Design and Development of a Cost-Effective Hydraulic Screw Jack-Based Punch-Die System for Small-Scale Manufacturing
Keywords:
Punch-die system, Hydraulic screw jack, Frame design, Cost-effective manufacturing, Sheet metal punching, Small-scale industriesAbstract
This paper presents the design and development of a cost-effective punch-die system integrated with a hydraulic screw jack for small-scale sheet metal manufacturing applications. Conventional punching machines are often expensive, bulky, and dependent on external power sources, making them unsuitable for rural workshops, cottage industries, and educational laboratories. The proposed system addresses these limitations through a compact, frame-based design fabricated from mild steel and equipped with a 10-ton manual hydraulic screw jack. The punch and die, manufactured from EN31 and H13 tool steels, respectively, ensure durability and precision in operations such as washer fabrication. Finite Element Analysis (FEA) was conducted to evaluate stress distribution and load-bearing capacity, confirming structural safety and minimal deflection under maximum load conditions. Experimental validation demonstrated consistent punching performance for mild steel sheets up to 3–5 mm thickness, with accurate force transmission, safety, and ease of operation. The system is portable, low-maintenance, and adaptable through interchangeable die sets, making it a versatile tool for training, prototyping, and small-scale production. By eliminating dependence on electricity and high-cost machinery, this design provides a practical solution for resource-constrained environments and offers significant potential for adoption in MSMEs and vocational education.
References
R. S. Khurmi and J. K. Gupta, A Textbook of Machine Design, 14th ed., New Delhi: Eurasia Publishing, 2005.
J. E. Shigley and C. R. Mischke, Mechanical Engineering Design, 7th ed., New York: McGraw-Hill, 2004.
Amada, “CNC Turret Punch Presses,” Amada Machine Tools, 2020.
Trumpf, “Punching Technology Overview,” Trumpf GmbH, 2021.
V. B. Bhandari, Design of Machine Elements, 3rd ed., New Delhi: McGraw-Hill, 2010.
K. M. Gupta, Material Selection and Mechanical Design: An Introduction, Springer, 2013.
H. R. Patel and D. Mehta, “Design and fabrication of hydraulic operated punching machine,” Int. J. Mech. Prod. Eng. Res. Dev., vol. 8, no. 3, pp. 257–264, 2018.
S. Singh and P. Sharma, “Development of low-cost sheet metal punching device for rural applications,” Int. J. Eng. Res. Technol., vol. 8, no. 5, pp. 123–127, 2019.
A. Thakkar and B. Solanki, “Manual punching system using hydraulic jack,” J. Emerging Technol. Innov. Res., vol. 7, no. 6, pp. 542–546, 2020.
A. Saxena and R. S. Jadon, “Finite element analysis of punching and blanking operations,” Int. J. Adv. Manuf. Technol., vol. 45, no. 7–8, pp. 722–732, 2009.
S. Kalpakjian and S. Schmid, Manufacturing Engineering and Technology, 7th ed., Pearson, 2014.
M. Groover, Fundamentals of Modern Manufacturing, 6th ed., Wiley, 2015.
R. Narayan and P. Kumar, “Design optimization of punching dies using FEA,” Mater. Today Proc., vol. 5, pp. 17685–17693, 2018.
J. Tlusty, Manufacturing Processes and Equipment, Prentice Hall, 2000.
A. Ghosh and A. K. Mallik, Manufacturing Science, New Delhi: East-West Press, 2010.
R. Kumar, “Low-cost hydraulic press design for rural applications,” Int. J. Eng. Trends Technol., vol. 34, no. 2, pp. 77–81, 2016.
M. Choudhury, “Advancements in die design for sheet metal punching,” Procedia Eng., vol. 97, pp. 1763–1771, 2014.
ISO 16092-3:2019, “Machine tools safety – Presses – Hydraulic presses,” ISO Standards, 2019.
S. S. Rattan, Theory of Machines, 4th ed., McGraw-Hill, 2017.
D. A. Stephenson and J. S. Agapiou, Metal Cutting Theory and Practice, 3rd ed., CRC Press, 2016
