Bharati vidyapeeth college of engineering

Department of mechanical engineering

A-y-2023-2024

Title :- PRESS TOOL DESIGN FORSHEET METAL

COMPONENTS
GROUP MEMBER:-
22162010-SHUBHAM SAKPAL (3754)
22162025-AJAY MAHAJAN (3769)
22162026-ARPAN RATHOD (3770)
GUIDE Name :-
Dr A.S. Bhongade
 Content
Introduction
Literature Survey
Problem Statement
Objectives
Applications
Design of components
Future scope
References
BVCOE, DEPARTMENT OF MECHANICAL ENGINEERING
2
TechnoPHILIA'21
Introduction

● Sheet metal process is a manufacturing process used to shape flat sheets of metal into desired
geometries.
● It plays a critical role in various industries, including automotive, aerospace, electronics, and
construction.
● Sheet metal processes include bending, stretching, deep drawing, and stamping, among others.
● This process offers advantages such as high production efficiency, cost-effectiveness, and the ability to
produce complex shapes with tight tolerances.
● Understanding material properties, process parameters, and tooling design is essential for successful
sheet metal operation
Literature survey
Name of the author Year of publication Title of paper Conclusion

Tomasz Trzepieci ´nski 10 June 2020 Recent Developments The main problems observed in SMF
concern processes carried out at elevated
and Trends in Sheet temperatures where high levels of friction
and wear occur due to high adhesion
Metal Forming between the tool surface and the
workpiece and surface fatigue is then
initiated. National and international
regulations have meant that the use of
environmentally friendly lubricants has
become increasing important. At the
same time friction conditions have to be
minimized in order to reduc eloads.An
example of environmentally friendly
technology is hydroforming, which
eliminates metallic contact of the forming
tool with the workpiece.Thus, friction
forces and tool wear are eliminated

For the material constituents, it can

Zerong Ding a, 23 June 2020 A review on forming be observed that the materials for
Hongyan Wang a, technologies of fibre metal layers have been extended
from aluminium alloys to steels,
Jiaming Luo b, metal laminates which allows lower cost thus wider
Nan Li applications in the automotive
industry. Thermoplastics have also
been replacing thermoset polymers
to enable faster production and
better recyclability.
Literature survey
Name of the author Year of publication Title of paper Conclusion

Tushar Y. Badgujar Januaury 2017 A STATE OF ART IN A The prediction and prevention of
wrinkling are extremely important
SHEET METAL in sheet metal forming. As a
STAMPING FORMING concluding remark, it can say
that, though we have sufficient
TECHNOLOGY-AN theoretical data depicts causes of
OVERVIEW a wrinkling defect, the scope for
future study for its practical
elimination is definitely high due
to parameter variations.

