Suez Canal University Faculty of Engineering Production and design dept.

4 th year

Report about:

Presses used in forming process and their design consideration

Prepared by:

Ahmed Mohammed Mahmud Amr Tarek Hegazy Ayah Ahmed Kenawy Manar El- Islam Yahiya Manar Shaban Abd El-Fatah Moemen Abdu Barkat Norhan Mohammed El-Sharawy
Supervised by:

D / Mohammad Saber
Data: ~1~

15/5/2012

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contents Types of press Presses controlled by work Presses controlled by the ram path Presses controlled by force Types of hammer Fields of application for hammers Screw presses Forms of structural design Advantages of screw presses Eccentric and crank presses and its types Application of eccentric and crank presses Knuckle-joint presses Hydraulic presses Advantages of hydraulic presses Reference

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Types of press
According to their characteristics, presses can be classified into those controlled mainly by work (energy), the ram path or force.

Presses controlled by work

Hammers and screw presses are machines whose main characteristic is their work capacity (Energy). A hammers work capacity is determined from the ram mass and drop height. With A screw press, the work capacity is stored in the rotating masses (mainly in the flywheel), Therefore it depends upon the angular velocity and the mass moment of inertia. The two kinds of machine are similar in that the work capacity can be influenced or adjusted. The force, on the other hand, cannot be directly adjusted, but depends upon the kind of work piece and the deformation distance.

Fig (1) The principle of presses controlled by work, a) drop hammer, b) screw press

Presses controlled by the ram path

These include crank presses and knuckle-joint presses. With these presses, the deformation is complete when the ram has reached its lowest position (bottom dead centre BDC). This means their characteristic value is the ram path limit, which comes from the crank radius r in ~4~

crank presses and from the leverage with knuckle-joint presses fig (2) With crank presses the nominal force of the press is available at a crank angle of 30 before BDC up to BDC, whereas with a knuckle-joint press, the nominal press force (depending on the leverage) is only available within a range of 3 to 4 mm before BDC.

Fig (2) Drive layout of presses controlled by the ram path, a) crank press, b) knuckle-joint press

Presses controlled by force

The operation of hydraulic presses depends upon force, as the only thing which can be adjusted about them is the force (via the operating pressure). As the deformation forces fluctuate within certain limits (differences in material strength, blank tolerances, lubrication and condition of the tooling), a dimensionally accurate part can only be produced on a hydraulic press if the deformation distance is limited. This can be carried out in the press itself using positive stops, or in the die. This kind of ram path limit is also needed for presses controlled by work.

Hammers
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Types of hammer
Hammers are classified according to the drive design into: Drop hammers Double-acting hammers Counterblow hammers. With drop hammers, the ram drops freely. The impact energy comes from the mass of the ram and the drop height. Belts, chains or with hydraulic drives the piston rod are used to lift the ram.

The hydraulic drop hammer has a three-part frame. The materials used are:
e.. Anvil and side columns: grey cast iron with added steel. This special cast iron is a better damper and has a more homo generous structure than cast steel. b) Ram: high-alloy, hardened and tempered cast electric steel or quenched and tempered steel. c) Guides: hardened, ground steel prism guides.

Fig (3) Mechanically powered hammer

Fields of application for hammers

Uses for hammer types: ~6~

Hammer type Drop hammers

Application Small to medium-sized impressiondie forgings, e.g. wrenches, levers, coupling components medium to large-sized impressiondie forgings, camshafts, flanges

Double-acting hammers

Counterblow hammers

difficult and extremely difficult impression-die forgings, e.g. large crankshafts, levers which are hard to form, large coupling components

Screw presses Forms of structural design

Flywheel construction is categorized: 1. According to the way the flywheel is accelerated: Friction wheel with disc drive. Hydraulic drive. Direct electric motor drive. wedge drive. 2. According to the way the ram is moved vertically: ram moves up and down with spindle and flywheel. Spindle fixed in place with flywheel. Only the ram, shaped like a nut, moves vertically. This construction is called a Vincent press. A screw press is a type of machine press in which the ram is driven up and down by a screw. The screw shaft can be driven by a handle, or a wheel. It works by using a coarse screw to convert the rotation of the handle or drive-wheel into a small downward movement of greater force. The overhead handle usually incorporates balls as a flyweight. This weight helps to maintain the momentum and thrust of the tool to make it easier to operate.

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The screw press was first invented and used by the Romans in the first century C.E. It was used primarily in wine and olive oil production. The screw press was also used in Gutenberg's printing press in the mid-15th century. A press is a metalworking machine tool used to shape or cut metal by deforming it with a die. It is frequently used to punch holes in sheet metal in one operation, rather than by cutting the hole or drilling. If used as a punch, the tool itself consists of a punch and a matching die, into which it very closely fits. Both are usually precision machined and then hardened. The material is introduced between the punch and die, and the machine operated. The punch will cut through the material in one movement by shearing it. The punch and die may be of any desired shape, so odd shaped holes and cutouts may be created. If used as a forging tool the dies can be many different shapes varying from flat to various shapes that will mold the metal to the desired configuration.

Fig (4) Ball-drive screw press

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Fig (5) PR 800 fully-automatic screw press (Photograph from LASCO Umformtechnik works, Coburg, Germany) Advantages of screw presses (Compared to hammers and crank presses) 1. Screw presses require only a small base. 2. The noise level is far lower than with hammers. 3. Screw presses are high-energy machines. For this reason, work pieces which require a lot of energy can be formed with them. 4. The dwell periods (the time during which the work piece is being forged) are short. This means that tool life is improved. 5. The spindle thread is not self-locking. This means that a screw press cannot block under stress. 6. Like hammers, screw presses have no kinetically-fixed bottom dead centre. It is no longer necessary to adjust the height of the tooling. Forging can also take place in a closed die, as the excess material can be balanced out in the height of the work piece.

Eccentric and crank presses

Eccentric and crank presses are controlled by the ram path.

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Types of these presses

These presses are categorized according to the design of the press frame (Figure 6) into: a) gap-frame presses. b) open-back presses. c) straight-side presses.

Application of eccentric and crank presses

Eccentric presses are mainly used for blanking, embossing and bending, as long as only small displacements are required, as the eccentric demands. Crank presses are used for all chip less forming methods where the deformation force does not have to be constant over a long distance, i.e. for the forward extrusion of short components, deep drawing, bending and impression-die forging on heavy forging presses. Knuckle-joint presses Knuckle-joint presses are a special kind of crank press where the crank force is produced via a (knuckle joint) joint system. In principle, the rules which govern a crank press apply here, both as concerns the construction design and the way it works.

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Fig (7) Knuckle joint press

Fig (8) Force-displacement diagram for a knuckle-joint press Hydraulic presses

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A hydraulic is a machine using a hydraulic cylinder to generate a compressive force. It uses the hydraulic equivalent of a mechanical lever, and was also known as a Bramah press after the inventor, Joseph Bramah, of England. He invented and was issued a patent on this press in 1795. As Bramah (who is also known for his development of the flush toilet) installed toilets, he studied the existing literature on the motion of fluids and put this knowledge into the development of the press.

Fig (9) Hydraulic press in a machine shop. This press is commonly used for hydro forming.

Advantages of hydraulic presses

The advantages of hydraulic presses are: a) Constant power all through the stroke, b) Force can be finely regulated (so no extra load-limiting safety device required), c) Work capacity unlimited until Wmax = Fmax smax. One disadvantage is the lower operating speed compared with crank presses, which results in lower output (parts per time unit).

Reference
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Metal Forming Practice Translated by Anne Koth www.wikipedia.org

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