3 Fundamentals of press design

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178 Sheet metal forming and blanking Table 4.2.3 (continuation) Aluminium and aluminium alloys Material No. Rm [N/mm Rp0,2 or Fields of application, 2 ] ReL [N/mm2 ] A80 [%] examples equipment construction, electrical installations, electrical construction, high-frequency engineering, Al 99,5 W7 3.0255.10 65...95 max. 55 40 aerials, coaxial cables screening; aluminium foils in capacitors, as packaging material, for heat insulation; household equipment architecture, automotive engineering, metal goods: sheet metals, strips, profiles, AlRMg 1 W 10 3.3319.10 100...140 35...60 23 rods, wires, pipes, forgings, extremely good cold forming properties, weldable, highly seawater resistant Al 99,9 Mg 1 W 10 3.3318.10 100...140 35...60 23 dito Al 99,85 Mg 1 W 10 3.3317.10 100...140 35...60 23 dito AlMg 2,5 G 25 3.3523.29 250...290 min. 180 7 car body work, pull-tab can lids food industry, equipment construction, automotive AlMg 3 W 19 3.3535.10 190...230 min. 80 20 engineering and shipbuilding, architecture: semi-finished products, roofing, packaging, screws, rivets equipment construction, AlMn 1 F 12 3.0515.24 120...160 min. 90 7 refrigeration, technology, heat exchangers, roofing, panelling mining, automotive engineering, aircraft construction, AlCuMg 1 W 3.1325.10 max. 215 max. 140 13 mechanical engineering: sheet metals, profiles, rods, pipes, forgings, screws, rivets AlMg 2 Mn 0,8 F 22 3.3527.24 220...260 max. 165 9 automotive engineering, shipbuilding, equipment construction: parts resistant to stress at high temperatures AlMgSi 0,8 F 28 3.2316.71 min. 275 min. 200 12 mechanical engineering, automotive engineering architecture, mining, automotive engineering, ship- AlMgSi 1 W 3.2315.10 max. 150 max. 85 18 building, mechanical engineering, food and textile industries: all types of semifinished products, screws Metal Forming Handbook / Schuler (c) Springer-Verlag Berlin Heidelberg 1998
Deep drawing and stretch drawing Titanium and titanium alloys Material No. Rm [N/mm Rp0,2 or Fields of application, 2 ] ReL [N/mm2 ] A80 [%] examples chemical equipment construction, electrodeposition, aircraft and Ti 99,8 3.7025.10 290...410 min. 180 30 spacecraft construction, surgery and orthopaedics: protheses, bone screws, implants and splints Ti 99,7 3.7035.10 390...540 min. 250 22 dito mechanical engineering, aircraft and spacecraft TiAl 6 V 4 F 89 3.7165.10 min. 890 min. 820 6 construction, electrical engineering, optics, precision mechanical engineering, medicine technology, fittings mechanical engineering, TiAl 5 Sn 2 F 79 3.7115.10 min. 790 min. 760 6 aircraft and spacecraft construction, fittings 4.2.3 Friction, wear and lubrication during sheet metal forming As particularly important areas of tribology, friction, wear and lubrication have a significant influence on process engineering related to sheet metal forming. The practice has shown that by a purposeful application of appropriate die materials, together with process-optimized lubricants, wear of forming and blanking dies can be significantly reduced. Friction Friction plays a major role in sheet metal forming. Friction is the result of internal deformation of the deformed material and of externally applied loads. In its different manifestations, friction results in complex wear mechanisms at the contact surfaces between the die and the workpiece. During forming and shear cutting operations, sliding friction conditions apply where lubrication is used. In describing friction in sheet metal forming, as a rule, the coefficient of friction µ [–] is used and it is expressed as the friction force divided by the normal force, in the form: F / F – or μ= [ ] R N Metal Forming Handbook / Schuler (c) Springer-Verlag Berlin Heidelberg 1998 179
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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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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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Page 163 and 164: Principles of die manufacture blank
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Page 215 and 216: Coil lines Fig. 4.3.1 Coil line for
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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 Fig. 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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