3 Fundamentals of press design

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VI Metal Forming Handbook This Handbook is the product of dedicated commitment and the wide range of specialized knowledge contributed by many employees of the SCHULER Group in close cooperation with Prof. Dr.-Ing. H. Hoffmann and Dipl.-Ing. M. Kasparbauer of the utg, Institute for Metal Forming and Casting at the Technical University of Munich. In close cooperation with the SCHULER team, they have created a solid foundation for the practical and scientific competence presented in this Handbook. We wish to offer our sincere thanks and appreciation to all those involved. Goeppingen, March 1998 Schuler GmbH Board of Management Metal Forming Handbook /Schuler (c) Springer-Verlag Berlin Heidelberg 1998
Contributors ADAM, K., Dipl.-Ing. (FH), SMG Süddeutsche Maschinenbau GmbH & Co BAREIS, A., Dipl.-Ing. (FH), Schuler Pressen GmbH & Co BIRZER, F., Prof. Dipl.-Ing., Feintool AG BLASIG, N., Dipl.-Ing. (FH), Schleicher Automation GmbH & Co BRANDSTETTER, R., Dipl.-Ing. (FH), Schuler Pressen GmbH & Co BREUER, W., Dipl.-Ing., Schuler Pressen GmbH & Co FRONTZEK, H., Dr.-Ing., Schuler GmbH HOFFMANN, H., Prof. Dr.-Ing., Lehrstuhl für Umformtechnik und Gießereiwesen, Technische Universität München JAROSCH, B., Dipl.-Ing. (FH), Schuler Pressen GmbH & Co KÄSMACHER, H., SMG Engineering für Industrieanlagen GmbH KASPARBAUER, M., Dipl.-Ing., Lehrstuhl für Umformtechnik und Gießereiwesen, Technische Universität München KELLENBENZ, R., Dipl.-Ing. (FH), Schuler Pressen GmbH & Co KIEFER, A., Dipl.-Ing. (BA), GMG Automation GmbH & Co KLEIN, P., Gräbener Pressensysteme GmbH & Co. KG KLEMM, P., Dr.-Ing., Schuler Pressen GmbH & Co KNAUß, V., Dipl.-Ing. (FH), Schuler Werkzeuge GmbH & Co KOHLER, H., Dipl.-Ing., Schuler Guß GmbH & Co KÖRNER, E., Dr.-Ing., Schuler Pressen GmbH & Co KUTSCHER, H.-W., Dipl.-Ing.(FH), Gräbener Pressensysteme GmbH & Co. KG LEITLOFF, F.-U., Dr.-Ing., Schäfer Hydroforming GmbH & Co MERKLE, D., Schuler Pressen GmbH & Co OSEN, W., Dr.- Ing., SMG Süddeutsche Maschinenbau GmbH & Co PFEIFLE, P., Dipl.-Ing. (FH), Schuler Pressen GmbH & Co REITMEIER, C., Dipl.-Ing., Schäfer Hydroforming GmbH & Co REMPPIS, M., Ing. grad., Schuler Pressen GmbH & Co ROSENAUER, K., Dipl.-Ing. (FH), Schuler Werkzeuge GmbH & Co Metal Forming Handbook /Schuler (c) Springer-Verlag Berlin Heidelberg 1998
Page 1 and 2: Metal Forming Handbook /Schuler (c)
Page 3 and 4: 123 METAL FORMING Metal Forming Han
Page 5: Preface Following the long traditio
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 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
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Press types and press construction
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3 Fundamentals of press design 3.2
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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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3 Fundamentals of press design 3.3
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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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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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Component development 100% D D 75%
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Component development Pure expansio
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Die engineering diameter and stroke
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5 Hydroforming 5.5 Materials and pr
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Materials and preforms for producin
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Presses for hydroforming Controllab
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5 Hydroforming 5.7 General consider
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General considerations inward hole
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6 Solid forming (Forging) 6.1 Gener
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General lets that can be produced t
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General Fig. 6.1.4 Examples of coin
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General Table 6.1.1: Comparison bet
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6 Solid forming (Forging) 6.2 Benef
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Benefits of solid forming 6.2.2 Wor
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Benefits of solid forming range”
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Benefits of solid forming sions fro
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Benefits of solid forming Where no
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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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