Internship Report REVISED 1

VISVESVARAYA TECHNOLOGICAL UNIVERSITY
JNANASANGAMA, BELAGAVI - 590018
Internship Report (14ME002)
On
PRESS TOOLS AND TOOL DEVELOPMENT
Submitted in partial fulfillment for the award of degree of
B.E Degree in Mechanical Engineering
Submitted by
ABDUL MUIEEZ
(USN: 1BO14ME002)
VIII SEMESTER, 2018-19
Internship Carried Out
At
M/S PEENYA FINE COMPONENT Pvt. Ltd.,

# 47-55/9-13, Raghavendra Industrial Estate, Tigalarapalya Main Road, Near Peenya II Stage , Bangalore
– 560058, India
DEPARTMENT OF MECHANICAL ENGINEERING

BRINDAVAN COLLEGE OF ENGINEERING, BANGALORE-560063
JUNE – 2019
BRINDAVAN COLLEGE OF ENGINEERING, BANGALORE-
560063
JUNE – 2019
COLLEGE CERTIFICATE
This is to certify that this internship report titled “ Press Tools and Tool
Development” carried out by ABDUL MUIEEZ bearing USN 1BO14ME002, a
bonafide student of BRINDAVAN College of Engineering, in partial fulfillment for
the award of B.E Degree in Mechanical Engineering of the Visvesvaraya
Technological University, Belagavi during the year 2018-19 is a genuine curriculum
program.
It is certified that all the corrections / suggestions indicated before the assessment
and evaluation have been incorporated by the intern in this internship report. The
internship report has been approved as it satisfies the academic requirements
prescribed by the relevant VTU notifications and institute for the award of B.E
degree.
_____________ _________________ _______________

