3 Fundamentals of press design

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244 Sheet metal forming and blanking medium-sized parts, in which two parts are formed from one blank or two adjacent blanks (Fig. 4.4.34 and cf. Fig. 4.9.2). Double parts produced from a single blank are separated as required in a subsequent operation. The production of double parts could refer to any suitable parts, for example passenger car doors. This kind of production doubles the output per press stroke and increases considerably the economy of the system, compared to gripper rail transfer systems. Moreover, dual production helps to better utilize the press load capacity when forming a single large and unstable part does not fully require the available press load. Large-panel crossbar transfer presses can be structured in different ways. Ideally, each die should be assigned to a separate slide to ensure optimum peripheral conditions for the die and for the forming process. The design is based on a modular structure comprising individual machines in which all the drive systems are connected to the main press drive system by means of central longitudinal drive shaft and intermediate couplings (cf. Fig. 3.2.9). This ensures synchronous running of all the stations: The transport system can be operated by a continuous transfer with only a minimal safety clearance to the top die. To transport large unstable parts in transfer presses, a two-axis transfer system equipped with crossbars and suction cups is used (Fig. 4.4.34). Unlike the off-center positioning of parts on feeder or robot arms as used on press lines (Fig. 4.4.35),here the parts are held directly by suction cup carriers located above the part. Due to the symmetrical arrangement of the suction cups relative to the center of gravity of the parts, higher accelerating forces acting on the part are permissible. In comparison with feeder mechanisms, stroke rates can be increased from 13 to 15 parts per minute with transport steps between 2,000 and 2,600 mm. The crossbars are fastened on carriages which execute the longitudinal feed step from one die to the next. The carriages run on the two lift beams of the transfer which move in the vertical direction to raise and lower the part. No supplementary aids, such as lifters or ejectors in the die, are required for part transport. The time-motion diagram differs markedly from that of the tri-axis transfer (Fig. 4.4.36). In contrast to a tri-axis transfer, the crossbar transfer cannot return during the forming process, as the crossbars are located between the dies. When the dies are closed the crossbars are located in a parked position outside the die area. The die spacing must in any Metal Forming Handbook / Schuler (c) Springer-Verlag Berlin Heidelberg 1998
Sheet metal forming lines motion curves part-specific tooling double die universal station carriage lift beam crossbar Fig. 4.4.34 Part transport with crossbar transfer system in the production of doors using a double die loading feeder arm of a press line crossbar of a transfer press loading and unloading unloading Fig. 4.4.35 Positioning of parts on a feeder or robotic arm of a press line and on a crossbar Metal Forming Handbook / Schuler (c) Springer-Verlag Berlin Heidelberg 1998 245
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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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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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Page 215 and 216: Coil lines Fig. 4.3.1 Coil line for
Page 217 and 218: Coil lines Fig. 4.3.3 Compact desig
Page 219 and 220: Sheet metal forming lines In the ca
Page 221 and 222: Sheet metal forming lines Fig. 4.4.
Page 223 and 224: Sheet metal forming lines ing of th
Page 225 and 226: Sheet metal forming lines (Fig. 4.4
Page 227 and 228: Sheet metal forming lines The two l
Page 229 and 230: Sheet metal forming lines 1,860mm a
Page 231 and 232: Sheet metal forming lines ver’s c
Page 235 and 236: Sheet metal forming lines During th
Page 237 and 238: Sheet metal forming lines 4.4.4 Des
Page 243 and 244: Sheet metal forming lines individua
Page 245 and 246: Sheet metal forming lines As early
Page 247 and 248: Sheet metal forming lines In modern
Page 249 and 250: Sheet metal forming lines 4.4.6 Tra
Page 251 and 252: Sheet metal forming lines protects
Page 253 and 254: Sheet metal forming lines Within th
Page 255 and 256: Sheet metal forming lines power req
Page 257 and 258: Sheet metal forming lines Press lay
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Page 261 and 262: Sheet metal forming lines Draw cush
Page 263: Sheet metal forming lines These com
Page 267 and 268: Sheet metal forming lines increase
Page 269 and 270: Sheet metal forming lines (cf. Fig.
Page 271 and 272: Sheet metal forming lines larly str
Page 273 and 274: Sheet metal forming lines ing parts
Page 275 and 276: Sheet metal forming lines - efficie
Page 277 and 278: Sheet metal forming lines - Automat
Page 279 and 280: Sheet metal forming lines Local ope
Page 281 and 282: Sheet metal forming lines modules a
Page 283 and 284: Sheet metal forming lines Table 4.4
Page 287 and 288: Sheet metal forming lines sion foll
Page 289 and 290: Blanking processes to complete brea
Page 291 and 292: Blanking processes Fig. 4.5.5 Top-t
Page 293 and 294: Blanking processes 56.8% 65.0% 67.4
Page 295 and 296: Blanking processes a configuration
Page 297 and 298: Blanking processes flat punch U bev
Page 299 and 300: Blanking processes Using these equa
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Page 303 and 304: Blanking processes 0.18 10 10.36 27
Page 305 and 306: Shearing lines Fig. 4.6.1 Slitting
Page 307 and 308: Shearing lines The blanking process
Page 309 and 310: Shearing lines Blanking presses for
Page 311 and 312: Shearing lines 4.6.3 High-speed bla
Page 313 and 314: 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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