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Energy. Remember that to size a press, you must do calculations for both tonnage and because you can have
enough tonnage but not enough energy. Insufficient energy is a
cause of press jams at bottom dead center (BDC).
To get an accurate calculation, you must convert all of the values to the same unit
pounds, and tons). This prepares the data for the second calculation: the required e
Metal Properties. You must know the coil material properties—shear strength and tensile strength square inch (PSI),
the material thickness in inches. When getting into high-speed, h
calculations, the ultimate tensile strength must be known.
Progression Layout. With a part that has 15 or more progressions, I recommend that you have strip layout on paper
that you can color-code and mark the loads at each station. The not missed anything that will create an additional
load. The strip layout also helps you to calculate in the press, which enables you to balance the loads for both the
press and die. Doiper regrind, as well as maximum die life for optimal part quality.
To calculate the balance of the die to the press, you have to take moments about the
die at each station. This will indicate the die's out-of-balance condition. Then, by repositioning the with the press's
centerline, you can improve the die-to-press balance.
It is not uncommon for this to require several pages of calculations and several how
In most press shops I visit, it is a common practice to position the die as close as possible to the incorrect. More often
than not, you can obtain a better press and die balance, as we
the die away from the feed.
Formula for Calculating Blanking and Piercing Tonnage (flat sheet)
Perimeter (in.) X Material Thickness (in.)* X Shear Strength (tons) = Required Tonnage
* This formula factors in the full material thickness to compensate for dull and worn punch and dies. However,
shearing actually takes place partway through the material; therefore, material shear distance is really only a
percentage of the total material thickness. If the punch and die are kept sharp, then the total required tonnage can
be reduced by multiplying by that percentage.
(Material shear distance is the distance from where the punch compresses the material to the point of fracture.
This is visible on the edge of any stamped part).
Loads can be reduced further by putting shear on the punches up to full material thickness or steeping the punches.
But this has to be done in a scientific manner, not by guesswork.
The calculation for drawing is similar to that used for blanking except the ultimate tensile strength of the coil
material is used because the sides of the shell or cup are in tension during the drawing operation.