Prof. Tariq Hafeezi Prof. Nayeem Pasha Dr. Nagarajan
Asst. Professor, Internal Guide Professor & H.O.D, Principal
Department of ME Department of ME BCE, Bengaluru
BCE, Bengaluru BCE, Bengaluru
________________ ________________
Internal Examiner External Examiner
BRINDAVAN COLLEGE OF ENGINEERING,
BANGALORE-560063
JUNE – 2019
DECLARATION
I, Abdul Muieez bearing USN No. 1BO14ME002 student of VIII semester,
B.E degree in Mechanical Engineering declare that this internship program
titled “Press Tools and Design of Tool Development” is original work carried
out by me, the undersigned at Peenya Fine Components Pvt. Ltd., after
endorsement and authorization from Brindavan College of Engineering , in
partial fulfillment of the curriculum requirements prescribed by Visvesvaraya
Technological University , Belagavi in the B.E Degree choice based credit
system scheme.
The content in this report is not submitted to any other university partially or
wholly for the award of any other degree.
Abdul Muieez
USN: 1BO14ME002
VIII Sem, B.E
Mechanical Engineering
Date: 25-2-2019
Place: Bengaluru
ACKNOWLEDGEMENT:
First, I would like to thank Mr. ABDUL WAHEED, Chief Executive Officer of
Peenya Fine Comp. for giving me the opportunity to do the internship at the
company. It was a wonderful experience.
My heartfelt gratitude to Mr. FAISAL, head designer and my external guide, for
teaching me the designing and also for being a wonderful guide.
I would also like to thank Mr. Nayeem Pasha, Head of the Department of
Mechanical Branch and Mr. Tariq hafeezi, internal guide and assistant professor at
BCE for accepting my intent of doing the internship at the company.
I would also like to thank the staff and my compadre at the industry for their
patience and openness for creating a wonderful learning experience and further
increasing my interest in tool design and have new plans for my future career.
Contents
ACKNOWLEDGEMENT .............................................................................................................. 4
ABSTRACT .................................................................................................................................... 6
CHAPTER 1 ................................................................................................................................... 7
ABOUT THE COMPANY ....................................................................................................................... 7
CHAPTER 2 ................................................................................................................................... 8
INTRODUCTION: ................................................................................................................................... 8
PRESS TOOL OPERATIONS: ................................................................................................................ 8
CUTTING TOOL OPERATIONS............................................................................................................ 9
NON CUTTING TOOL OPERATIONS: ............................................................................................... 13
CHAPTER 3 ................................................................................................................................. 15
OBSERVATIONS: ................................................................................................................................. 15
MECHANICAL PRESSES .................................................................................................................... 16
HYDRAULIC PRESS ............................................................................................................................ 18
PNEUMATIC PRESSES ........................................................................................................................ 21
CHAPTER 4 ................................................................................................................................. 24
PRESS TOOL CONSTRUCTION: ........................................................................................................ 24
BLANKING TOOL ................................................................................................................................ 26
CHAPTER 5 ................................................................................................................................. 28
SHEARING THEORY: .......................................................................................................................... 28
DESIGN OF WASHER COMPONENT: ............................................................................................... 29
INTERNSHIP REFLECTIONS.................................................................................................... 38
ABSTRACT
This report documents the work done and observed during the 4 week
internship done at Peenya Fine Comp (p) ltd in the department of tool
design.
The report presents the tasks observed and completed by myself under
the supervision of trainers in the industry which includes understanding
the basic knowledge for designing of simple and compound tools,
understanding the working of various sheet metal stamping machines in
the factory, learning the difference between mechanical, hydraulic and
pneumatic machines, knowing the applications of each machines and also
the method to design a simple blanking tool along with all the required
calculations used in the industry.
Press tools and design of blanking tool
CHAPTER 1
ABOUT THE COMPANY
Peenya Fine Comp is one of the most respected and relied upon sheet metal
stamping company in South India for more than 25 years, catering directly to the
assembly lines of global Tier 1 corporations such as Whirlpool of India Ltd.,
Automotive Axles Ltd. & Avtec Ltd. to name a few. They are committed in the
quality and they are a certified ISO 9001-2008 company.
With a growing number of young minds at work with some of the most
experienced practitioners in the sheet-metal and automotive industry, Peenya Fine
Comp is a company that commits to deliver what it espouses.
Their mission statement is “raising the bar”, and the company ensures it is doing
so with the quality of their output. Supplying sheet metal stamped parts across the
global customers is the company’s vision.
COMPANY’S CLIENTS:
Page 7
CHAPTER 2
INTRODUCTION:
Almost all the processes happening in this company is sheet metal
pressing/stamping. So, I happened to come across lots of press tools designed to
produce a variety of components that are then supplied to their clients.
Press tools may be defined as a mechanical device used for production of variety
of components in large capacity by applying an external force by the aid of machine
tool called as a press.
The press tools are manufactured based on the idea of mass production, if the
number of pieces/components to be manufactured is below 1000 components this
process might not be the most economical one. Majority of the mechanical industries
manufacture components in mass. The major reason for mass production is to satisfy
the customer requirements, consistency and to effectively reduce the cost of
production.
Press tools are commonly used in hydraulic, pneumatic, and mechanical presses
to produce the sheet metal components in large volumes. Generally press tools are
categorized by the types of operation performed using the tool, such as blanking,
piercing, bending, forming, drawing, trimming etc. The press tool will also be
specified as a blanking tool, piercing tool, bending tool etc based on the types of
operations performed by that tool.
PRESS TOOL OPERATIONS:

Press tool operations can be broadly divided into two categories; one involving
cutting operations and the other involving non cutting operations.
Cutting operations are those which shear the sheet metal into two or more pieces
depending on the design of the die. Examples of cutting operations are blanking,
trimming, piercing etc
Non cutting operations are those which do not cut or separate the sheet metal, instead
the sheet metal is bent or pressed in order to give it a shape. Examples of non cutting
operations are bending, forming and drawing.
Page 8
CUTTING TOOL OPERATIONS

