4/25/2016

HydraulicAndMechanicalPresses

HydraulicAndMechanicalPresses
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Machinesforsheetmetalprocessingandpartmanufacture,cutting,bending,punching,
etc.,(manual,pneumatic,electric,hydraulic)
Pressesfordeepdrawing,forging,extrusionandotherprocesses,wecanalsoprovide
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Thepressrepresentsaspecifictypeofmachinetool,essentialintheperformanceofindustrial
manufacturingprocesses.Pressesdeliverenergythroughaforcethatactsoveradistanceorstroke.
Oneimportantapplicationisinmetalforgingmanufacture.Theenergyofthepressisusedtoclose
thedie,forgingthepartwithin.Pressmachinetoolsapplyforce/energytotheworkdifferentlythan
drophammers,(thatdeliverenergytotheworkthroughacollision),hammersaretheotherclassof
machinetoolsusedtoforgemetalparts.Drophammersarecoveredonthepreviouspage.This
pagewillcoverdifferenttypesofpressmachines,theirfunction,andcapabilities,althoughitis
locatedinthemetalforgingsection,forgingisonlyoneclassofmanufacturingprocessesthatemploy
presses.
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Pressmachinesarealsotheprimarymachinetoolusedinmetalextrusionandsheetmetal
fabricationprocesses.Hydraulicandmechanicalpressesareemployedduringsheetmetalformingto
theextentthatsheetmetalprocesses,ingeneral,areoftenreferredtoaspressworking.Presses
maybeusedinthemanufactureofplasticparts.Machiningoperations,suchasbroaching,mayalso
requirepresses.
Pressmachinetoolsvaryinsizeandintheamountofforcetheycanoutput.Theenergyfromapress
isoftenusedtodoworkrequiringatremendousamountofforce,suchasalargeamountofplastic
deformationofasizablepieceofmetal.Themethodandnaturebywhichapressmachinewilldeliver
itsenergywillvary,dependentonitstype.

Figure:176

Machinepressesshownherearevertical,meaningthattheforcevectorisupanddownrelativeto
gravity.Inmanycasesthesesamemachinetypesareutilizedhorizontally,meaningtheforceis
deliveredinapathperpendiculartothedirectionoftheforceofgravity.Iftheforcebeexerted
vertically,horizontally,oratsomeintermediateangle,theworkingprinciplesofeachtypeofmachine
toolarethesame.
Pressmachinetoolsareoftwomaintypes,hydraulicpressesandmechanicalpresses.Selectionofa
typeofmachinepressdependsonthefactorsofthemanufacturingprocess.Thefirstconsideration
wouldbethebasictypeofprocessthepresstoolwillbeemployedtoperform.Forexample,apress
formetalforging,apressforextrusion,apressforimpactextrusion,orapressforsheetmetal
workingwillallhavedifferentgeneralrequirements.Thenextveryimportantfactorinmachinepress
selectionforamanufacturingoperationisthepresscapacityrequired.Requiredpresscapacityis
likelyrelatedtothesizeoftheworkstock,andtypeofprocess.Lengthofstrokeoverwhichthepress
deliversforceisanotherprimaryfactorwhenchoosingapressmachinetool,thisalsowillberelated
tothebasictypeofprocessbeingemployed.Theseinitialconsiderationsshouldgiveanimmediate
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ideaofthegeneraltypeofpressrequired.Afterthis,allthespecificfactorsofthemanufacturing
processshouldbeweighed,todeterminethebestchoiceforapressmachinetool.

HydraulicPresses
Hydraulicpressesareapowerfulclassofmachinetools,theyderivetheenergytheydeliverthrough
hydraulicpressure.Fluidpressure,inaparticularchamber,canbeincreasedordecreasedbythe
useofpumps,andvalves.Sometimesdevicesandsystemsmaybeusedtoincreasethecapacityof
thepumpsinmorepowerfulpresses.Thesepressescanoperateoveralongdistanceandata
constantspeed.Hydraulicpressesaregenerallyslowerrelativetootherpressmachinetypes.This
involveslongercontactwiththework,thereforethecoolingoftheworkcanbeanissuewhenhot
formingapartwithhydraulicforce.Hydraulicpressesarecapableofbeingthemostpowerfulclassof
presses.Somemaybeaslargeasbuildings,andcandeliverawesomepressure.Thelargest
hydraulicpressesarecapableofapplying75,000tons,(150,000,000lbs),offorce.Thehydraulic
pressshownisbeingusedtomanufactureametalforging.Extrusionisalsoaverycommonusefor
suchapress,althoughextrusionisoftenperformedhorizontally.

