3 Fundamentals of press design

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468 Solid forming (Forging) gram can serve to illustrate the metal flow in the relevant forming process. This allows to predict and eliminate problems such as crack formation, underfilling and excessive die loads prior to actual die try-out (Fig. 6.4.1). Fig. 6.4.1 FEM study of material flow for a flange upsetting process with relief borehole Metal Forming Handbook / Schuler (c) Springer-Verlag Berlin Heidelberg 1998
6 Solid forming (Forging) 6.5 Force and work requirement Determination of the force and work requirement is used as a basis for selection of the forming machine and the structural design of the forming dies. In practice, calculation of these characteristics simultaneously produces values of process-related parameters such as the overall degree of true strain, flow stress, forming pressure, compressive stresses on the inside wall of the extrusion container, etc. (cf. Sect. 2.2). The process limits and the respective case of application of the forming method must also be taken into consideration here. The formulae provided below are based on only one method of calculation and make no claim of completeness. The flow stress levels are average values obtained from the flow curves of VDI 3200 Sheets 2 and 3. To calculate the process variables concerning machine selection, the upper limit of a flow curve should be selected. However, in making calculations regarding die configuration, the lower limit of a flow curve should be selected. Table 6.5.1 provides an overall view of the process limits for the main extrusion processes. 6.5.1 Forward rod extrusion The forward rod extrusion method transforms a billet into a solid part with a reduced cross section (cf. Fig. 6.1.1). The die opening which determines the shape of the extruded parts is formed solely by the press container. As a result of the wall friction which occurs – also during the ejection process – the ratio of height to diameter of the initial billet h 0/d 0 [–] should be no greater than 5 to 10 (Fig. 6.5.1). If the required 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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Metal Forming Handbook / Schuler (c
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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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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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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
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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
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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
Page 485 and 486: Formed part and process plan requir
Page 487: Formed part and process plan 6.4.2
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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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
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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
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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: Presses used for solid forming Fig.
Page 537 and 538: Presses used for solid forming 6.8.
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Presses used for solid forming Fig.
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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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