Blanking Tool
• When a component is produced with one single punch and die where the entire
outer profile is cut in a single stroke the tool is called a blanking tool.
• Blanking is the operation of cutting flat shapes from sheet metal.
• The outer area of metal remaining after a blanking operation is generally discarded
as waste.
• Size of blank or product is the size of the die & clearance is given on punch.
• It is a metal cutting operation
Page 9
PIERCING:
Piercing involves cutting of clean holes with a resulting scrap slug*. The operation
is called die cutting and can also produce flat components where the die, the shaped
tool, is pressed into a sheet material employing a shearing action to cut
holes. This method can be used to cut parts of different sizes and shapes in sheet
metal, leather and many other materials. Piercing operation can be carried out before
or after or at the same time of the blanking operation.
Blanking tool and piercing tool are very similar in design.
The main difference between simple variations of these tools is the allotment of
clearance. In blanking operation, clearance is given to the punch. The component
size is equal to that of the die. Here, slug is the desired part. In piercing operation,
Page 10
clearance is given to the die. The component size is equal to the punch. Here, slug is
scrap.
*slug: when the punch passes through the sheet metal strip and the die, the piece cut from the strip is known
as the slag.
Blanking Piercing
Punching or blanking is a process in which the It is a process by which a hole is cut (or torn) in
punch removes a portion of material from the metal. It is different from punching in that
larger piece or a strip of sheet metal. If the small piercing does not generate a slug. Instead, the
removed piece is the useful part and the rest is metal is pushed back to form a jagged flange on
scrap, the operation is called blanking the back side of the hole.
The piece cut out is called as blank and may be A pierced hole looks somewhat like a bullet hole
further processed. Blanks are often cut out of a in a sheet of metal
sheet or strip
Blanking wastes certain amount of material. Size of the component is generally larger in
When designing a sheet metal blanking process piercing than blanking.
the geometry of blanks should be nestled as
efficiently as possible to minimize the material
waste.
Page 11
TRIMMING TOOL:
When cups and shells are drawn from flat sheet metal the edge is left wavy and
irregular, due to uneven flow of metal. This irregular edge is trimmed in a trimming
die. Shown is flanged shell, as well as the trimmed ring removed from around the
edge. While a small amount of Material is removed from the side of a component in
trimming tool.
Page 12
NON CUTTING TOOL OPERATIONS:

BENDING:
Bending tools apply simple bends to stampings. A simple bend is done in which the
line of the bend is straight. One or more bends may be involved, and bending tools
are a large important class of press tools.
FORMING AND DRAWING:
Page 13
Forming tools apply more complex forms to work pieces. The line of bend is curved
instead of straight and the metal is subjected to plastic flow or deformation.
Drawing tools transform flat sheets of metal into cups, shells or other drawn shapes
by subjecting the material to severe plastic deformation.
Shown in fig is a rather deep shell that has been drawn from a flat sheet
Page 14
CHAPTER 3
OBSERVATIONS:
My observations in the industry was limited to tool design, more specifically the
blanking tool design, since the blanking tool is relatively simple in design or you can
say ‘basic’ in terms of learning. So, I spent quite some time learning about the design
of blanking tool in detail. But, before I start with blanking tool, one must understand
the components of any press tool in general.
In the company, all three kinds of presses were used i.e., mechanical presses,
pneumatic presses and hydraulic presses.
Fig. mechanical press
Page 15
A brief overview about these presses is given below:
MECHANICAL PRESSES:
Mechanical presses belong to a class of machine tools that encompass a wide

range of different machine types. Primarily, the mechanical press transforms the
rotational force of a motor into a translational force vector that performs the pressing
action. Therefore, the energy in a mechanical press comes from the motor. These
types of presses are generally faster than hydraulic or screw presses, (actually the
screw press may also be classified as a mechanical press). Unlike some presses, in a
mechanical press, the application of force varies in both speed and magnitude
throughout the distance of the stroke. When performing a manufacturing operation
using a mechanical press, the correct range of the stroke is essential.
Page 16
Page 17
Presses are chosen based on the characteristics of the manufacturing process.

