3 Fundamentals of press design

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98 Fundamentals of press design distributedI/O distributed I/Omodule central I/O switchcabinet PLC machine . . . . . . . . . . . . parallel individual signals distributed I/Omodule sensorsandactuators PLC I/O switchcabinet machine serialbus distributed I/Omodule Fig. 3.5.3 PLC with central and distributed input/output systems distributed I/Omodule parallel individual signals terminalbox terminalbox terminalbox terminalbox . . . . . . . . . . . . sensorsandactuators Metal Forming Handbook / Schuler (c) Springer-Verlag Berlin Heidelberg 1998
Press control systems The communication system connects the PLC, and provides data exchange with the visual displays within the machine and also communication with external systems. 3.5.5 Functional structure of the control system Depending on the type of machine or press, the control system is broken down according to the following functional groupings: – feed, – main drive system, – safety control, – slide functions (interlocking, overload safeguard, weight compensation, die clamping system, adjustment), – draw cushion or blank holder functions (pressure control, adjustment), – moving bolster functions (traversing, lifting/lowering, clamping), – functions of the workpiece transport devices and dies, – hydraulic, pneumatic, lubrication functions, – special die changing functions. Cam operated limit switches play a special role in press control systems. These press-specific functional units generate switching signals for certain functions depending on the position of the crank angle. A difference must be drawn between electromechanical rotating cam limit switches (Fig.3.5.4), which are used for safety-relevant functions, and electronic cam switches that are programmable. The latter comprise a measuring system for the crank angle of the press and an electronic evaluating module. In contrast to mechanical presses, valves for the downstroke and upstroke of the slide are separate in a hydraulic press, so eliminating the need for a cam operated safety device. 3.5.6 Major electronic control components Safety control systems used in Europe are generally still the dual-channel, self-monitoring conventional type using contactors. In contrast, since the mid-eighties, the safety control systems used in large-panel Metal Forming Handbook / Schuler (c) Springer-Verlag Berlin Heidelberg 1998 99
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Metal Forming Handbook /Schuler (c)
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123 METAL FORMING Metal Forming Han
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Preface Following the long traditio
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Contributors ADAM, K., Dipl.-Ing. (
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Contents Index of formula symbols .
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Contents 3.6.5 Measures to be under
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Contents 5.3 Component development
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Index of formula symbols � rib an
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Index of formular symbols d inner d
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Index of formular symbols p G avera
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1 Introduction Technology has exert
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Introduction Fig. 1.1 L. Schuler, M
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2 Basic principles of metal forming
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Methods of forming and cutting tech
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2 Basic principles of metal forming
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Basic terms in which � 1 is defor
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Basic terms cation of an exterior f
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Basic terms fracture, this characte
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3 Fundamentals of press design 3.1
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Press types and press construction
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Page 67 and 68: Press types and press construction
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Page 71 and 72: Mechanical presses , distance s[m]
Page 73 and 74: Mechanical presses stress on the fr
Page 75 and 76: Mechanical presses stroke [mm] 900
Page 77 and 78: Mechanical presses This offers a nu
Page 79 and 80: Mechanical presses or bottom mounte
Page 81 and 82: Mechanical presses In crossbar tran
Page 83 and 84: Mechanical presses with a long serv
Page 85 and 86: Mechanical presses Fig. 3.2.9 Drive
Page 87 and 88: Mechanical presses Overload safety
Page 89 and 90: Mechanical presses Slide cushion So
Page 91 and 92: Mechanical presses imum pneumatic p
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Page 95 and 96: Hydraulic presses Design of the dri
Page 97 and 98: Hydraulic presses pumps suspended i
Page 99 and 100: Hydraulic presses pressure in the p
Page 101 and 102: Hydraulic presses F 4 I P (F ) max
Page 103 and 104: Hydraulic presses are two variation
Page 105 and 106: Hydraulic presses presscrown retain
Page 107 and 108: Changing dies to a weight of 3 t pr
Page 109 and 110: Changing dies gearwithguidinggroove
Page 111 and 112: Changing dies are changed in solid
Page 113 and 114: Changing dies hydraulic clamping me
Page 115 and 116: Press control systems 3.5.3 Operati
Page 117: Press control systems 3.5.4 Structu
Page 121 and 122: Press control systems Fig. 3.5.5 PL
Page 123 and 124: Press control systems Fig. 3.5.7 Sw
Page 125 and 126: Press control systems Other approac
Page 127 and 128: Press safety and certification 3.6.
