3 Fundamentals of press design

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XIV Metal Forming Handbook 6.5.3 Backward cup extrusion and centering . . . . . . . . . 474 6.5.4 Reducing (open die forward extrusion). . . . . . . . . . 475 6.5.5 Ironing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476 6.5.6 Upsetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476 6.5.7 Lateral extrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . 477 6.6 Part transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478 6.6.1 Loading station . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479 6.6.2 Transfer study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481 6.7 Die design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485 6.7.1 Die holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488 6.7.2 Die and punch design . . . . . . . . . . . . . . . . . . . . . . 491 6.7.3 Die and punch materials . . . . . . . . . . . . . . . . . . . . 496 6.7.4 Die closing systems (multiple-action dies) . . . . . . . . . . . . . . . . . . . . . . . 502 6.8 Presses used for solid forming . . . . . . . . . . . . . . . . . . . . 505 6.8.1 Choice of press . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505 6.8.2 Mechanical presses . . . . . . . . . . . . . . . . . . . . . . . . . 507 6.8.3 Hydraulic presses . . . . . . . . . . . . . . . . . . . . . . . . . . 514 6.8.4 Supplementary equipment . . . . . . . . . . . . . . . . . . 517 6.8.5 Special features of hot and warm forming lines . . 520 6.8.6 Sizing and coining presses . . . . . . . . . . . . . . . . . . . 522 6.8.7 Minting and coin blanking lines . . . . . . . . . . . . . . 526 Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 541 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543 Metal Forming Handbook /Schuler (c) Springer-Verlag Berlin Heidelberg 1998
Index of formula symbols � rib angle, bending angle, ° clearance angle, ° die opening angle, ° corner angle for blanking ° �1 required bending angle ° �2 desired bending angle ° � draw ratio, corner angle when bending total draw ratio maximum draw ratio ° � elongation, starting measurement �A relative cross section change % � efficiency �A degree of utilization of the sheet metal, utilization force �F forming efficiency factor � coefficient of friction V volumetric flow 1/s � stress N/mm2 · �tot �max � m mean stress N/mm 2 � max largest stress N/mm 2 � md mean comparative stress N/mm 2 � min smallest stress N/mm 2 � N normal contact stress N/mm 2 � r radial stress N/mm 2 Metal Forming Handbook /Schuler (c) Springer-Verlag Berlin Heidelberg 1998
Page 1 and 2: Metal Forming Handbook /Schuler (c)
Page 3 and 4: 123 METAL FORMING Metal Forming Han
Page 5 and 6: Preface Following the long traditio
Page 7 and 8: Contributors ADAM, K., Dipl.-Ing. (
Page 9 and 10: Contents Index of formula symbols .
Page 11 and 12: Contents 3.6.5 Measures to be under
Page 13: Contents 5.3 Component development
Page 17 and 18: Index of formular symbols d inner d
Page 19 and 20: Index of formular symbols p G avera
Page 21 and 22: 1 Introduction Technology has exert
Page 23 and 24: Introduction Fig. 1.1 L. Schuler, M
Page 25 and 26: 2 Basic principles of metal forming
Page 27 and 28: Methods of forming and cutting tech
Page 45 and 46: 2 Basic principles of metal forming
Page 47 and 48: Basic terms in which � 1 is defor
Page 49 and 50: Basic terms cation of an exterior f
Page 51 and 52: Basic terms fracture, this characte
Page 53 and 54: 3 Fundamentals of press design 3.1
Page 55 and 56: Press types and press construction
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Press types and press construction
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Press types and press construction
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3 Fundamentals of press design 3.2
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Mechanical presses , distance s[m]
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Mechanical presses stress on the fr
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Mechanical presses stroke [mm] 900
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Mechanical presses This offers a nu
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Mechanical presses or bottom mounte
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Mechanical presses In crossbar tran
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Mechanical presses with a long serv
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Mechanical presses Fig. 3.2.9 Drive
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Mechanical presses Overload safety
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Mechanical presses Slide cushion So
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Mechanical presses imum pneumatic p
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3 Fundamentals of press design 3.3
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Hydraulic presses Design of the dri
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Hydraulic presses pumps suspended i
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Hydraulic presses pressure in the p
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Hydraulic presses F 4 I P (F ) max
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Hydraulic presses are two variation
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Hydraulic presses presscrown retain
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Changing dies to a weight of 3 t pr
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Changing dies gearwithguidinggroove
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Changing dies are changed in solid
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Changing dies hydraulic clamping me
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Press control systems 3.5.3 Operati
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Press control systems 3.5.4 Structu
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Press control systems The communica
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Press control systems Fig. 3.5.5 PL
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Press control systems Fig. 3.5.7 Sw
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Press control systems Other approac
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Press safety and certification 3.6.
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Press safety and certification with
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Press safety and certification - st
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Press safety and certification Manu
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Press safety and certification pres
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Press safety and certification 3.6.
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Press safety and certification tion
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Casting components for presses Fig.
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4 Sheet metal forming and blanking
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Principles of die manufacture icall
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Principles of die manufacture becau
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Principles of die manufacture go-ah
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Principles of die manufacture produ
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Principles of die manufacture Fig.
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Principles of die manufacture a b c
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Principles of die manufacture the p
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Metal Forming Handbook / Schuler (c
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Principles of die manufacture 0.00
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Principles of die manufacture blank
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Principles of die manufacture how i
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Principles of die manufacture spott
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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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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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