3 Fundamentals of press design

More documents

Recommendations

Info

398 Sheet metal forming and blanking Example: A production unit has to be configured in which 44 pressed parts – primarily A parts – have to be produced every year for 100,000 vehicles. The unit comprises a blanking line, a crossbar transfer press and a tri-axis transfer press. A possible configuration of this stamping plant with optimized material flow and peripheral devices is illustrated in Fig. 4.9.6.The material is supplied in the form of coil stock and stored in the coil storage, from where it is fed to the blanking line. This supplies through the blank storage both large-panel transfer presses with a total of 4 million blanks a year. Following production on the transfer presses, the parts are transported in part-specific racks to the intermediate storage for finished parts. Table 4.9.3 lists the part spectrum for both forming presses. The crossbar transfer press is run using eight individual and eight double die sets, whereby the double dies in this example always produce two different parts. Their die change time amounts to 10 min. The tri-axis transfer press manufactures 20 different parts using 20 die sets. The die change time is also 10 min. Overall, the 44 parts are produced using 36 sets of dies – 20 on the tri-axis transfer press, and 24 on the crossbar transfer press. If 222 working days are available per year, parts for 450 vehicles must be produced every day. In three-shift operation with working periods of 1,260 min per day, the total of approx. 4.8 million parts indicated in Table 4.9.2 (achieved with 3.9 million strokes) can be produced every year on the transfer presses. This is based on a planned capacity utilization of 80%. Three days are selected as a production cycle. If we take the simplified assumption that every part is only run once per cycle, three times 450 parts must be produced per cycle. The intermediate storage for finished parts has a theoretical maximum inventory of 1,800 pressed parts of each part type: 1,350 parts from running production plus 450 parts as a minimum safety inventory. On average, however, as body-inwhite production runs on a parallel basis, only around half of the parts are located in the intermediate storage. At any point in time, the inventory comprises 900 � 44, i.e. approx. 40,000 parts. As a result, the part storage and the capital investment this involves are considerably lower than when producing on conventional press lines. 4.9.3 Quality assurance through quality control The aim of achieving zero-defect production calls for continuous quality control. This involves the detection of any changes in the production process which could precede a defect, and the segregation of individual defective parts. Conventional methods of quality assurance in stamping plants include visual inspections – in the case of deep drawn Metal Forming Handbook / Schuler (c) Springer-Verlag Berlin Heidelberg 1998
Organization of stamping plants Table 4.9.3: Production data for crossbar and tri-axis transfer presses Production cycle: 3 days Availability: 70% Die change time (min): 10 Crossbar transfer press Die sets: Planned utilization rate: 16 (24) 80% Part name Parts/ stroke Part requirement/day Strokes/ parts/cycle Part batch size body side, outer, right 1 450 1350 1350 body side, outer, left 1 450 1350 1350 door, outer, front, right + left 2 450 1350 2700 trunk lid, inner 1 450 1350 1350 roof 1 450 1350 1350 trunk lid, outer 1 450 1350 1350 door, inner, front, right + left 2 450 1350 2700 body side, inner, rear, right + left 2 450 1350 2700 door, outer, rear, right + left 2 450 1350 2700 door, inner, rear,right + left 2 450 1350 2700 hood, outer 1 450 1350 1350 hood, inner 1 450 1350 1350 fender, outer, front, right + left 2 450 1350 2700 wheel house, inner, front, right + left 2 450 1350 2700 floor, mid 1 450 1350 1350 floor, front 2 450 1350 2700 Tri-axis transfer press Production cycle: 3 days Availability: 70% Die change time (min): 10 Die sets: 20 Planned utilization rate: 80% Part name Parts/ Stroke Part requirement/day Strokes/ parts/cycle Part batch size floor, rear 1 450 1350 1350 lock reinforcement, front, right 1 450 1350 1350 lock reinforcement, rear, right 1 450 1350 1350 rib, reinforcement, rear, right 1 450 1350 1350 hinge pillar, front, right 1 450 1350 1350 hinge reinforcement, front, right 1 450 1350 1350 rib, reinforcement, front, right 1 450 1350 1350 lock reinforcement, front, left 1 450 1350 1350 lock reinforcement, rear, left 1 450 1350 1350 rib, reinforcement, rear, left 1 450 1350 1350 hinge pillar, front, left 1 450 1350 1350 hinge reinforcement, front, left 1 450 1350 1350 rib, reinforcement, front, left 1 450 1350 1350 dash panel 1 450 1350 1350 shelf, rear 1 450 1350 1350 seat, reinforcement, rear 1 450 1350 1350 wheel house inner, rear, left 1 450 1350 1350 wheel house inner, rear, right 1 450 1350 1350 sunroof 1 450 1350 1350 sunroof aperture panel 1 450 1350 1350 Metal Forming Handbook / Schuler (c) Springer-Verlag Berlin Heidelberg 1998 399