Figure:177

Thebasicworkingprinciplesofthehydraulicpressaresimple,andrelyondifferencesinfluid
pressure.Fluidispumpedintothecylinderbelowthepiston,thiscausesthefluidpressureunderthe
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pistontoincrease.Simultaneously,fluidispumpedoutofthetopchannel,causingthefluidpressure
abovethepistontodecrease.Ahigherpressureofthefluidbelowthepistonthanthefluidaboveit
causesthepistontorise.Inthenextstep,fluidispumpedoutfrombelowthepiston,causingthe
pressureunderthepistontodecrease.Simultaneously,fluidispumpedintothecylinderfromthetop,
thisincreasesthefluidpressureabovethepiston.Ahigherpressureofthefluidabovethepiston,
thanthefluidbelowit,movesthepistondownward.

MechanicalPresses
Mechanicalpressesbelongtoaclassofmachinetoolsthatencompassawiderangeofdifferent
machinetypes.Primarily,themechanicalpresstransformstherotationalforceofamotorintoa
translationalforcevectorthatperformsthepressingaction.Therefore,theenergyinamechanical
presscomesfromthemotor.Thesetypesofpressesaregenerallyfasterthanhydraulicorscrew
presses,(actuallythescrewpressmayalsobeclassifiedasamechanicalpress).Unlikesome
presses,inamechanicalpress,theapplicationofforcevariesinbothspeedandmagnitude
throughoutthedistanceofthestroke.Whenperformingamanufacturingoperationusinga
mechanicalpress,thecorrectrangeofthestrokeisessential.
Pressesarechosenbasedonthecharacteristicsofthemanufacturingprocess.Mechanicalpress
machinetoolsarecommonlyusedinmetalforgingmanufacture,andsheetmetalworking.The
desiredapplicationofforcewilldictatethetypeofmachinerequired.Extrusionwilloftennecessitatea
moreconsistentforceoveralongerdistance.However,amechanicalpressmayoftenbeagood
choiceforimpactextrusion,sinceafast,quicklyrepeatableapplicationofforceoveralimited
distanceiswhatisneededforthattypeofmanufacturingprocess.Themostpowerfulmechanical
pressesinmodernmanufacturingindustrywillhaveapresscapacityofabout12,000tons,
(24,000,000lbs).

CrankPress
Thecrankpressusesacranklinkattachedtoadriveshaft.Thecranklinkrotateswiththedriveshaft
andisattachedtoaconnectingrodbyarotationaljoint.Theconnectingrodrocksbackandforth
duringthemotionofthecrank.Theconnectingrodis,inturn,attachedtoarambyarotationaljoint.
Theramoperatesinasliderjointandtravelsaonedimensionalpathinbothdirections.Itisthrough
thispaththatthecrankpressdeliversitsforce.Thecrankpressdoesallowforastokeofarelatively
longdistance.

Figure:178

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KnuckleJointPress
Theknucklejointpresstranslatestheenergyofamotorthroughapowerfullinkagedesign,andis
capableofdeliveringatremendousamountofforce.Thedriveshaftcrankrotatescompletely.The
linksarewellgroundedtosupportsuchpressure.

Figure:179

EccentricPress
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Theeccentricpressusesamotortodriveaneccentricshaft,rotatinginaconnectingrod.The
connectingrodmovesaraminasliderjointonedimensionally.Theeccentricshaftitselfisround,
thereforeitmaycompletelyrotatewithintheconnectingrod.Thecenterofthedriveisnotthecenter
oftheoverallshaft.Asthemotorrotates,thecenterofthedriveremainsstablebuttheoverallcenter
oftheshaftchanges.Thiscausestheshafttochangeposition,providingmotion.Theactualprinciple
ofaneccentricpressisverysimilartoacrankpress.

Figure:180

RackAndPinionPress
Therackandpinionpressdeliversthemotorsenergyfromageardirectlyconnectedtothedrive
shaft.Therackisactuallyaroundgearofinfiniteradius.Arotatinggear(pinion),providesforce
throughtherack.Thisgivestheonedimensional,translationalmotiondesiredofpressmachines.

Figure:181

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ScrewPresses
Screwpressesusetherotationalenergyofamotortoturnalargescrew.Typically,africtiondiskis
usedtotranslatetheforcefromthedriveshafttothescrew'shead.Thescrewpushesaramwith
greatmechanicaladvantage.Screwpressesaresimilartohydraulicpressesinthattheyarerelatively
slowandrequirealongercontactwiththework.Screwpressesarealsosimilartohydraulicpresses
inthattheycanproduceaconstantamountofforceoveralongstroke.Somescrewpressmachine
toolsinmodernindustrycanproduce31,000tons,(62,000,000lbs),offorce.

Figure:182

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