Mechanical press machine tools are commonly used in metal forging manufacture,
and sheet metal working. The desired application of force will dictate the type of
machine required. Extrusion will often necessitate a more consistent force over a
longer distance. However, a mechanical press may often be a good choice for impact
extrusion, since a fast, quickly repeatable application of force over a limited distance
is what is needed for that type of manufacturing process. The most powerful
mechanical presses in modern manufacturing industry will have a press capacity of
about 12,000 tons, (24,000,000 lbs).
 Speed. The speed in which mechanical presses can be ran are higher than
hydraulic presses. This allows for higher production and efficiency.
 Consistency of tonnage at bottom of the stroke. With a mechanical press,
you’re maximum tonnage delivery happens in a smaller window as compared
to a hydraulic press. However, this again helps attribute to the speed at which
mechanical presses can be ran because you know the absolute limit of what
your press will be hitting at the bottom of its stroke.
HYDRAULIC PRESS:
Hydraulic presses are a powerful class of machine tools, they derive the energy
they deliver through hydraulic pressure. Fluid pressure, in a particular chamber, can
be increased or decreased by the use of pumps, and valves. Sometimes devices and
systems may be used to increase the capacity of the pumps in more powerful presses.
These presses can operate over a long distance and at a constant speed. Hydraulic
presses are generally slower relative to other press machine types. This involves
longer contact with the work, therefore the cooling of the work can be an issue when
hot forming a part with hydraulic force. Hydraulic presses are capable of being the
most powerful class of presses. Some may be as large as buildings, and can deliver
awesome pressure. The largest hydraulic presses are capable of applying 75,000
tons, (150,000,000 lbs), of force. The hydraulic press shown is being used to
manufacture a metal forging. Extrusion is also a very common use for such a press,
although extrusion is often performed horizontally.
Page 18
The hydraulic press depends on Pascal's principle-the pressure throughout a

closed system is constant. One part of the system is a piston acting as a pump, with
a modest mechanical force acting on a small cross-sectional area; the other part is a
piston with a larger area which generates a correspondingly large mechanical force.
Only small-diameter tubing (which more easily resists pressure) is needed if the
pump is separated from the press cylinder.
Pascal's law: Pressure on a confined fluid is transmitted undiminished and acts with
equal force on equal areas and at 90 degrees to the container wall.
A small effort force acts on a small piston. This creates a pressure which is
transferred through the hydraulic fluid to a large piston
Press Tool is the process which is used to produce the sheet metal components.
Operations like Blanking, piercing, bending, forming etc. can be performed using
press tool process. The basic operation that is performed using press tool is blanking
and piercing. Both blanking and piercing process includes shearing of the sheet
Page 19
metal, therefore initially the shearing strength of the sheet metal material has to be
determined
Hydraulic press utilities are further increased by the new generation

controls with fluid management. The shorter response time of valve
delivers the oil to the actuator faster, to offer the better efficiency. For
further improving the performance, accumulators are also provided in the
fluid power system for better fluid management. The new generation
controls along with high efficiency hydraulic circuits are the major
factors in improving the hydraulic press performance. Electronically
controlled proportional valves and electronic pressure switches are used
to set or adjust the pressing force during the process. The stroke and
distance can be controlled in microns by a laser dimension control
system. The stroke, force and speed can be electronically controlled,
therefore a PLC in the control panel. All these variables can be set and
stored in a list of menus, which are instantly retrievable, when the job or
process is to be changed.
Leak control management

Today, our presses are being equipped with new generation leak control
management, including system save assemblies, modular concept with
stack-system and Parker new generation EO-2 zero leak fittings.
Hydraulics: The smarter choice

The main reasons why all over the world people are changing from
mechanical to hydraulic presses are :
1. Flexibility of operation
2. Multiple utilities
3. Full tonnage at any point of stroke
4. Ability to operate with a very wide range of stroke like 10 mm to 1500
mm on the same machine.
5. The working stroke can be adjusted at any position throughout the
length.
6. Any desired speeds can be set at any position, and can be simply re -
programmed.
Page 20
7. Different operations can be carried at different pressures simply by