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 and 14:
Contents 5.3 Component development
Page 15 and 16:
Index of formula symbols � rib an
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 29 and 30:
Page 31 and 32:
Page 33 and 34:
Page 35 and 36:
Page 37 and 38:
Page 39 and 40:
Page 41 and 42:
Page 43 and 44:
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
Page 57 and 58:
Page 59 and 60:
Page 61 and 62:
Page 63 and 64:
Page 65 and 66:
Page 67 and 68:
Page 69 and 70:
Page 71 and 72:
Mechanical presses , distance s[m]
Page 73 and 74:
Mechanical presses stress on the fr
Page 75 and 76:
Mechanical presses stroke [mm] 900
Page 77 and 78:
Mechanical presses This offers a nu
Page 79 and 80:
Mechanical presses or bottom mounte
Page 81 and 82:
Mechanical presses In crossbar tran
Page 83 and 84:
Mechanical presses with a long serv
Page 85 and 86:
Mechanical presses Fig. 3.2.9 Drive
Page 87 and 88:
Mechanical presses Overload safety
Page 89 and 90:
Mechanical presses Slide cushion So
Page 91 and 92:
Mechanical presses imum pneumatic p
Page 93 and 94:
Page 95 and 96:
Hydraulic presses Design of the dri
Page 97 and 98:
Hydraulic presses pumps suspended i
Page 99 and 100:
Hydraulic presses pressure in the p
Page 101 and 102:
Hydraulic presses F 4 I P (F ) max
Page 103 and 104:
Hydraulic presses are two variation
Page 105 and 106:
Hydraulic presses presscrown retain
Page 107 and 108:
Changing dies to a weight of 3 t pr
Page 109 and 110:
Changing dies gearwithguidinggroove
Page 111 and 112:
Changing dies are changed in solid
Page 113 and 114:
Changing dies hydraulic clamping me
Page 115 and 116:
Press control systems 3.5.3 Operati
Page 117 and 118:
Press control systems 3.5.4 Structu
Page 119 and 120:
Press control systems The communica
Page 121 and 122:
Press control systems Fig. 3.5.5 PL
Page 123 and 124:
Press control systems Fig. 3.5.7 Sw
Page 125 and 126:
Press control systems Other approac
Page 127 and 128:
Press safety and certification 3.6.
Page 129 and 130:
Press safety and certification with
Page 131 and 132:
Press safety and certification - st
Page 133 and 134:
Press safety and certification Manu
Page 135 and 136:
Press safety and certification pres
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
Page 157 and 158:
Principles of die manufacture the p
Page 159 and 160:
Metal Forming Handbook / Schuler (c
Page 161 and 162:
Principles of die manufacture 0.00
Page 163 and 164:
Principles of die manufacture blank
Page 165 and 166:
Page 167 and 168:
Page 169 and 170:
Principles of die manufacture how i
Page 171 and 172:
Principles of die manufacture spott
Page 173 and 174:
Page 175 and 176:
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 -
Page 207 and 208:
Deep drawing and stretch drawing se
Page 209 and 210:
Deep drawing and stretch drawing fo
Page 211 and 212:
Deep drawing and stretch drawing pu
Page 213 and 214:
Deep drawing and stretch drawing ag
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 233 and 234:
Page 235 and 236:
Sheet metal forming lines During th
Page 237 and 238:
Sheet metal forming lines 4.4.4 Des
Page 239 and 240:
Page 241 and 242:
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
Page 259 and 260:
Sheet metal forming lines higher st
Page 261 and 262:
Sheet metal forming lines Draw cush
Page 263 and 264:
Sheet metal forming lines These com
Page 265 and 266:
Sheet metal forming lines motion cu
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 285 and 286:
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 and 330:
Shearing lines Fig. 4.6.21 Automati
Page 331 and 332:
Shearing lines Fig. 4.6.24 Passenge
Page 333 and 334:
Shearing lines F F resistance weldi
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
Page 341 and 342:
Shearing lines - provision of all i
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
Page 349 and 350:
Shearing lines interference, or whe
Page 351 and 352:
Fine blanking - smaller dimensional
Page 353 and 354:
Fine blanking f i blanking force F
Page 355 and 356:
Fine blanking blanking force F s I
Page 357 and 358:
Fine blanking plate of the die, whi
Page 359 and 360:
Fine blanking case hardening nitrit
Page 361 and 362:
Fine blanking not been soft anneale
Page 363 and 364:
Fine blanking it is also possible t
Page 365 and 366:
Fine blanking Example: We wish to p
Page 367 and 368: Fine blanking s h S1 tearing E frac
Page 369 and 370: Fine blanking punches, as well as t
Page 371 and 372: Fine blanking subsequently quenched
Page 373 and 374: Fine blanking Fig. 4.7.22 Two-stati
Page 375 and 376: Fine blanking Blanking plate 2 is l
Page 377 and 378: Fine blanking 1 2 5 6 3 Fig. 4.7.25
