Punch force is an important factor in the sheet metal forming operations. The amount of force is mainly based on the material type, shape, size etc. The analysis on theoretical Vs actual forces is playing an important role in the optimization of the sheet metal forming processes. The total press tonnage will be based on the punch forces. Also the type of the die is a key factor in the actual force. In this study, the combination die is designed and fabricated to manufacture the U clamps. The die is used to form the U clamps by using mild steel and aluminum sheets. The punch forces are analyzed in various aspects.