Page 129 and 130: Press safety and certification with
Page 131 and 132: Press safety and certification - st
Page 133 and 134: Press safety and certification Manu
Page 135 and 136: Press safety and certification pres
Page 137 and 138: Press safety and certification 3.6.
Page 139 and 140: Press safety and certification tion
Page 141 and 142: Casting components for presses Fig.
Page 143 and 144: 4 Sheet metal forming and blanking
Page 145 and 146: Principles of die manufacture icall
Page 147 and 148: Principles of die manufacture becau
Page 149 and 150: Principles of die manufacture go-ah
Page 151 and 152: Principles of die manufacture produ
Page 153 and 154: Principles of die manufacture Fig.
Page 155 and 156: Principles of die manufacture a b c
Page 157 and 158: Principles of die manufacture the p
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Page 163 and 164: Principles of die manufacture blank
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Page 167 and 168: Principles of die manufacture Fig.
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Principles of die manufacture how i
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Principles of die manufacture spott
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Principles of die manufacture Fig.
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Principles of die manufacture Fig.
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Deep drawing and stretch drawing me
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Deep drawing and stretch drawing In
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Deep drawing and stretch drawing ac
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Deep drawing and stretch drawing 3
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Deep drawing and stretch drawing 20
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Deep drawing and stretch drawing β
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Deep drawing and stretch drawing Ex
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Deep drawing and stretch drawing Bl
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Deep drawing and stretch drawing bl
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Deep drawing and stretch drawing Ta
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Deep drawing and stretch drawing Au
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Deep drawing and stretch drawing Ti
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Deep drawing and stretch drawing Hi
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Deep drawing and stretch drawing -
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Deep drawing and stretch drawing -
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Deep drawing and stretch drawing se
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Deep drawing and stretch drawing fo
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Deep drawing and stretch drawing pu
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Deep drawing and stretch drawing ag
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Coil lines Fig. 4.3.1 Coil line for
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Coil lines Fig. 4.3.3 Compact desig
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Sheet metal forming lines In the ca
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Sheet metal forming lines Fig. 4.4.
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Sheet metal forming lines ing of th
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Sheet metal forming lines (Fig. 4.4
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Sheet metal forming lines The two l
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Sheet metal forming lines 1,860mm a
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Sheet metal forming lines ver’s c
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Sheet metal forming lines During th
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Sheet metal forming lines 4.4.4 Des
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Sheet metal forming lines individua
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Sheet metal forming lines As early
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Sheet metal forming lines In modern
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Sheet metal forming lines 4.4.6 Tra
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Sheet metal forming lines protects
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Sheet metal forming lines Within th
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Sheet metal forming lines power req
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Sheet metal forming lines Press lay
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Sheet metal forming lines higher st
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Sheet metal forming lines Draw cush
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Sheet metal forming lines These com
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Sheet metal forming lines motion cu
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Sheet metal forming lines increase
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Sheet metal forming lines (cf. Fig.
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Sheet metal forming lines larly str
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Sheet metal forming lines ing parts
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Sheet metal forming lines - efficie
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Sheet metal forming lines - Automat
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Sheet metal forming lines Local ope
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Sheet metal forming lines modules a
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Sheet metal forming lines Table 4.4
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Sheet metal forming lines sion foll
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Blanking processes to complete brea
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Blanking processes Fig. 4.5.5 Top-t
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Blanking processes 56.8% 65.0% 67.4
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Blanking processes a configuration
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Blanking processes flat punch U bev
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Blanking processes Using these equa
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Blanking processes x S = 66. 6 (s a
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Blanking processes 0.18 10 10.36 27
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Shearing lines Fig. 4.6.1 Slitting
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Shearing lines The blanking process
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Shearing lines Blanking presses for
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Shearing lines 4.6.3 High-speed bla
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Shearing lines mass counterbalance
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Shearing lines Fig. 4.6.9 Influence
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Shearing lines Fig. 4.6.11 Rotor an
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Shearing lines Fig. 4.6.13 Complete
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Shearing lines Fig. 4.6.15 Complete
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Shearing lines Fig. 4.6.17 Flexible
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Shearing lines which run, backlash-
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Shearing lines that up to 150 strok
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Shearing lines Fig. 4.6.21 Automati
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Shearing lines Fig. 4.6.24 Passenge
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Shearing lines F F resistance weldi
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Shearing lines In contrast to conve
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Shearing lines The stripper plate i
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Shearing lines Fig. 4.6.32 Examples
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Shearing lines - provision of all i
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Shearing lines Fig. 4.6.35 Machine
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Shearing lines Fig. 4.6.37 Failure
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Shearing lines Structure of the ele
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Shearing lines interference, or whe
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Fine blanking - smaller dimensional
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Fine blanking f i blanking force F
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Fine blanking blanking force F s I
