3 Fundamentals of press design

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310 Sheet metal forming and blanking Fig. 4.6.22 Punch-bundled rotor and stator lamination stacks punched part with cams punched part without cams Fig. 4.6.23 Joining laminations by means of punch-bundling punch 4.6.5 Production and processing of tailored blanks blank female die Welded blanks comprising different materials, thicknesses or coatings are known as tailored blanks. The most important benefits offered by tailored blanks are weight savings and also reduction of the number of parts required to form assemblies, for example in the case of car body Metal Forming Handbook / Schuler (c) Springer-Verlag Berlin Heidelberg 1998
Shearing lines Fig. 4.6.24 Passenger car reinforcement formed from a tailored blank reinforcing components (Fig. 4.6.24). In the production of complete assemblies, this reduces lead times and the susceptibility to corrosion due to the smaller number of welding joints. By using scrap parts from previous blanking operations, for manufacturing tailored blanks it is possible to reduce scrap in the stamping plant. Costs for input materials can also be reduced by using lower-cost sheet metal grades for low-stress applications. In addition, tailored blanks can be configured to special shapes for specific cases of application. Such shapes are generally not offered by steel manufacturers. These benefits have led to the widespread processing of tailored blanks. Tailored blanks are manufactured on blank welding lines (Fig. 4.6.25). The blanks produced on a blanking press are loaded in stack form, aligned, centered and fed to the automatic welding machine. The blanks are then welded by means of resistance, laser or induction welding methods (Fig. 4.6.26). Where resistance welding is used, a control system checks the process, assuming high output and quality. The welding unit comprises two loading and centering tables for blank feed, a traversing unit to hold the Metal Forming Handbook / Schuler (c) Springer-Verlag Berlin Heidelberg 1998 311
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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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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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Page 283 and 284: Sheet metal forming lines Table 4.4
Page 285 and 286: Sheet metal forming lines Fig. 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
Page 301 and 302: Blanking processes x S = 66. 6 (s a
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
Page 315 and 316: Shearing lines Fig. 4.6.9 Influence
Page 317 and 318: Shearing lines Fig. 4.6.11 Rotor an
Page 319 and 320: Shearing lines Fig. 4.6.13 Complete
Page 321 and 322: Shearing lines Fig. 4.6.15 Complete
Page 323 and 324: Shearing lines Fig. 4.6.17 Flexible
Page 325 and 326: Shearing lines which run, backlash-
Page 327 and 328: Shearing lines that up to 150 strok
Page 329: Shearing lines Fig. 4.6.21 Automati
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Page 335 and 336: Shearing lines In contrast to conve
Page 337 and 338: Shearing lines The stripper plate i
Page 339 and 340: Shearing lines Fig. 4.6.32 Examples
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Page 343 and 344: Shearing lines Fig. 4.6.35 Machine
Page 345 and 346: Shearing lines Fig. 4.6.37 Failure
Page 347 and 348: Shearing lines Structure of the ele
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Page 351 and 352: Fine blanking - smaller dimensional
Page 353 and 354: Fine blanking f i blanking force F
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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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3 Fundamentals of press design

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