adjusting the PLC command, pressure switch setting or pressure control
valve.
8. Full programmable control over full ram stroke and position is
possible.
9. Better tooling life and better product quality with better looking, crisp,
clean forms and accuracy are achieved with a hydraulic press.
Hydraulic presses are very strong and dependable. They are able to create a large
amount of pressing tonnage. They are ideal for hydroforming, which is a type of
metal shaping involving a liquid agent. They move very slowly, which gives the
metal plenty of time to be thoroughly shaped.
However, hydraulic presses require a lot of maintenance. They must have the oil
inside them that provides the pressure against the baseplate at a particular pressure,
and they have a great deal of other devices that monitor and regulate the oil pressure
to ensure the press works efficiently.
PNEUMATIC PRESSES:
Pneumatic presses are controlled by the manipulation of pressurized air. The air
is forced into a tube which fills with the air and applies pressure that causes the press
to move downwards. Once the press' stroke is finished, the air is evacuated through
valves, and mechanical springs cause the pump to move upwards again.
Page 21
The pneumatic press is finding its way onto shop floors to shoulder workloads
normally reserved for mechanical and hydraulic presses at nearly half the capital
equipment cost. The main advantages of Pneumatic Presses are their speed. It can
carry on ten times swifter than hydraulic presses. Pneumatic baling presses are much
faster than hydraulic baling presses, and that means there are many jobs they can
perform faster and more efficiently.
Page 22
ADVANTAGES OF PNEUMATIC MACHINES:
Like hydraulics, pneumatics is a type of fluid power application where instead of an

incompressible liquid, pneumatics employ gas in their system. Hydraulics present
certain advantages over pneumatics, but in a given application, pneumatic powered
equipment is more suitable, particularly in industries where the factory units are
plumbed for compressed air.
The air used in pneumatic devices is dried and free from moisture so that it does not
create any problem to the internal parts of the system. Moreover, to avoid corrosive
actions, oil or lubricants are added so that friction effects can be reduced.
Compressed air is used in most of the machines and in some cases compressed
carbon dioxide is used. As most of the pneumatic devices are air based, they have a
less complicated design and can be made of inexpensive material. Mass production
techniques can be adopted to produce pneumatic systems, which not only save
money but save time too.
Other major advantages are listed below.
1. Initial cost is less; hydraulics equipment cost as much as twice the price of
pneumatic equipment.
2. A pneumatic water treatment automation system reduces the costs of
installation and operation compared with conventional electrical installations.
For opening and closing of underwater valves, pneumatic systems work well
because they can sustain overload pressure conditions.
3. Pneumatic actuators also have long life and perform well with negligible
maintenance requirement throughout their life cycle.
4. Very suitable for power transmission when distance of transmission is more.
Page 23
Pneumatic presses' greatest advantage is their speed. They can move ten times
faster than hydraulic presses. They can also stop at any time that the operator opens
the valves to release the air. Pneumatic presses are extremely versatile, able to be
placed on a factory in any position in which the operator requires it to be, even upside
down. Pneumatic presses are very easy to use, and the controls resemble those of
more traditional styles of press.
Pneumatic presses also have very few moving parts, making them very low-
maintenance. They have no fluid inside them, eliminating the fear of leakage. Very
few of the parts even require oiling. The air tubes in a pneumatic press can last up to
five years without being replaced, making pneumatic presses durable and
dependable.
The major disadvantage of pneumatic systems is that they cannot be employed

