We manufacture Deep Drawing Transfer Press. Deep drawing process & Deep drawing press & Double action deep drawing press & Triple action deep drawing press
When producing deep-drawn parts at high speed, the goal is to increase the flexibility of the product conveyance equipment motion between each process while at the same time reducing wasted motion to the greatest extent possible. In conventional press lines, the number of conveyance motions is limited to a few patterns, and because it is necessary to design dies that will match these motions it constrains the product shape and in some cases productivity (SPM) may have to be sacrificed.
In this project we turned the conventional concept on its head, thereby enabling the conveyance of products using optimal motion based on the shape of the dies, and we developed a system that will automatically generate that motion. The concept behind conveyance motion optimization is shown below.
Based on the above concept, 3-D die design data is used together with the press motion data (created using the above-mentioned press forming condition optimization system) to automatically calculate the
conveyance motion for each process stage.
Deep Drawing Transfer Press
A deep drawing transfer press is a specialized type of metalforming machine that combines the capabilities of a deep draw press and a transfer press. It utilizes a series of synchronized ram movements to transfer a blank from one station to another, performing multiple forming operations in a single press cycle.
Key Components of a Deep Drawing Transfer Press:
- Transfer System: The transfer system consists of a series of stations equipped with transfer arms or grippers that move the blank from one station to another. These stations are precisely aligned to ensure accurate positioning of the blank throughout the forming process.
- Drawing Rams: Each station may have one or more drawing rams that perform the deep drawing operations. These rams apply force to the blank, causing it to flow over the die and take on the desired shape.
- Trimmer Rams: Trimmer rams are used to remove excess material from the edges of the drawn part, ensuring that it has a clean edge and meets the desired dimensions.
- Blank Holder: A blank holder is typically used in each station to grip the blank during the forming operation, preventing it from wrinkling or buckling.
- Dies: Each station has a corresponding die that gives the blank its desired shape at that stage of the forming process. The dies may have different shapes and depths depending on the complexity of the final part.
Working Principle of a Deep Drawing Transfer Press:
- Blank Feeding: The blank is fed into the first station of the transfer press.
- Initial Forming: The first drawing ram descends, forming the blank into an initial shape.
- Transferring the Blank: The transfer system moves the partially formed blank to the next station.
- Subsequent Forming: The drawing ram at the next station applies force, further forming the blank into the desired shape.
- Trimming: The trimmer ram removes excess material from the edges of the drawn part.
- Ejecting the Finished Part: The finished part is ejected from the press.
Advantages of Using a Deep Drawing Transfer Press:
- High Productivity: The ability to perform multiple forming operations in a single press cycle significantly increases productivity.
- Reduced Material Waste: The transfer system ensures accurate positioning of the blank, minimizing material waste.
- Complex Shape Capability: The combination of drawing and transfer operations allows for the production of complex shapes with multiple draw stages.
- Consistent Quality: The synchronized ram movements and precise die alignment ensure consistent and high-quality parts.
- Versatility: Deep drawing transfer presses can handle a wide range of materials, including aluminum, steel, and stainless steel.
Applications of Deep Drawing Transfer Presses:
Deep drawing transfer presses are widely used in various industries, including:
- Automotive Industry: Producing car body panels, fenders, hoods, and other automotive components.
- Appliance Industry: Manufacturing cooking pots, pans, sinks, and other appliance components.
- Aerospace Industry: Creating aircraft components, such as fuel tanks, fuselage sections, and engine housings.
- Electrical Industry: Producing electrical enclosures, housings, and components.
- Medical Device Manufacturing: Manufacturing medical implants, surgical tools, and other medical devices.
Conclusion:
Deep drawing transfer presses are sophisticated machines that combine high productivity, reduced material waste, and the ability to produce complex shapes, making them valuable assets in modern manufacturing. Their versatility and precision make them essential tools for industries that require the production of high-quality, complex metal components.
Details of the Deep Drawing Transfer Press
The calculated conveyance motion is transmitted together with the press forming conditions to the recipe databank in the servo press line’s centralized control panel as the press operation data. (Figure 5) These systems enable the line operator to simply call up the operation data for each product from the recipe databank, thereby allowing the optimal forming conditions for the high-speed production of deep-drawn parts.
Die Designs Suited for High-Speed Production When developing this high-speed line, the speed of the press itself during a forming cycle reached a maximum of 27 SPM, and the slide stroke length was
increased to 1100 mm, which thereby increased the maximum speed during the forming portion of the stroke by a factor of approximately 1.7 times, and it was thus deemed necessary to change the design of
the dies and the materials of the components used in the dies.
We then measured the die behavior and stress conditions when actually running at high speeds, and determined which components would require countermeasures.
