Forming Processes

Metal Forming/Press Operations

Forming processes are one of the most popular means of producing high volume products. Examples include appliance, aircraft, and automotive industries.
Major Reasons:
Production costs are low Well suited for high production applications Process capabilities Processes are built into tooling

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Tools

One of the basic tools used in these processes is a punch & die.
A punch is the portion of the tool attached to the ram of the press and is inserted into the die. A die is usually the stationary portion of the tool attached to the press bed. It has a cavity to accept the punch.

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Tools

Punch & die

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Tools

A progressive die is a tool capable of performing several operations from raw material to final product. These dies can be made from catalog items and divided into removable sections.

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Die alignment and clearance

Uniform clearance General rule - 5-7% material thickness

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Punch & dies are capable of performing the following examples of cold working(CW) operations:
Blanking - cutting desired shape from strip, burrs left on strip Piercing - leaving desired shape on strip, burrs on scrap

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Punch & die capabilities continued:

Forming & Bending Shearing Ironing Drawing

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Process Capabilities

Blanking vs. Piercing

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Tools

Forming & Bending

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Shearing

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Ironing

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Process Capabilities

Drawing

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Calculating Pressure for a Process (Tons)

General formula for a hole

Diameter of hole x Thickness of material x Ultimate Tensile Strength (UTS) = Pressure in Tons Guidelines
Mild Steel = 80 - 60,000 psi, Brass = 60,000 psi, Bronze = 40,000 psi, Copper = 30,000 psi Alum = 20,000 psi

Example
2 dia. hole in steel plate
2 x .250 x 80= 40 tons

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Calculating Pressure for a Process (Tons)

General Formula - Profile

P= (L x 1/3) x material thickness x 60 (UTS) Example = Punch a 1x 2 rectangle in brass
P= (6 x 1/3) x .250 x 60 = 29.7 ~ 30 tons Machinerys Handbook 23rd Edition

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Progressive Dies

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Progressive Dies

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Machine Tools- Presses

Classification
Manual
Foot operated

Light work -shearing

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Machine Tools- Presses

Mechanical
Max pressure near bottom of stroke Faster motion Operations - cutting, shallow forming, drawing, and progressive die operations Limitation - length of stroke set by design of mechanism = less flexibility Capacities up to 6,000 tons

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Machine Tools- Presses

Mechanical Press Drive Mechanisms

Crank = Simple design - used for piercing, blanking, and drawing operations Eccentric/Cam = Short ram stroke which provides a dwell a bottom of stroke Knuckle Fast action and high mechanical advantage Applications include coining and sizing Toggle = Drawing presses to move the blank holder Screw = Slow action

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Machine Tools- Presses

Hydraulic
Motion as a result of piston motion = longer or variable stroke lengths can be programmed (within limitations of the piston). Steady pressure for operations such as deep drawing Single-slide Multiple-slide Capacities up to 50,000 tons

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Machine Tools- Presses

Frame classification
Gap
Open arrangement of press frame Excellent clearance around dies Can handle long and wide parts

Arch
Lower portion of press near the bed is wide to accommodate large sheet material

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Machine Tools- Presses

Frame classification continued:

Straight side
Strong frame designheavy loads are taken up in vertical direction of massive frame Less of a tendency for punch & die to misalign

Horn
Heavy shaft projecting from frame Used primarily for cylindrical work involving seaming, flanging, riveting, and embossing

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Machine Tools- Presses

Frame classification continued:

Inclined
Vertical design can be tilted back to allow parts and scrap to slide out Used on parts involving bending, piercing, blanking, etc.

Turret Presses
Production of sheet metal parts having a variety of patterns, holes, cutouts, etc. in various sizes Current presses are CNC controlled and combined into machining centers, capable of laser, forming, and water-jet operations.

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Machine Tools- Presses

Frame classification continued:

Four Slide
Complex forming of small to medium size parts Machine Basics 4-slides at 90 degrees controlled by cam to progressively move through a cycle to achieve a final part Can be tooled with punches, cut-off tools, lifting/shifting tools, and welding systems.

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Machine Tools- Presses

Frame classification

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Machine Tools- Presses

Accessories

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