Understanding the Punch Press in Sheet Metal Fabrication

A punch press is a critical piece of machinery in the sheet metal fabrication industry. It is used to cut, shape, and create holes in sheet metal through a process called punching. This versatile and powerful machine plays a significant role in manufacturing components for our various industries, including packaging, restaurant, medical, and automation. Here’s a detailed look at what a punch press is and how it functions in sheet metal fabrication.

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What is a Punch Press?

A punch press is a mechanical device that uses a combination of force and tooling to punch holes or shapes into sheet metal. It operates by driving a punch (a solid, cylindrical tool) through the sheet metal and into a die (a specialized tool that defines the shape and size of the hole). The punch press can be manually operated, mechanically driven, or powered by hydraulic or pneumatic systems, depending on the requirements of the operation.

Punch Press Terminology

There are several functions in a punch press, with many punch presses capable of performing multiple functions in one machine. 

1. Mechanical Punch Press: Uses a flywheel to store energy and deliver a high-impact force to the punch. It is suitable for high-speed operations and high-volume production.

2. Hydraulic Punch Press: Uses hydraulic fluid to generate force. It provides greater control over the punching process, making it ideal for thicker materials and more complex shapes.

3. CNC Punch Press: Computer Numerical Control (CNC) punch presses are automated and programmable, allowing for high precision and repeatability. They are capable of performing complex punching patterns and are ideal for mass production.

4. Turret Punch Press: Features a rotating turret that holds multiple punches and dies, enabling quick changes between different punching operations. This versatility makes it suitable for varied and complex fabrication tasks.

How a Punch Press Works

The operation of a punch press involves several key steps:

1. Setup: The sheet metal is positioned on the worktable and secured in place. The appropriate punch and die are selected and installed in the machine.

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2. Programming (for CNC): For CNC punch presses, the desired punching pattern is programmed into the machine’s control system. The program dictates the movement of the punch and the positioning of the sheet metal.

3. Punching: The punch press exerts force to drive the punch through the sheet metal and into the die. The material is sheared and removed, creating a hole or shape in the metal.

4. Ejection: The punched-out scrap material, known as a slug, is ejected from the die. The process is repeated for each hole or shape required.

Benefits of Punch Presses

The benefits of using a punch press include:

• Precision and Consistency: Punch presses deliver accurate and repeatable results, ensuring high-quality components.

• Speed and Efficiency: High-speed punching capabilities enable quick production of large volumes of parts.

• Versatility: Able to handle various materials and thicknesses, and produce complex shapes and patterns.

• Cost-Effectiveness: Reduces material waste and labor costs through efficient and automated processes.

A punch press is an indispensable tool in sheet metal fabrication, offering the precision, efficiency, and versatility needed to produce high-quality components across various industries. Punch presses play a vital role in modern manufacturing, helping businesses meet stringent quality standards and production demands. Understanding how a punch press works and its applications can help manufacturers optimize their fabrication processes and achieve superior results.

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I'm in need of a new drill press; my old one (a benchtop standard-type unit of indefinite origin) is just too "loose". So, what should I buy? (Keep in mind that my business is restoring mechanical clocks; I need one that is reliably accurate.)

I've thought about buying one of the various "precision" drill presses that are made, but someone suggested one of the popular quill equipped, dovetail column mill/drill units. The rationale is that they have to be tighter and more durable than a drill press to begin with, so using one primarily for drilling would not be taxing it's capabilities.

Thoughts? Recommendations? At the other extreme of a Moore no. 3 jig borer would be the tiny Servo precision drill that most of the catalog companies carry. Mid size would be something like the Aciera precision drill pictured below. I've got two of these. Both were capable of 10,000 RPM top speed but the previous owner replaced the orignal Swiss motors with Baldors such that top RPM is now 6,000.

Servo


Aciera


Of course the drop dead ultimate mid size drill machine would be the Felhmann...I do not have one of these !

I drill a lot of small holes.... about this week,.020 and .025" in nickel silver..... the drill presses in my shop for fine work are a Hamilton and a coulpe of Camrons.... both models have shown up on ebay or you can buy them new.....however this week I was useing one of the old ones.... a flat belt Sigourney #0, it is the one Pratt & Whitney sold to fit on a bench between their 7" bench lathe and little mill. Charles, I have a Boremaster color brochure that I picked up at the EMO show in Hanover, Germany in . I don't recall seeing Bormaster heads at IMTS in Chicago ever, so for them to turn up in little 'ol Charlotte seems odd indeed.

Why on Earth do you ask ??


Clockmaker, another machine that would drill small holes as precise as they get, and yet be home shop sized is one of the smaller Hauser jig borers. I just happen to have one for sale that came out of an IBM toolroom.

Well, this guy has his machine as precision drill press so I thought I would include. You know, just to see the spread of what "Precision" means.

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But I really don't know of a "precision" drill press cause drilled holes really are not precision. For absolute precision locating of holes a jig borer (or grinder) is absolute. And next would be a quality vert. mill.

But I am gonna assume you don't really want a precision hole boring machine. I think you want a high quality drill press and of small size. I would opt fer the servo units. I don't have one, but definitely lust for one. I believe some even have a pressure gauge to show you how much force it actually took to break that bit. JR It pretty much depends on the RPM range you need. Even the cheapest mill/drill is a great precision drill press. Limited only by a top speed probably under rpm.

There are some cheaper alternatives to the "Servo" precision drill press if you need high rpm. The "Turbo Micro" model MSC sells does 10,000 to 30,000 rpm with a 1/8" capacity chuck and 1" of quill travel. It's a reasonable machine at least I am happy with it.

There is no perfect single drilling machine for a modest hobby shop. Well maybe a full-size mill is. I make good use of the mill/drill, the micro and an ancient Rockwell 17" floor drill press.

Bob If you want one that will last:

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We had two of these exact same Carltons in the boiler shop; same year too - . They drilled tube sheets, slosh plate and all kinds of boiler fitting and farm-in stuff 16/5 for almost 30 years. When they went to DIPEC to survey I inspected them. They must have had good care because I recall the quill and the head travel on the rail still trammed the floor-plate within 0.005" (or was it 0.008"?) in a 1 ft circle. Don,

On the subject of the Bormaster drill press, I mentioned it because the brochure that I have shows a drill press on a cabinet that is very much like the Aciera you have shown. I do not know if bormaster actually made the drill press or bought it and installed their multi drill head on it.

There were actually two on display at the Charlotte show. One was a small one like the Aciera with a small 4 position attachment on it. The other one was much larger with a 6 head built into the spindle. This machine also had the electronics cabinet on the side to set a different speed for each station. This happened automaticaly when you indexed to each new station.

I will try to scan the brochure later if I can find it. It is of little help perhaps for the original post but your pictures just reminded me of it.

There was also a very nice Deckel drill press for very small work that I have a photo of somewhere. I think there is even a link to it on Tonys archive website?

I just checked and it is not a Deckel that I saw it was this one...http://www.lathes.co.uk/leinenmicromill/


Charles