Deep Drawing Transfer Press Components
Of those components requiring countermeasures, if there were areas where standardized products could be used, the design standards were changed to match these products, but a problem cropped up due to the
high impact load being exerted on the suspension pins used for the suspension of structural components in the upper die (bend pads, etc.) because the standardized parts used up to that time would only last
a few thousand shots before breaking.
As a result, in this project our customer developed an original design for these pins that incorporate cushioning media that internally disperse and absorb the impact loads. We have verified that the durability of these pins under actual high-speed production conditions exceeds 300,000 shots, and we believe that they contribute to stable production.
The deep draw operation was performed on a double-action servo-hydraulic press. Figure 1 shows a schematic of the deep draw tooling. The deep draw die was 228.6 mm wide (9”) with an inner radius of 114.3 mm (4.5”). The die entry radius was 12.7 mm (0.5”). those of the die. The punch was 101.6 mm wide (4”) and had an entry radius of 12.7 mm (0.5”). Two blank sizes were drawn: 177.8 mm (7”) and 203.2 mm (8”) in diameter.
A total of five repeats were conducted per condition. The tooling was not cooled, however, the tooling was allowed to cool for 10 minutes between tests to avoid an increase in tooling temperature prior to forming. The tools were not coated and, as a result, were cleaned between tests to remove aluminum pickup from the blanks.
The deep draw procedure consisted of heating the AA7075-T6 blanks in a convection furnace at 470°C for 10 minutes. While the blank was heating in the furnace, lubricant was applied to the surfaces of the die, binder, and punch. After 10 minutes, the blank was manually transferred to the die opening. The blank transfer was performed using a pair of tongs to hold the blank and subsequently dropping it onto the die face and took 3-4s. The drawing operation was performed on a double-action hydraulic press.
Once in the die cavity, a binder load was applied onto the blank using hydraulic pressure. The speed of the binder was not directly controlled. However, it took the binder 2-3s to fully clamp the blank. Once clamped the punch descended and made contact with the blank in 1s, formed the blank at a speed of 10 mm/s, and drew the blanks to a depth of 55 mm. The temperature at which the blanks were formed was 405-415°C. Two lubricants were tested for both blank sizes:
Fuchs Forge Ease Al278 (diluted in water using a ratio of 1:2 by volume) and a dry Polytetrafluoroethylene (PTFE) spray. The lubricant was cleaned after each drawing operation using soap and acetone. The binder loads that were investigated were: 10, 15, 20, and 30 kN. The load-displacement data was obtained from a data acquisition system in the hydraulic press.
The earring profiles were measured by scanning the formed cups on an optical scanner, using an image resolution of 1500 dots per inch (dpi). The scanned images were then analyzed using a Matlab script developed by Norder [3] and an earring profile of the scanned cup was generated.
Sheet metal forming is used to produce various products from mild steel, stainless steel, copper, aluminum, gold, platinum, tin, nickel, brass, and titanium. To reduce costs and increase the performance of manufactured products, more and more lightweight and high-strength materials have been used as a substitute to conventional steel. These materials usually have limited formability, thus, a thorough understanding of deformation processes and the factors limiting the forming of sound parts is important, from both engineering and economic viewpoints.
In sheet metal forming, a piece of material is plastically deformed between tools to obtain the desired product. Sheet metal forming is characterized by the conditions in which the stress component normal to the plane of the sheet is generally much smaller than the stresses in the plane of the sheet. The common defects that occur in sheet metal forming are wrinkling, necking, scratching and cracks. Wrinkling occurs in areas of high compressive strains and necking in areas with high tensile strains. Scratching is caused by defects on the tool surface and orange peel may occur after excessive deformation depending on the grain size of the material.
Hydraulic presses are powerful machines used to apply a significant amount of force to an object through hydraulic fluid pressure. They are essential in various industrial applications, providing the necessary force for processes such as metal forming, stamping, bending, and molding. The versatility and efficiency of hydraulic presses make them indispensable tools in manufacturing and production lines. This document will explore the different types of hydraulic presses, their application areas, components, operational principles, manufacturing process, and the challenges and advancements in the industry.
Types of Hydraulic Presses
Hydraulic presses come in various designs, each suited to specific applications and requirements. The primary types of hydraulic presses include C-frame presses, H-frame presses, four-column presses, straightening presses, arbor presses, laminating presses, and transfer presses.
C-frame presses, also known as gap-frame presses, have a C-shaped frame that provides three-sided access to the work area. This design is ideal for applications requiring easy loading and unloading of materials.
H-frame presses, or two-post presses, have a robust H-shaped frame that offers excellent stability and strength. They are commonly used for heavy-duty tasks such as metal forming and straightening.
