Design and Development of a Cost-Effective Hydraulic Screw Jack-Based Punch-Die System for Small-Scale Manufacturing

Abstract

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.

Introduction

Punching is a key sheet metal process used in industries like automotive, aerospace, and general manufacturing. Conventional punching machines, while effective, are expensive, bulky, and power-dependent—making them unsuitable for small-scale industries, rural workshops, and educational labs.

Project Goal:
This project introduces a low-cost, power-independent punch-die system using a manual hydraulic screw jack integrated into a robust mild steel frame. It targets MSMEs, vocational institutes, and rural settings, offering a compact, efficient, and safe alternative to traditional punching systems.

Key Features & Benefits:

• Manual Operation using a hydraulic screw jack allows controlled, smooth force application (~6 tons), suitable for punching mild steel sheets (1–5 mm thick).

• Robust Frame Design ensures structural integrity, load distribution, and tool longevity.

• Materials: Mild steel frame, EN31 punch, H13 die, and bronze guide bushings.

• Safety and Portability: Interchangeable die sets, energy independence, and minimal maintenance.

• CAD & FEA Analysis confirmed structural safety and low deformation under load.

Literature Review Highlights:

• CNC and hydraulic systems offer precision but are costly and complex.

• Manual fly presses are cheap but lack force and consistency.

• Prior research supports hydraulic systems for safety and accuracy in small-scale applications.

• There is a gap for affordable, energy-independent systems—especially in rural and educational contexts.

Methodology:

1. Conceptualization: Identified need for compact, cost-effective punching alternative.

2. Feasibility Study: Selected a 10-ton hydraulic jack (for 6-ton required force).

3. Design & Analysis: Performed force calculations, stress/load analysis, and spring load design.

4. CAD Modelling: Designed and validated through FEA (max stress ~180 MPa < yield strength).

5. Fabrication: Assembled from mild steel, tested on various sheet thicknesses.

6. Testing: Demonstrated reliable performance, accuracy, and operator safety.

Conclusion

This study successfully demonstrated the design and development of a cost-effective punch-die system integrated with a hydraulic screw jack for small-scale sheet metal fabrication. The compact frame-based design, fabricated from mild steel and fitted with tool steel punch and die, ensured structural stability and durability. Experimental trials confirmed that the system could reliably punch mild steel sheets up to 5 mm thickness with an accuracy range of 95–99%. The observed punching force closely matched theoretical predictions, validating the system’s efficiency. The design proved to be safe, portable and economical, with an estimated fabrication cost of ?5900—significantly lower than conventional hydraulic or CNC punching machines. These results confirm the system’s suitability for small-scale industries, MSMEs, rural workshops and educational institutions where affordability and accessibility are critical.

References

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Copyright

Copyright © 2025 Mr. Mohsin Lalabhai Shaikh, Mr. Babasaheb Shankar Hajare, Mr. Vishal Suresh Kadam. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.