The press tool design process is a crucial aspect that every sheet metal dies manufacturer must consider. It decides the quality of metal stamped parts. It determines the shape, cut, and required force on the metal sheet to get the desired result.
The design process decides the configuration of the tool and the press die. A press tool is inbuilt into a pressing machine that does the job of cutting and reforming a metal part from a metal sheet. A press die is a die set that makes an impression on the metal sheet to form the desired metal part.
An optimally designed press tool accounts for metal sheet processes that offer two main benefits-
- High productivity rate
- High accuracy rate
This article describes different types of press tools and operations along with design considerations.
Types of press tools
Sheet metal dies manufacturer may use any of the following types of press tools depending the geometry requirements of the metal part.
- Simple tool
.Simple press tool performs simple sheet metal processes such as piercing and blanking operations.
2. Combination tool:
The combination tool performs a combination of forming and cutting operations in a single stroke.
3. Progressive tool :
The progressive press tool performs a set of metal sheet processes that includes multiple cutting and forming operations.
4. Bending tool:
The bending tool performs two operations V bending or U bending to bend a metal sheet into the desired shape.
5. Drawing tool:
The drawing tool uses axial force for axial elongation of the metal sheet.
Types of Sheet Metal Stamping Processes
The sheet metal process is classified into two categories:
- Metal Forming operation
Here the force is used on the metal sheet to transform it into various shapes. Examples include:
- Bending
- Flanging
- Drawing
- Stretching
- Coining
- Ironing
2. Metal cutting operation
Here the metal is cut out from the metal sheets to match the design requirements. Examples are:
- Shearing
- Blanking
- Trimming
- Notching
- Piercing
Design Considerations- Press tool design for Sheet Metal Process
For optimum results,sheet metal dies manufacturer consider following factors during the design process for sheet metal stamping:
- Dimensions of the end product
- Power requirement
- Type of operations
- No. of operations
- Overall work size
- Speed of operation.
- Amount of production- Mass or small-batch or huge batch.
- Maintenance costs
- Operational safety
- The durability of the working components
The dimensions and design of the metal parts are the first deciding factors in choosing a progressive die stamping. Next, it should be efficient enough to produce metal stamped products at the required rate and amount. The design should produce accurate results and utilize maximum sheet metal material.
The press tool design should also offer safe operation and easy maintenance. The working components must be strong enough to work for a long period with minimal wear and tear.
The parts of the press tools must be easily replaceable and able to create metal stamped parts of prerequisite tolerances. The dimensional accuracy of press tool parts should be within specified tolerances.
Steps to design any Sheet metal stamping press tool or die.
Step #1:
Calculate the force required to bend or form the metal sheet. This step is referred to as press tonnage.
Step #2:
Select the right kind of press tool. Here the design of the metal part plays a decisive role.
Step#3:
Calculate the shut height of the tool. A shut height is a distance between the top and bottom of the slide. The height is calculated with strike down and adjustment up.
Step#4:
Calculate die thickness.
Step #5:
Calculate die margins for minimum cross-sections.
Step#6:
Create a strip layout and compare material utilization.
Step #7:
Design a layout for the Locate elements
Step #8:
Select a proper hardware drawing die plan- for pillar sets, punch height, etc,
Step #9:
Calculate the center of pressure
Step#10:
Check the amount of scrap and ways to dispose of.
Conclusion
The press tool design is complicated task and requires accurate measurements and alignments. Any deviation in measurement can affect the quality of the metal sheet process. Therefore, the design considerations are important factors in deciding the speed and precision of the metal sheet processes to create precision metal parts.
