Useful online formula for press tool design

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Online Formula for press Tool Design

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1. Cutting force 2. Stripping force 3. Flat blank length 4. Correction factor for flat blank length 5. Pre-form for full circle forming 6. Number of drawing process 7. Draw clearance 8. Number of draw reduction 9. Draw reduction percentage 10. Area of flat ring 11. Area of Cylinder 12. Area of fillet 13. Area of invert fillet 14. Area of hemisphere 15. Area of spherical ring & dish

F= A x T
Cutting force
F = Cutting force S = Material thickness L = Total cutting length A = L x S = Shear area

Material Aluminum Aluminum Tempering Carbon Steel Copper alloy Low alloys Material nations & Equivalents Nickel alloys Stainless Steel Tungsten Carbide Wrought stainless Steel

T = Shear strength Note : Shear strength = 80% of tensile strength

P= ( L x S x T ) / 10
Stripping force
P = Stripping force S = Material thickness L = Total cutting length A = L x S = Shear area

T = Shear strength

L = a + ( R + q x s/2 )( Pi x / 180)
Manufacturing Conversion Charts Drill Angle Drill size Energy Efficiency Math Area Machining Cutting Time Technical articles Work Done Velocity

L = Flat blank length a, b = Length of legs R = Bend radius q = Correction factor ( refer to table below ) = Bend angle Pi = 3.1416
Correction factor q

Correction factor

Ratio R : s Correction factor

5.0 1.0

3.0 0.9

2.0 0.8

1.2 0.7

0.8 0.6

0.5 0.5

http://www.wisetool.com/formular/formula.htm

12/12/2010

Useful online formula for press tool design

Page 2 of 3

Geometric Tolerancing GDT Tolerance chart ISO

R = Bend radius
S = Material thickness

E = ( D + s ) 0.707 C = ( D + s ) 1.414
E = Center distance C = Center distance between two apart radii s = Material thickness D = Inside diameter of final formed part R = D/2 ( approximate ) Note : if R = D/2, radii will be tangent, if R /= D/2, radii will require blending.

Quality Control AQL Process Capability CPK Sampling plan Level I, II, III

Draw clearance

Thickness S < 0.4 0.4 - 1.27 1.27 - 3.18 > 3.175

1st Draw 1.08 S 1.08 - 1.10 S 1.10 - 1.13 S 1.13 - 1.15 S

2nd Draw 1.09-1.10 S 1.10 - 1.13 S 1.13 - 1.15 S 1.15 - 1.20 S

Sizing Draw 1.04-1.05 S 1.05 - 1.06 S 1.06 - 1.08 S 1.08 - 1.10 S

S = Material thickness H/D < 0.75 Draw reduction ( number of draw ) 0.7 - 1.5 1.5 - 3.0 3.0 - 4.7
H = Draw piece height D = Mean diameter of draw piece

No. of draw 1 2 3 4

% = 1 -( MD / D )
Draw % of reduction % = percentage of reduction
MD = Mean diameter of draw piece D = Flat blank diameter

A = 0.7854 (( DXD )-(dXd))

D = Flat blank diameter d = Hole diameter

A = 3.1416 ( D x H )
D = Mean diameter H = Shell height

A= 4.935 RD + 6.283 (R x R)
D = Hole diameter R = Radius ( 1/2 thickness )

A= 4.935 RD - 6.283 (R x R)
D = Outer diameter R = Radius ( 1/2 thickness )

http://www.wisetool.com/formular/formula.htm

12/12/2010

Useful online formula for press tool design

Page 3 of 3

A= 6.283 ( R x R )
R = Radius ( 1/2 thickness )

A = 6.283 RH
R = Radius ( 1/2 thickness ) H = Shell height

A = 9.87 RD
D = center to center diameter R = Radius ( 1/2 thickness ) Online formula

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http://www.wisetool.com/formular/formula.htm

12/12/2010