3 Fundamentals of press design

General
lets that can be produced today is increased substantially by the use of
piercing, flow piercing, trimming and bending processes.
The range of parts includes not only fastening elements (screws, bolts,
nuts, rivets, etc.), but parts for the construction industry (L and T-fittings
for heating systems) and components used in mechanical engineering
applications (ball bearing races, balls, rollers and cages). Most solid
formed parts are used in the automotive and motor cycle industry. Engine
components (valves, camshafts, cams, connecting rods), gear parts (gear
shafts, gear wheels, synchronous rings, differential bevel gears), chassis
components (stud axles, ball hubs, stepped housing elements, shock
absorbers), steering components (steering column joints, tie rod ends),
brake components (brake pistons) and components for electrical motors
(starter motor pinions, drivers, pole rotors), can be economically produced
by solid forming. In addition, solid formed parts are used in
household appliances, office equipment, clocks or medical equipment.
Figure 6.1.3 offers an overview of different shapes which can be produced.
The forming techniques described here are currently also used to
produce gears that can be produced very economically. In many cases,
no machining is necessary or at most one final grinding or hardening
process may be required at the teeth. Components with straight teeth
(spur gears) – such as hub sleeves, bevel wheels and gears –, helical teeth
(e.g. planetary gears, small gears) and special teeth forms (e.g. ring
gears) can be produced. This type of gears can be formed with any
desired tooth that is often involute in shape.
Contours are formed on the surface using the indentation processes
(DIN 8583 sheet 5) coining and roll embossing. Here, the complete
punch
container
workpiece
upsetting die
upsetting extrusion
Fig. 6.1.2 Upsetting, open die extrusion, ironing
Metal Forming Handbook / Schuler (c) Springer-Verlag Berlin Heidelberg 1998
α
punch
ironing die
workpiece
ironing
α
2
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