3 Fundamentals of press design

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140 Sheet metal forming and blanking For the evaluation of the geometry data, which has been established by the processing plan and the draw development as well as the production parameters, CAE solutions are available which are based upon mathematical and plasto-mechanical equations or on experimentally proven data. Analytical and numerical simulation belong to these solutions. The numerical methods, and here in particular the Finite Element Method (FEM), deliver today the most accurate results. Stampings can be almost completely interactively analysed on a workstation in relation to the most important failure criteria. The results are the distribution of stress (tears) (Fig. 4.1.14), the tendency towards wrinkling (Fig. 4.1.15) and the variation of the sheet metal thickness. The necessary steps and the prerequisites for a simulation run are as follows: – preparation of CAD data for the punch, female die and blank holder as well as the total geometry of the draw development in the working direction (Fig. 4.1.8), – determination and input of the blank size (cf. Sect. 4.2.1 and 4.5), – input of the process parameters such as sheet metal material, rolling direction, blank holder force, frictional conditions, – definition i.e. establishment of the FE mesh (partly automatic) and – initiation of the calculation process. By varying the process and die parameters, the simulation can be repeated as often as required until a failure-free drawing part is produced. The advantage of this process lies in the fact that any objective and necessary component changes can be introduced at any time prior to the actual manufacture of the dies. Specific measures for the controlling metal flow, for example through the shape of the blank or through the use of draw beads, can be simulated. Similarly, calculations can be made to predict and compensate for spring back (cf. Sect. 4.8.1). Through process simulation, process planners and die designers receive reliable information at an early stage in the die development, which really contributes to the production of fully operational and reliable dies. Metal Forming Handbook / Schuler (c) Springer-Verlag Berlin Heidelberg 1998
Principles of die manufacture 0.00 Maximum strain limit 0.0000 Wrinkling Metal Forming Handbook / Schuler (c) Springer-Verlag Berlin Heidelberg 1998 1.20 0.0400 Fig. 4.1.14 Representation of stress distribution by means of FEM simulation Fig. 4.1.15 Representation of possible wrinkle formation by means of FEM simulation 141
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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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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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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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Page 115 and 116: Press control systems 3.5.3 Operati
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Page 119 and 120: Press control systems The communica
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Page 125 and 126: Press control systems Other approac
Page 127 and 128: Press safety and certification 3.6.
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Page 131 and 132: Press safety and certification - st
Page 133 and 134: Press safety and certification Manu
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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
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Page 163 and 164: Principles of die manufacture blank
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Page 169 and 170: Principles of die manufacture how i
Page 171 and 172: Principles of die manufacture spott
Page 177 and 178: Deep drawing and stretch drawing me
Page 179 and 180: Deep drawing and stretch drawing In
Page 181 and 182: Deep drawing and stretch drawing ac
Page 183 and 184: Deep drawing and stretch drawing 3
Page 185 and 186: Deep drawing and stretch drawing 20
Page 187 and 188: Deep drawing and stretch drawing β
Page 189 and 190: Deep drawing and stretch drawing Ex
Page 191 and 192: Deep drawing and stretch drawing Bl
Page 193 and 194: Deep drawing and stretch drawing bl
Page 195 and 196: Deep drawing and stretch drawing Ta
Page 197 and 198: Deep drawing and stretch drawing Au
Page 199 and 200: Deep drawing and stretch drawing Ti
Page 201 and 202: Deep drawing and stretch drawing Hi
Page 203 and 204: Deep drawing and stretch drawing -
Page 205 and 206: Deep drawing and stretch drawing -
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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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