for tasks that require working under high pressures. However, modern technology is
working on finding better solutions to this address this problem so that heavy
engineering tasks can be executed using pneumatic devices. In a nutshell, in order
to execute low scale engineering and mechanical tasks, pneumatic devices would be
the best suited and a viable alternative over hydraulic systems.
CHAPTER 4
PRESS TOOL CONSTRUCTION:
The complete die set consists of a punch, die and some other accessories which
are described in this section later. Perfect alignment of punch and die is most
important for satisfactory working of punch. Accessories of die set provide the
required alignment and rigidity to the system and improve accuracy of the system
performance.
Page 24
The general press tool construction will have following elements:
• Shank: It is used to locate the press tool in press for alignment purpose.
• Top Plate: It is used to hold top half of the press tool with press slide.
• Punch Back Plate: This plate prevents the hardened punches penetrating into top
plate.
• Punch Holder: This plate is used to accommodate the punches of press tool.
• Punches: To perform cutting and not cutting operations either plain or profiled
punches are used.
• Die Plate: Die plate will have similar profile of the component where cutting dies
usually have holes with land and angular clearance and non cutting dies will have
profiles.
• Die Back Plate: This plate prevents the hardened Die inserts penetrating into
bottom plate.
Page 25
• Guide Pillar & Guide Bush: Used for alignment between top and bottom halves of
the press tools.
• Bottom plate: It is used to hold bottom half of the press tool with press slide.
• Stripper plate: it is used to strip off the component from punches.
• Strip guides: It is used to guide the strip into the press tool to perform the operation
These were the parts or components of a general press tool. Now let’s see in detail
the components of a blanking tool in detail.
BLANKING TOOL:
Fig. blanking die
Blanking is the shearing operation in which the sheet metal is squeezed between
a punch and die as shown in fig.1. Due to the high cutting force of punch the desired
Page 26
profile of the sheet metal gets separated from the strip. The separated portion of sheet
metal is called Blank.
But before we start the design, there’s one more aspect of any pressing or stamping
process to be known, that is, the shearing theory.
Page 27
CHAPTER 5
SHEARING THEORY:
Cutting processes are those in which a piece of sheet metal is separated by applying
a great enough force to caused the material to fail. The most common cutting
processes are performed by applying a shearing force, and are therefore sometimes
referred to as shearing processes. When a great enough shearing force is applied, the
shear stress in the material will exceed the ultimate shear strength and the material
will fail and separate at the cut location. This shearing force is applied by two tools,
one above and one below the sheet. Whether these tools are a punch and die or upper
and lower blades, the tool above the sheet delivers a quick downward blow to the
sheet metal that rests over the lower tool. A small clearance is present between the
edges of the upper and lower tools, which facilitates the fracture of the material. The
size of this clearance is typically 2-10% of the material thickness and depends upon
several factors, such as the specific shearing process, material, and sheet thickness.
The effects of shearing on the material change as the cut progresses and are visible
on the edge of the sheared material. When the punch or blade impacts the sheet, the
clearance between the tools allows the sheet to plastically deform and "rollover" the
edge. As the tool penetrates the sheet further, the shearing results in a vertical
burnished zone of material. Finally, the shear stress is too great and the material
fractures at an angle with a small burr formed at the edge. The height of each of these
portions of the cut depends on several factors, including the sharpness of the tools
and the clearance between the tools.
Page 28
DESIGN OF WASHER COMPONENT:

A washer is a thin plate (typically disk-shaped) with a hole (typically in the middle)
that is normally used to distribute the load of a threaded fastener, such as
a bolt or nut.
Designing the washer component is fairly simple, but designing the tool that would
manufacture this washer is quite a task. Once designing the tool is complete, then
the tool produced can manufacture thousands of same components a day.
To design the tool, we need to know the material with which the component is to be
made and also its properties like the young’s modulus, shear strength etc.
Now, let’s look at the parameters we need to find:
Page 29
• shear force required to blank and pierce
• clearance
• size of punch and die
• dimensions of strip or strip layout
Following is a problem I was given to solve
Component: Washer
Material: mild steel (st 37-2, DIN 17100)
Outer diameter: 40 mm
Inner diameter: 8mm
Thickness: 2mm
The washer component can be manufactured in two ways:
First one is by using compound tool- this is the ideal way to manufacture this
component because the piercing and blanking operation can be done with a single
stroke or press. This presents the advantages of low time consumption and higher
accuracy.
Page 30
Second method is by using a progressive tool- this method takes quite some time
because the blanking and piercing operations are performed individually taking one
stroke for one operation. This consumes time and also has lower accuracy.
The material used is mild steel of grade or standard st 37-2 or DIN 17100. It is
Chemical C≤ 16mm C>16mm Si Mn P S

elements max max max max max. max.
%,by mass 0.17 0.17 -- 1.40 0.045 0.045

important to know the properties of this grade. The following table shows its
properties
DIN 17100 St 37-2 steel equivalent grade:

St 37-2 steel plate/sheet is in DIN 17100 standard, the material number is 1.0037.
The equivalent grade of St 37-2 steel are EN 10025 EN 10025, NFA 35-501 E 24-
2, UNI 7070 Fe 360 B, BS 4360 40 A, ASTM A 283 C - A 570 Gr. 33.
Comparison of steel grades
EN 10025 S235JR
St 37-2
NFA 35-501 E 24-2
DIN 17100 UNI 7070 Fe 360 B
Material #:1.0037 BS 4360 40 A
ASTM A 283 C - A 570 Gr. 33
DIN 17100 St 37-2 steel chemical composition %:

Main chemical composition in DIN 17100 St 37-2 steel is carton max 0.17,
manganese max 1.40, phosphorus max 0.045, sulphur max 0.045. More detailed
information about DIN 17100 St 37-2 steel, please refer to the down table:
DIN 17100 St 37-2 steel mechanical property:

St37-2 steel plate is one mainly of Carbon steel, St37-2 is a type of steel sheet under
EN standard which is used to build ship, bridge, belongs to high strength sheet.
Yield Fracture Notch Impact
thickness StrengthReH[N/mm2] TensileStrengthRm[N/mm2]transv. Elongation[%]transv. Energy1)Ch
transv.min. min. Vcomplete
Page 31
samplelongitud.
min [J]
t ≤ 16mm 235
t > 16mm 225
t < 3mm 360-510
t ≥ 3mm 340-470
Up to
1.5mm
Degree: 0
1.51- 16
AV: 27J
2.00mm 17
2.01- 18
2.50mm 19
2.51- 24
2.99mm
≥ 3mm
Page 32
As it is a compound tool, usually a single row strip layout is the most economic
layout.
t= 2mm
A=0.75t
=0.75X2 = 1.5mm
Width of strip= maximum length of component+ scrap allowance (both sides)
= 40+2(0.75 X t)
= 40+2(0.75 X 2)
= 43mm
Pitch = maximum width of component + scrap allowance
= 40+0.75t
= 41.5mm
Page 33
CALCULATION OF SHEAR FORCE / CUTTING FORCE
Shear force, Fs = shear area X thickness X shear stress
For blanking operation,
Fs = π X D X t X S
Where, S = shear stress = 210 N/mm^2
Fs = π x 40 x 2 x 210
= 52778.756 N
For piercing operation,
Fs = π x d x t x S
= π x 8 x 2 x 210
= 10555.75 N
Total operational force = blanking shear force + piercing shear force
= (52778.756 + 10555.75) N
= 63334.5 N
Stripping force = 10%-20% of total operational force
= 0.2 x 63334.5 N
= 12666.9 N
Total shear force = total operational force + stripping force
Page 34
= (63334.5 + 12666.9) N
= 76001.4 N
SELECTION OF PRESS
𝑡𝑜𝑡𝑎𝑙 𝑠ℎ𝑒𝑎𝑟 𝑓𝑜𝑟𝑐𝑒
Press capacity / press tonnage =
0.7
0.7 is taken because efficiency is considered to be 70%

76001.4
=
0.7
= 108573.43 N
≈ 11.067 tonnes
The standard tonnage press available is 16 tonnes.
Hence, the press tonnage is taken as 16 tonnes.
SIZE OF DIE AND PUNCH
Clearance, c = 0.0032 x t x √S
= 0.0032 x 2 x √210
= 0.093mm (can be approximated to 0.1 mm)
Design of piercing punch
Size of punch = max diameter = 8mm
Size of die = max diameter + 2 x clearance
= 8 + 2 x 0.1 mm
= 8.2 mm
Page 35
Design of blanking punch
Size of punch = max diameter – 2 x clearance
= 40 – 2 x 0.1 mm
= 39.8mm
Size of die = max diameter
= 40 mm
Also, the size of the die required to resist the pressing force of the press is given by
Thickness of die = press tonnage^⅓
= cube root of 16000
= 25.198 mm
= 26 mm
Top plate thickness = 1.25 x Td
= 1.25 x 26 mm
Page 36
= 32.5 mm
Bottom plate thickness = 1.5 x Td
= 1.5 x 26 mm
= 39 mm
These are the main calculations required for making a tool die set.
Therefore,
Pressing machine capacity required = 16 tonnes
Clearance between die and punch = 0.1 mm
Thickness of die = 26 mm
Thickness of top plate = 32.5 mm
Thickness of bottom plate = 39 mm
These are the minimum requirements for designing the die.
Page 37
INTERNSHIP REFLECTIONS:
This internship proved to be a success for me in reasons more than one. My

interests in this area of engineering grew day after day and I’ll not be lying if I said
I would study further in this field. My communications, morale and knowledge
improved considerably.
During my time in the industry, I was fortunate enough to experience working of