Four-column presses, or four-post presses, have four vertical columns that provide superior support and uniform force distribution. These presses are suitable for large-scale applications requiring high precision and repeatability.
Straightening presses are specialized hydraulic presses used to straighten bent or distorted metal components. They are widely used in the automotive and construction industries.
Arbor presses are smaller, manually operated hydraulic presses used for light-duty tasks such as assembly, riveting, and broaching. They are commonly found in workshops and small manufacturing facilities.
Laminating presses are used to bond multiple layers of material together under heat and pressure. These presses are essential in industries such as electronics, where laminated components are common.
Transfer presses are automated hydraulic presses that move the workpiece through multiple stations for different operations. They are highly efficient and used in high-volume production environments.
Application Areas
Hydraulic presses are employed in various industries, thanks to their ability to deliver consistent and precise force. Key application areas include:
Metal forming and forging: Hydraulic presses are crucial in shaping and forming metal parts through processes such as stamping, bending, and deep drawing. They are essential in the production of automotive parts, machinery components, and structural elements.
Automotive industry: In the automotive sector, hydraulic presses are used for manufacturing various parts, including body panels, chassis components, and engine parts. They play a critical role in ensuring the structural integrity and performance of vehicles.
Aerospace industry: The aerospace industry relies on hydraulic presses for forming and shaping high-strength materials used in aircraft components. Precision and reliability are paramount in this industry, making hydraulic presses indispensable.
Plastic and rubber molding: Hydraulic presses are used in the molding of plastic and rubber components, including automotive parts, household goods, and medical devices. They ensure consistent product quality and precision.
Electrical and electronics industry: In the electronics sector, hydraulic presses are used for laminating circuit boards, forming connectors, and assembling electronic components. They provide the necessary force and precision for delicate operations.
Medical device manufacturing: Hydraulic presses are used in the production of medical devices, including surgical instruments, implants, and diagnostic equipment. They ensure the high precision and quality required in the medical field.
Packaging industry: Hydraulic presses are employed in the packaging industry for forming and shaping packaging materials, such as cardboard, plastic, and metal. They help produce packaging solutions that are strong, durable, and aesthetically pleasing.
Components of a Hydraulic Press
A hydraulic press comprises several key components that work together to generate and control the applied force. The main components include the frame, hydraulic cylinder, hydraulic pump, control valves, hydraulic fluid, pressure gauges and sensors, and die and tooling.
The frame is the main structure of the hydraulic press, providing stability and support for all other components. It is typically made of high-strength steel to withstand the significant forces generated during operation.
The hydraulic cylinder is the core component that generates the pressing force. It consists of a cylindrical chamber, a piston, and a piston rod. When hydraulic fluid is pumped into the cylinder, it moves the piston, which in turn applies force to the workpiece.
The hydraulic pump is responsible for generating the hydraulic fluid pressure needed to move the piston. It draws hydraulic fluid from a reservoir and delivers it to the cylinder under high pressure.
Control valves regulate the flow of hydraulic fluid to and from the cylinder, controlling the movement and force of the press. These valves can be manually operated or automated, depending on the press design.
Hydraulic fluid, typically oil, is the medium through which force is transmitted in the hydraulic system. It must have suitable properties, such as viscosity and lubricity, to ensure efficient operation and protect system components.
Pressure gauges and sensors monitor the hydraulic fluid pressure within the system. They provide real-time feedback to the operator or control system, ensuring safe and accurate press operation.
Die and tooling are the interchangeable components that come into direct contact with the workpiece. They are designed to shape, form, or cut the material as required by the specific application.
How Hydraulic Presses Work
Hydraulic presses operate based on Pascal’s principle, which states that pressure applied to a confined fluid is transmitted equally in all directions. This principle allows hydraulic presses to generate significant force with relatively small input pressure.
The operation of a hydraulic press begins with the hydraulic pump drawing fluid from the reservoir and delivering it to the cylinder. The control valves regulate the flow of fluid, directing it into the cylinder to move the piston. As the piston moves, it applies force to the workpiece placed between the die and tooling.
The hydraulic fluid plays a crucial role in this process, as it transmits the applied pressure and lubricates the system components. The pressure gauges and sensors continuously monitor the fluid pressure, providing feedback to ensure the press operates within safe limits.
The force generated by the hydraulic press can be precisely controlled by adjusting the hydraulic fluid pressure and the position of the control valves. This allows for accurate and repeatable operations, essential for high-quality manufacturing.
Manufacturing of Hydraulic Presses
The manufacturing of hydraulic presses involves several stages, from design and engineering to assembly and quality control. Each stage is critical to ensuring the press’s performance, reliability, and safety.
Design and engineering: The process begins with the design and engineering phase, where specifications for the press are developed based on the intended application. This includes selecting suitable materials, determining the required force and stroke, and designing the frame and hydraulic system.
