passing it through a
consecutive series of rolls.
The rolls with predetermined
profile produce the shape.
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• Diameter of roll is gradually increasing
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Drawing
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Two methods for drawing operations
Simple Drawing
Deep drawing
Simple Drawing
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Deep Drawing
Deep drawing is a process of cold forming a flat precut
blank into a hollow vessel.
Various forms can be produced.
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31 Ironing
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Exercise
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1. Identify the operations performed
3
2
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2
Pin planishing
3
Notching
4 Bending
1 Piercing
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2. Identify the operations performed
2
1 3
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Flanging 2 Trimming
Embossing 3
1
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3. Identify the operations performed
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Flanging 1
2
Forming
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