3 Fundamentals of press design

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412 Hydroforming On the basis of the various semi-finished product shapes (Fig. 5.2.8), hydroforming can be applied to a wide variety of fields. Three main user groups have emerged as the most significant over recent years (Table 5.2.1): – the automotive engineering and supply industry, – sanitary and domestic installation industry, – pipe and pipe component manufacturers. Table 5.2.1: Fields of application for the hydroforming technique Sector automotive industry vehicles – road – water – air – rail chemical, gas, oil industry, power station construction domestic appliance industry bicycle industry processing of sections pumps and fittings heating, ventilation, air conditioning furniture industry lighting industry optics Assembly chassis, exhaust and intake systems, add-on parts, drive system, seats, frames/bodywork, steering piping and tank components, pipe fittings fittings, machines pipe fittings frame construction, semifinished pipes, rail-bound vehicles, utility vehicles housings fittings frames, moulded elements street lighting telescopes, torches Metal Forming Handbook / Schuler (c) Springer-Verlag Berlin Heidelberg 1998 Component (examples) cross members, side members, manifolds, roof rails, spoilers, gear shafts, seat frame components, A/B/C pillars, roof frame profiles, steering column with compensation T-fittings, reducers, housings, panelling tube bends, T-fittings, reducers, cross pieces, bends pedal bearings, joints, frames joints, girders, calibrated tubes, sections, roof arches, frames, structural members intake pipes tube bends, reducers, T-fittings, manifolds legs, structural members, joints, shells, shelves light masts, lamp shells housings
5 Hydroforming 5.3 Component development 5.3.1 User-oriented project management In practical industrial application, it is increasingly important to design a component not only for functionality but also for producibility. “Simultaneous engineering” and “early involvement” have become important watchwords in the field of product design, with customer and process developer cooperating from an early stage in determining component configuration. Only in this way is it possible to optimize functional and process engineering related factors within a short timeframe. A component development activity can be, for example, carried out as follows: 1. preliminary meeting (customer and developer) 2. technical and economic feasibility study (customer and developer) 3. component configuration suitable for hydroforming (customer and developer) and definition of a production sequence 4. prototype development: CAD surface data generation (customer) and CNC milling data generation (developer), manufacture of a forming die and production of prototypes using different materials and wall thicknesses (developer) 5. try-out of prototypes (customer) 6. definition of quality-relevant (QA) data (customer) 7. series production (customer or supplier) Metal Forming Handbook / Schuler (c) Springer-Verlag Berlin Heidelberg 1998
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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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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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Page 409 and 410: 4 Sheet metal forming and blanking
Page 411 and 412: Organization of stamping plants Whe
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Page 419 and 420: Organization of stamping plants Tab
Page 421 and 422: Organization of stamping plants ele
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Page 425 and 426: 5 Hydroforming 5.1 General One of t
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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
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Page 451 and 452: General considerations inward hole
Page 453 and 454: 6 Solid forming (Forging) 6.1 Gener
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Page 457 and 458: General Fig. 6.1.4 Examples of coin
Page 459 and 460: General Table 6.1.1: Comparison bet
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Page 465 and 466: Benefits of solid forming range”
Page 467 and 468: Benefits of solid forming sions fro
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Page 471 and 472: Materials, billet production and su
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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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