Press Tool Design (Blanking Die)

This article is a step-by-step guide to designing a press tool ( a blanking die). Press Tool is also called a Stamping Die. We shall design the Stamping Die for the “Power Screw Support Bracket” of a “Car Scissor Jack.” We shall be designing the Stamping Die for the “Blanking” process. In this article, I shall provide all the design calculations like

  • The Force Calculations
  • The Tonnage Calculations
  • The Thickness Calculations
  • The Spring Calculations

Before we start, let’s understand why we should learn Press Tool Design.



Why should Mechanical Engineers Learn Press Tool Design?

Press Tool Design or Stamping die design is related to manufacturing processes and manufacturing tooling. A mechanical engineer with knowledge of manufacturing processes and manufacturing tooling can for sure become a tool designer. He or she can also become a better product designer. This can be a mini project for mechanical engineering students.


1) The objective of this mini-project

This mini-project aims to design Blanking Die for the “Power Screw Support Bracket” of a “Car Scissor Jack.”

About the Press & Press Tool

1.1) Press:

A Press is a Machine that provides the Force necessary to cut/form the sheet metal workpiece.

1.2) Press Tool:

A “Press Tool” is a “Tool,” which cuts or forms the sheet metal workpiece. “Press Tool” is also called “Stamping Die.” Press Tool is used predominantly in the automotive industry.


2) About Blanking

Blanking is a shearing operation performed on sheet metal. The Blank (Useful Product) is sheared from the Raw Material (Sheet Metal Strip)

2.1) Cutting Clearance

Cutting Clearance: The space/gap between the Punch’s cutting edge and the cutting edge of the die. Proper clearance is very much essential for the shearing to happen.

Cutting Clearance for Blanking (6% to 8% of sheet metal thickness)
Precision Blanking = 6% of sheet metal thickness
Ordinary Blanking = 8% of sheet metal thickness

3) The Design Process

Below mentioned flow chart depicts the design process to design the Blanking Die (Press Tool)


4) Design of Blanking Die (Press Tool)

4.1) Understand Requirements

Below mentioned drawing depicts the part drawing for which the Blanking die (press tool) is designed.

4.1.1) The Part Material

As per the part drawing, the part material is LOW CARBON HIGH STRENGTH COLD ROLLED STEEL AS PER IS 14491 of GRADE: 260Y
As per IS 14491, for LOW CARBON HIGH STRENGTH COLD ROLLED STEEL AS PER IS 14491 of GRADE: 260Y

σy = 260 N/mm2
σt = 350 N/mm2

4.1.2) The Part Material Thickness

As per the part drawing, the part material thickness is 3.15mm.


4.2) Concept Design (Strip Layout Design)

Below mentioned flow chart depicts the design process to design the Strip Layout.

4.2.1) Check Material Availability

Of all the sizes available with the material supplier, below mentioned raw material size is selected.
Length = 2500mm
Width = 1000mm

The Raw material can be slit along its Length or its Width.

Slit along Length Slit Along Width

Slit along Length Slit Along Width

4.2.2) Calculate Punch & Die Dimensions

Calculations – Cutting Clearance, Punch Shape & Die Shape

Cutting Clearance (Considering Ordinary Blanking) = 8% of sheet metal thickness
= 8% x 3.15 mm
= 0.252 mm

Die Opening Dimension = Component Dimension
= 62.5mm x 24mm

Punch Shape Dimension = Component Dimension – (2 * Cutting Clearance)
= (62.5 – (2 x 0.252)) mm x (24 – (2 x 0.252)) mm
= 61.996 mm x 23.496 mm

4.2.3. Calculate the Bridge Dimensions

Feed Bridge is a function of the length of the component.

Length of the Component, mmFeed Bridge, mmMinimum Feed Bridge, mm
L ≤ 50t1.6
51 ≤ L ≤ 1501.25 t2.4
151 ≤ L ≤ 2501.5 t3.2
251 ≤ L ≤ 4001.75 t4.8
Calculations – Feed Bridge & Edge Bridge

Feed Bridge = 1.25 * t
= 1.25 * 3.15
= 3.9375 mm

Edge Bridge = 1.2 * 3.9375
= 4.725 mm

Illustration of Feed Bridge Dimensions – Slit along Length

Illustration of Feed Bridge Dimensions – Slit along Width

Illustration of Feed Edge Dimensions – Slit along Length

Illustration of Feed Edge Dimensions – Slit along Width


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