Page 379 and 380: Fine blanking blankingpunch 1 2 inn
Page 381 and 382: Fine blanking vee-ring piston diehe
Page 383 and 384: Fine blanking measuring the pressur
Page 385 and 386: Fine blanking pallets reach the sta
Page 387 and 388: Bending Table 4.8.1 gives the small
Page 389 and 390: Bending Accordingly, the necessary
Page 391 and 392: Bending Example: You wish to bend a
Page 393 and 394: Bending F F b or b 2 b ⋅s ⋅R =
Page 395 and 396: Bending Fig. 4.8.7 Roll forming: ro
Page 397 and 398: Bending Fig. 4.8.13 Hat sections Fi
Page 399 and 400: Bending Table 4.8.3: Material coeff
Page 401 and 402: Bending The roll stand for profile
Page 403 and 404: Bending frame Fig. 4.8.23 Work shaf
Page 405 and 406: Bending Fig. 4.8.25 Roller straight
Page 407 and 408: Bending W W t t W Wma s Fig. 4.8.28
Page 409 and 410: 4 Sheet metal forming and blanking
Page 411 and 412: Organization of stamping plants Whe
Page 413 and 414: Organization of stamping plants Tab
Page 415 and 416: Organization of stamping plants lic
Page 417: Organization of stamping plants bat
Page 421 and 422: Organization of stamping plants ele
Page 423 and 424: Organization of stamping plants une
Page 425 and 426: 5 Hydroforming 5.1 General One of t
Page 427 and 428: Process technology and example appl
Page 433 and 434: 5 Hydroforming 5.3 Component develo
Page 435 and 436: Component development a component d
Page 437 and 438: Component development 100% D D 75%
Page 439 and 440: Component development Pure expansio
Page 441 and 442: Die engineering diameter and stroke
Page 443 and 444: 5 Hydroforming 5.5 Materials and pr
Page 445 and 446: Materials and preforms for producin
Page 447 and 448: Presses for hydroforming Controllab
Page 449 and 450: 5 Hydroforming 5.7 General consider
Page 451 and 452: General considerations inward hole
Page 453 and 454: 6 Solid forming (Forging) 6.1 Gener
Page 455 and 456: General lets that can be produced t
Page 457 and 458: General Fig. 6.1.4 Examples of coin
Page 459 and 460: General Table 6.1.1: Comparison bet
Page 461 and 462: 6 Solid forming (Forging) 6.2 Benef
Page 463 and 464: Benefits of solid forming 6.2.2 Wor
Page 465 and 466: Benefits of solid forming range”
Page 467 and 468: Benefits of solid forming sions fro
Page 469 and 470:
Benefits of solid forming Where no
Page 471 and 472:
Materials, billet production and su
Page 473 and 474:
Page 475 and 476:
Page 477 and 478:
Page 479 and 480:
Page 481 and 482:
Page 483 and 484:
Page 485 and 486:
Formed part and process plan requir
Page 487 and 488:
Formed part and process plan 6.4.2
Page 489 and 490:
6 Solid forming (Forging) 6.5 Force
Page 491 and 492:
Force and work requirement d 0 d 2
Page 493 and 494:
Force and work requirement For die
Page 495 and 496:
Force and work requirement The mini
Page 497 and 498:
Force and work requirement dies) (c
Page 499 and 500:
Part transfer There is a broad rang
Page 501 and 502:
Part transfer For cold forming proc
Page 503 and 504:
Page 505 and 506:
6 Solid forming (Forging) 6.7 Die d
Page 507 and 508:
Die design wedge adjustment auxilia
Page 509 and 510:
Die design Table 6.7.1: Modular sys
Page 511 and 512:
Die design Fig. 6.7.5 Shearing die
Page 513 and 514:
Die design for radial stress � r
Page 515 and 516:
Die design The off-center applied f
Page 517 and 518:
Die design Table 6.7.4: Heat treatm
Page 519 and 520:
Die design Powder metal-manufacture
Page 521 and 522:
Die design ledeburitic 12 % chromiu
Page 523 and 524:
Die design system integrated into b
Page 525 and 526:
6 Solid forming (Forging) 6.8 Press
Page 527 and 528:
Presses used for solid forming mult
Page 529 and 530:
Presses used for solid forming slid
Page 531 and 532:
Presses used for solid forming Fig.
Page 533 and 534:
Presses used for solid forming duct
Page 535 and 536:
Page 537 and 538:
Presses used for solid forming 6.8.
Page 539 and 540:
Page 541 and 542:
Presses used for solid forming tati
Page 543 and 544:
Presses used for solid forming adeq
Page 545 and 546:
Presses used for solid forming Embo
Page 547 and 548:
Presses used for solid forming ment
Page 549 and 550:
Presses used for solid forming feed
Page 551 and 552:
Presses used for solid forming hopp
Page 553 and 554:
Presses used for solid forming coin
Page 555 and 556:
Presses used for solid forming Univ
Page 557 and 558:
Presses used for solid forming Meda
Page 559 and 560:
Presses used for solid forming CNC-
Page 561 and 562:
Presses used for solid forming forc
Page 563 and 564:
Index A.S.T.M.-standard 451 abrasio
Page 565 and 566:
Index cylinder -, counterpressure 4
Page 567 and 568:
Index flying shear 288 flywheel 51-
Page 569 and 570:
Index modified top drive 205-207 mo
Page 571 and 572:
Index sand blasting 460 sandwich co
Page 573:
Index washing/cleaning machine 219
show all

3 Fundamentals of press design

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?