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Fine blanking plate of the die, whi
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Fine blanking case hardening nitrit
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Fine blanking not been soft anneale
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Fine blanking it is also possible t
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Fine blanking Example: We wish to p
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Fine blanking s h S1 tearing E frac
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Fine blanking punches, as well as t
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Fine blanking subsequently quenched
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Fine blanking Fig. 4.7.22 Two-stati
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Fine blanking Blanking plate 2 is l
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Fine blanking 1 2 5 6 3 Fig. 4.7.25
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Fine blanking blankingpunch 1 2 inn
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Fine blanking vee-ring piston diehe
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Fine blanking measuring the pressur
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Fine blanking pallets reach the sta
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Bending Table 4.8.1 gives the small
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Bending Accordingly, the necessary
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Bending Example: You wish to bend a
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Bending F F b or b 2 b ⋅s ⋅R =
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Bending Fig. 4.8.7 Roll forming: ro
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Bending Fig. 4.8.13 Hat sections Fi
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Bending Table 4.8.3: Material coeff
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Bending The roll stand for profile
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Bending frame Fig. 4.8.23 Work shaf
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Bending Fig. 4.8.25 Roller straight
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Bending W W t t W Wma s Fig. 4.8.28
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4 Sheet metal forming and blanking
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Organization of stamping plants Whe
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Organization of stamping plants Tab
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Organization of stamping plants lic
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Organization of stamping plants bat
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Organization of stamping plants Tab
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Organization of stamping plants ele
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Organization of stamping plants une
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5 Hydroforming 5.1 General One of t
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Process technology and example appl
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5 Hydroforming 5.3 Component develo
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Component development a component d
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Component development 100% D D 75%
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Component development Pure expansio
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Die engineering diameter and stroke
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5 Hydroforming 5.5 Materials and pr
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Materials and preforms for producin
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Presses for hydroforming Controllab
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5 Hydroforming 5.7 General consider
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General considerations inward hole
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6 Solid forming (Forging) 6.1 Gener
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General lets that can be produced t
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General Fig. 6.1.4 Examples of coin
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General Table 6.1.1: Comparison bet
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6 Solid forming (Forging) 6.2 Benef
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Benefits of solid forming 6.2.2 Wor
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Benefits of solid forming range”
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Benefits of solid forming sions fro
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Benefits of solid forming Where no
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Materials, billet production and su
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Formed part and process plan requir
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Formed part and process plan 6.4.2
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6 Solid forming (Forging) 6.5 Force
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Force and work requirement d 0 d 2
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Force and work requirement For die
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Force and work requirement The mini
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Force and work requirement dies) (c
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Part transfer There is a broad rang
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Part transfer For cold forming proc
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Metal Forming Handbook / Schuler (c
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6 Solid forming (Forging) 6.7 Die d
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Die design wedge adjustment auxilia
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Die design Table 6.7.1: Modular sys
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Die design Fig. 6.7.5 Shearing die
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Die design for radial stress � r
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Die design The off-center applied f
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Die design Table 6.7.4: Heat treatm
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Die design Powder metal-manufacture
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Die design ledeburitic 12 % chromiu
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Die design system integrated into b
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6 Solid forming (Forging) 6.8 Press
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Presses used for solid forming mult
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Presses used for solid forming slid
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Presses used for solid forming Fig.
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Presses used for solid forming duct
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Presses used for solid forming 6.8.
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Presses used for solid forming tati
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Presses used for solid forming adeq
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Presses used for solid forming Embo
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Presses used for solid forming ment
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Presses used for solid forming feed
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Presses used for solid forming hopp
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Presses used for solid forming coin
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Presses used for solid forming Univ
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Presses used for solid forming Meda
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Presses used for solid forming CNC-
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Presses used for solid forming forc
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Index A.S.T.M.-standard 451 abrasio
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Index cylinder -, counterpressure 4
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Index flying shear 288 flywheel 51-
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Index modified top drive 205-207 mo
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Index sand blasting 460 sandwich co
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Index washing/cleaning machine 219
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3 Fundamentals of press design

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