these machines first hand and learn many different aspects that goes in during a
project or product manufacturing process. Another valuable lesson I learned is that
the mathematics done during the calculations of tool is not always put as it is into
the work. Instead the tools are designed sometimes by changing the variables by
experience.
The first week of the internship, I was going around the industry looking at all
the pressing machines at work. The interest in those machines only grew after
knowing the process explanation. The only complaint I had was the noise the
machines made while stamping process, but it’s not something that could be helped
as it was the bound to be in any sheet metal stamping industry. The last two weeks
Page 38
were spent only on the blanking tool design. The learning process here was
interesting and peaceful.
Overall, my experience at Peenya Fine Comp. was positive and I’m very happy
with the amount of things that I have learned during this month long internship.
OUTCOMES FROM THE INTERNSHIP
TECHNICAL OUTCOMES:
1. Understanding working of pressing tools.

2. Understanding the different kinds of pressing machines and learning the
advantages and disadvantages of each.
3. Learning the shearing theory to help understand the principle of cutting dies.
4. Learning the basics of designing blanking tool.
5. Application of academic knowledge in industrial works.
NON TECHNICAL OUTCOMES:
1. This internship helped me enhance my communication skills.

2. Develop time management skills.
3. Improved my writing ability.
Page 39
4. Understand the interactions between different departments and also between

workers and managers.
5. Learning to work in a group to achieve a common goal.
Page 40

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VISVESVARAYA TECHNOLOGICAL UNIVERSITY

JNANASANGAMA, BELAGAVI - 590018

Internship Report (14ME002)

Submitted in partial fulfillment for the award of degree of

B.E Degree in Mechanical Engineering

M/S PEENYA FINE COMPONENT Pvt. Ltd.,

DEPARTMENT OF MECHANICAL ENGINEERING

_____________ _________________ _______________

PRESS TOOL OPERATIONS:

CUTTING TOOL OPERATIONS

Blanking tool and piercing tool are very similar in design.

NON CUTTING TOOL OPERATIONS:

FORMING AND DRAWING:

Fig. mechanical press

A brief overview about these presses is given below:

Mechanical presses belong to a class of machine tools that encompass a wide

Presses are chosen based on the characteristics of the manufacturing process.

The hydraulic press depends on Pascal's principle-the pressure throughout a

Hydraulic press utilities are further increased by the new generation

Leak control management

Hydraulics: The smarter choice

7. Different operations can be carried at different pressures simply by

ADVANTAGES OF PNEUMATIC MACHINES:

Like hydraulics, pneumatics is a type of fluid power application where instead of an

Other major advantages are listed below.

The major disadvantage of pneumatic systems is that they cannot be employed

The general press tool construction will have following elements:

• Stripper plate: it is used to strip off the component from punches.

Fig. blanking die

DESIGN OF WASHER COMPONENT:

Now, let’s look at the parameters we need to find:

• shear force required to blank and pierce

• size of punch and die

• dimensions of strip or strip layout

Following is a problem I was given to solve

Material: mild steel (st 37-2, DIN 17100)

Inner diameter: 8mm

The washer component can be manufactured in two ways:

Chemical C≤ 16mm C>16mm Si Mn P S

%,by mass 0.17 0.17 -- 1.40 0.045 0.045

DIN 17100 St 37-2 steel equivalent grade:

DIN 17100 St 37-2 steel chemical composition %:

DIN 17100 St 37-2 steel mechanical property:

Width of strip= maximum length of component+ scrap allowance (both sides)

Pitch = maximum width of component + scrap allowance

CALCULATION OF SHEAR FORCE / CUTTING FORCE

Shear force, Fs = shear area X thickness X shear stress

For blanking operation,

Where, S = shear stress = 210 N/mm^2

For piercing operation,

Total operational force = blanking shear force + piercing shear force

Stripping force = 10%-20% of total operational force

Total shear force = total operational force + stripping force

0.7 is taken because efficiency is considered to be 70%

The standard tonnage press available is 16 tonnes.

Hence, the press tonnage is taken as 16 tonnes.

SIZE OF DIE AND PUNCH

= 0.093mm (can be approximated to 0.1 mm)

Design of piercing punch

Size of punch = max diameter = 8mm

Size of die = max diameter + 2 x clearance

Design of blanking punch

_____ _ _______