Muhammad Arsyad July 2020 Mini Press Tool as Metal forming is often found in several
industries making household appliances,
Suyuti Learning Practical: automotive,manufacturing electronic
components and others ranging from
Designing, small or medium-sized industries.The
mini press tool was produced as a
Manufacturing, and learning medium to help improve
Analysis students' knowledge and skills. The mini
press tool was performed in mechanic
laboratory of mechanical engineering
department, which is divided some stage,
such as designing stage using Autodesk
software,manufacturing the components,
assembling the parts,and analysing the
performance.
Objectives
 - Understand the principles of sheet metal processes.
 - Analyze different types of sheet metal materials and their properties.
 - Investigate various forming techniques such as bending, stretching, and deep drawing.
 - Explore the effects of process parameters on quality and efficiency.
 - Evaluate the use of lubricants and coatings in sheet metal process to reduce friction
and improve surface finish.
 - Investigate the design and optimization of pressure tools for sheet metal processes.
What is sheet metal process ?
● Sheet metal process is a versatile manufacturing process used to transform
flat sheets of metal into a variety of shapes and components.
● It is crucial in numerous industries such as automotive, aerospace,
electronics, and consumer goods manufacturing.
● Sheet metal process enables the production of complex geometries with
high precision and consistency.
● This process offers cost-effective production solutions, making it ideal for
large-scale manufacturing.
● It facilitates the creation of lightweight yet durable components,
contributing to advancements in vehicle fuel efficiency and structural
design.
● Sheet metal forming plays a pivotal role in achieving design innovation,
allowing for the realization of creative and functional product designs.
● Its adaptability to a wide range of metals and alloys makes it suitable for
diverse applications, from everyday household items to critical aerospace
components.
● With continuous advancements in technology and materials, sheet metal
forming remains at the forefront of modern manufacturing, driving
progress and innovation across industries.
Parameters affecting sheet metal process
• Friction and lubrication : Key factor influencing product quality productivity and environmental
performances
• Material Selection : Use of advance high strength steel and aluminum alloy for lightweight
aluminum structures
• Forming Techniques: Utilization of non convential methods such as electromagnetic and electro
hydraulic forming ,hot forming to meet requirements of hugh deformation rates and improved
formability
• Stimulation & analysis : Devlopment of Effecient methods for analyzing operation startergies,
utilizing numerical analysis software for designing tooling and process parameters in virtual
environment
Types of sheet metal process
● Bending: Involves the deformation of a metal sheet along a
straight axis, typically using a press brake or similar
equipment.
● Deep Drawing: Utilizes a punch and die to form a flat sheet
of metal into a three-dimensional shape, often used for
producing cylindrical or box-shaped parts.
● Stretch Forming: Involves stretching a metal sheet over a die
to create complex contours or curves, commonly used in
automotive body panel production.
● Stamping: Utilizes a die and punch to cut or deform metal
sheets into desired shapes, commonly used for mass
production of small to medium-sized parts.
● Roll Forming: Involves passing a metal sheet through a series
of rollers to gradually bend it into a desired cross-sectional
profile, suitable for producing long, continuous shapes.
Applications of Sheet Metal process:
● Automotive Industry: Production of body panels, chassis components, and structural
reinforcements.
● Aerospace Sector: Manufacturing of aircraft fuselages, wings, and engine components.
● Electronics Manufacturing: Fabrication of enclosures, heat sinks, and connectors for electronic
devices.
● Construction Sector: Creation of roofing, cladding, and structural components for buildings.
● Appliance Manufacturing: Production of kitchen appliances, HVAC systems, and white goods.
● Medical Equipment: Fabrication of instrument casings, trays, and equipment enclosures.
● Furniture Industry: Manufacturing of metal furniture frames, brackets, and decorative
elements.
● Renewable Energy Sector: Production of solar panel frames, wind turbine components, and
energy storage enclosures.
DESIGN OF COMPONENTS FOR BLANK DIE SET

1. CIRCULAR PUNCH
2. GUIDE PILLAR
3. BUSH
4. TOP PLATE
5. BOTTOM PLATE
CIRCULAR PUNCH
GUIDE PILLAR
BOTTOM PLATE
TOP PLATE WITH PUNCH
BUSH
References
• Department of Materials Forming and Processing, Rzeszow University of Technology, al. Powst.
Warszawy 8,35-959 Rzeszów, Poland; [email protected]
• International Journal of Lightweight Materials and Manufacture,Zerong Ding a,Hongyan Wang
a, Jiaming Luo b,Nan Li,23 June 2020
• JOURNAL INDUSTRIAL ENGINEERING & MANAGEMENT RESEARCH
( JIEMAR)Muhammad Arsyad Suyuti , July 2020
• A STATE OF ART IN A SHEET METAL STAMPING FORMING TECHNOLOGY-
ANOVERVIEW,Tushar Y. Badgujar, January 2017
• International Journal of Engineering Research & Technology (IJERT) Study and Analysis of
Press Tool Design, Gaurav C. Rathod, Dr. D. N. Raut, Samadhan Adlinge , July - 2017