3 Fundamentals of press design

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432 Hydroforming – The single-part construction eliminates the need for welding seams. – The calibration process ensures a high degree of accuracy in the contours and dimensions of hydroformed components. – Strain hardening generally lends hydroformed components a high degree of torsional rigidity. Their elastic recovery properties are less pronounced than is the case with welded sheet metal shells. For this reason, it is often possible for the wall thickness of hydroformed components to be relatively low compared to cast parts or shell constructions. This effect can be used either to reduce weight or to enhance strength or rigidity. – Using the same die, it is possible to use and test tubes which, within certain limits, have different wall thicknesses and starting diameters and are made of different materials (provided the ultimate deformation is not exceeded). This allows the weight and strength properties of the part to be optimized. – Experience has shown that lower flow resistance and larger fatigue strength are achieved in exhaust systems. By selective component and process configuration, it is possible to save both energy and material and to reduce development and production times. Thus, generally it is possible to reduce manufacturing costs. Bibliography Leitloff, F.-U.: Innenhochdruckumformen mit dem Schäfer-ASE-Verfahren, Stahl (1995) 5. Malle, K.: Aufweiten - Stauchen - Expandieren, VDI Journal 137 (1995) 9. N. N.: ASE-Verfahren bringt Hohlkörper in Form, Stahlmarkt (1993) 4. N. N. : Hochdruckumformen - Fertigungsverfahren mit Zukunft, Stahl (1993) 4. N. N.: Mit Wasser immer in Form, Automobil-Industrie (1993) 4. N. N.: Schäfer bringt Hohlkörper in Form, Technische Informationsbroschüre zur Schäfer-ASE- Technologie, Wilhelm Schäfer Maschinenbau GmbH & Co. Schäfer, A. W., Fröb, K., Bieselt, R., Hassanzadah, G.: Kaltgeformte T-Stücke für den Anlagenbau – Anforderungen und technische Realisierbarkeit, 3R International 29 (1990) 9. Metal Forming Handbook / Schuler (c) Springer-Verlag Berlin Heidelberg 1998
6 Solid forming (Forging) 6.1 General Processes and parts The terms sheet metal forming and solid forming are based on practical industrial application, and subdivide the field of forming technology into two distinct areas. This distinction is made in addition to the definitions established by DIN 8582 “Forming” (cf. Fig. 2.1.3). Solid forming entails the three-dimensional forming of “compact” slugs (for example sheared billets), while the sheet metal forming method generally processes “flat” sheet metal blanks to create three-dimensional hollow structures with an approximately constant sheet metal thickness. The forces exerted during solid forming are substantially higher than those necessary for sheet metal forming. As a result, it is necessary to use relatively rigid compact-design machines and dies. Solid forming involves not only the processes of extrusion, indentation and drawing which are dealt with in most detail here, but also for example rolling, open die forging (cf. Fig. 2.1.4) or closed die forging (cf. Fig. 2.1.5). The processes cold extrusion and drawinginvolve forming a slug or billet placed in a die, most commonly for the production of discrete parts. Hot extrusion uses a basically similar forming mechanism to create semi-finished products such as rods, tubes and sections. The basic processes involved in cold extrusion (Fig. 6.1.1) are classified depending on their forming direction as forward, backward and lateral extrusion and also according to the final form of the workpiece as rod (solid), tube and cup extrusion. When producing solid parts, the classical operations of cold extrusion technology are supplemented by processes like upsetting and ironing (Fig. 6.1.2). The shape variety of parts formed from slugs or bil- 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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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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Page 409 and 410: 4 Sheet metal forming and blanking
Page 411 and 412: Organization of stamping plants Whe
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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 437 and 438: Component development 100% D D 75%
Page 439 and 440: Component development Pure expansio
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Page 443 and 444: 5 Hydroforming 5.5 Materials and pr
Page 445 and 446: Materials and preforms for producin
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Page 449 and 450: 5 Hydroforming 5.7 General consider
Page 451: General considerations inward hole
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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
Page 461 and 462: 6 Solid forming (Forging) 6.2 Benef
Page 463 and 464: Benefits of solid forming 6.2.2 Wor
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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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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
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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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