Beruflich Dokumente
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Matthew De Kam
I. INTRODUCTION
S t L
This equation relates the load force (F) to the shear strength
of the material (S), the thickness of the material (t), and the
length of the cut (L).
B. Cutting Clearance
The clearance between the diameter of the punch and the
diameter of the blanking die will affect the overall press
loading. The clearance between punches and die holes
depends on the thickness and hardness of the stock material.
The following equation relates these variables to clearance:
c=at
The clearance (c) depends on material thickness (t) and an
allowance constant (a). The allowance constant is based on
material properties and increases with hardness as shown in
the chart below.
Metal Group
1100S and 5052S Aluminum
2025ST and 6061ST
Aluminum; prass; soft coldrolled steel, soft stainless
Cold-rolled
steel, half-hard;
steel
stainless steel, half-hard and
full hard
a
0.045
0.060
0.075
C. Tool sharpness
It is straightforward to see the relationship between tool
sharpness and the press force necessary. Dull punches and
dies will contribute to increased press load. It is helpful to be
able to sense the load on the press in order to evaluate if it is
time to sharpen punches and dies.
D. Cutting Shear
Good die design will make use of a shear angle on punches
and cutting surfaces. The angle creates a scissors-like action
between the punch and the die. The cutting operation is then
D. Ram Velocity
The last contributing factor to press loading is the velocity of
the press ram. Increasing the velocity of the ram will increase
the force according to the following equation:
d v
f m
dt
B. Load Cells
Small load cells are also used to determine press loadings.
Load cells can be placed between the die and the press ram to
determine the press loading. These load cells output a voltage
that is proportional to the loading of the press. This voltage is
conditioned with amplification and filtration circuitry. These
types of miniature load cells are generally used during die
setup, and are not generally intended for permanent control
applications.
C. Piezoelectric Transducers
Piezoelectric transducers are a more recent technology that is
useful for determining press loading. The transducers are
mounted to the press frame in the same positions as strain
gauges. These transducers are easier to mount, and require
much less additional circuitry to condition the signal. The
output signal is strong, clean, and can in some cases be
outputted directly to a digital readout.
D. Calibration
Each of the load sensing methods mentioned requires a
precise method of calibration in order to obtain meaningful
results. This calibration must be very accurate to allow the
load sensing system to display true data. Calibration is
generally performed by applying several known loads to the
press. These known loads should be in the middle of the
expected load range of the press. By applying known loads
and comparing them to the load sensing system readouts a
calibration curve for the system can be obtained. This
calibration curve is then used to interpret all further results of
the load sensing system. Current calibration techniques are
complex, and the hardware required can often cost as much
as the load sensing system.
IV. LOAD SENSITIVE CONTROL SYSTEMS
A. Digital Readout
One option for using the load data is simply to have a digital
readout near the press controls. When the operator of the
press sees any strange load profiles or any high load values
the press can be shutdown and adjusted.
V. INDUSTRY APPLICATION
A. Background
Currently in the manufacturing industry, a third-tier
automotive supplier uses metal stamping presses extensively
in production. These presses generally run progression dies
as explored previously in this paper. This manufacturer is
interested in determining the actual press loading so that it
can better evaluate the condition of its many stamping
processes. The improved diagnostics are focused on providing
more accurate assessment of die wear and press performance.
B. Press Design
The presses used by this manufacturer are primarily of the
same design. The press design was done specifically to
provide this manufacturer with a quality press for a low,
predictable cost. Two models with two different tonnage
ratings are primarily used in this facility; a twenty-ton press
and a sixty-ton press. These presses are of a unique design,
as can be seen in the figures below.
At
Rear
6 .5
( 10 34) .5 2
Ar
4A t A r
A xs
Tonnage Rating
Fpress
Stress
Fpress
A xs
7.143 10
Fig 8. Stamping press drive linkage. The geometry of this dynamic system was
used to find the transfer function for the press.
m 30
f rm
rm
rf
26.742
rc 4.5
m 3000
c( t ) f t
rf
xc( t) rc cos c( t )
3.607
xb ( t ) xc( t )
yb ( t ) .45 xb ( t )
4
2
y b( t ) 0
2
4
vb ( t )
0.5
d
yb ( t)
dt
1.5
1.5
1.5
t
10
vb( t ) 0
ab ( t )
d
vb ( t)
dt
10
0.5
t
f( t ) m ab ( t )
1 10
f( t )
1 10
0.5
t
Fig 9. These calculations show the typical position, velocity, and force profile for
the given drive system. These calculations were used to find a transfer function
for the press.
press load curve and tested to see if the load was within
specified constant lower and upper bounds. These bounds
were set at the specified press load rating.
Fig 13. A load-limiting control system. This system simply cuts power to the
press when the load becomes larger than the specified limit magnitude.
1) Digital Display
This simple type of control system relies heavily on the
machine operator to monitor the load, and take action if it
exceeds the presses limitations. This system was simulated
using Simulink software.
Fig 14. System output for a load exceeding the specified load limit of sixty tons.
Fig 12. Disturbance signal for all simulations. This signal simulates both the
positive and negative force encountered by the press ram during the piercing
operation.
limits.
Fig 18. This feedback control system saturates the press load to keep it within
acceptable limits.
Fig 19. The output of the saturating load control system. Notice the smooth peak
stays below sixty tons.
[2]
D. Falcone. (2002, Nov.) Equipping Your Press With the Right Tonnage
Monitor. The Croydon Group, Ltd. Rockford, IL. [Online]. Available:
http://www2.thefabricator.com/Articles/Stamping_Article.cfm?ID=276
[3]
The ram stroke then takes a great deal of energy out of the
rotating flywheel. In this situation if the press cycles too often
the flywheel will not have enough time to restock its energy
by getting back up to speed. This can cause the press to stall
on jobs which a well under rated press loading. A press with a
[4]
[5]