Material selection: High-quality materials, such as high-strength steel for the frame and durable alloys for the hydraulic components, are selected to ensure the press’s longevity and performance.
Fabrication of components: The individual components of the hydraulic press, including the frame, cylinder, and pump, are fabricated using precision machining and manufacturing techniques. This ensures that each component meets the required tolerances and specifications.
Assembly process: The fabricated components are then assembled into the complete hydraulic press. This involves mounting the cylinder, pump, and control valves onto the frame, connecting the hydraulic lines, and installing the die and tooling.
Quality control and testing: Rigorous quality control measures are implemented throughout the manufacturing process to ensure the press meets all specifications and standards. This includes pressure testing the hydraulic system, verifying the accuracy of the control valves, and performing operational tests to ensure the press functions correctly.
Advancements and Innovations
The hydraulic press industry is continually evolving, driven by advancements in technology and increasing demands for efficiency and precision. Key innovations include automation and control systems, energy efficiency improvements, and smart hydraulic presses.
Automation and control systems: Modern hydraulic presses are often equipped with advanced control systems that automate the pressing process. This includes programmable logic controllers (PLCs), human-machine interfaces (HMIs), and sensors that monitor and adjust the press’s operation in real time. Automation improves efficiency, reduces the risk of human error, and enhances the consistency of the finished products.
Energy efficiency improvements: Manufacturers are focusing on developing hydraulic presses that consume less energy and have a smaller environmental footprint. This includes using variable displacement pumps, energy recovery systems, and optimizing the hydraulic system’s design to minimize energy losses.
Smart hydraulic presses: The integration of IoT (Internet of Things) technology into hydraulic presses has led to the development of smart presses. These presses can communicate with other machines and systems, providing real-time data on their status, performance, and maintenance needs. This connectivity allows for predictive maintenance, reducing downtime and extending the press’s lifespan.
Challenges in Hydraulic Press Manufacturing
The manufacturing of hydraulic presses presents several challenges, including precision and quality requirements, cost management, technological advancements, and environmental considerations.
Precision and quality requirements: Hydraulic presses must deliver consistent and precise force, which requires high levels of accuracy in the manufacturing process. Ensuring each component meets the required tolerances and specifications is critical to the press’s performance and reliability.
Cost management: The cost of materials, labor, and energy can significantly impact the overall cost of manufacturing hydraulic presses. Manufacturers must balance quality and cost to remain competitive in the market.
Technological advancements: Keeping up with technological advancements is essential for manufacturers to meet the evolving demands of the industry. This requires continuous investment in research and development to incorporate new technologies and improve existing designs.
Environmental considerations: Environmental regulations and sustainability concerns are increasingly important in hydraulic press manufacturing. Manufacturers must develop eco-friendly presses that consume less energy, use recyclable materials, and minimize their environmental impact.
Conclusion
Hydraulic presses are essential machines in various industries, providing the necessary force for processes such as metal forming, stamping, and molding. Understanding the different types of hydraulic presses, their components, and how they work is crucial for effective application and operation.
The manufacturing process of hydraulic presses involves careful design and engineering, material selection, precision fabrication, and rigorous quality control. Despite the challenges, advancements in technology and innovations are driving the industry forward, leading to more efficient, precise, and environmentally friendly hydraulic presses.
As industries continue to evolve, the hydraulic press industry must adapt and innovate to meet the demands of efficiency, precision, and sustainability. Through continuous research and development, manufacturers can enhance the performance and reliability of hydraulic presses, contributing to the success of various industrial applications.
EMS Metalworking Machinery
We design, manufacture and assembly metalworking machinery such as:
- Hydraulic transfer press
- Glass mosaic press
- Hydraulic deep drawing press
- Casting press
- Hydraulic cold forming press
- Hydroforming press
- Composite press
- Silicone rubber moulding press
- Brake pad press
- Melamine press
- SMC & BMC Press
- Labrotaroy press
- Edge cutting trimming machine
- Edge curling machine
- Trimming beading machine
- Trimming joggling machine
- Cookware production line
- Pipe bending machine
- Profile bending machine
- Bandsaw for metal
- Cylindrical welding machine
- Horizontal pres and cookware
- Kitchenware, hotelware
- Bakeware and cuttlery production machinery
as a complete line as well as an individual machine such as:
- Edge cutting trimming beading machines
- Polishing and grinding machines for pot and pans
- Hydraulic drawing presses
- Circle blanking machines
- Riveting machine
- Hole punching machines
- Press feeding machine
You can check our machinery at work at: EMS Metalworking Machinery – YouTube
Applications:
- Beading and ribbing
- Flanging
- Trimming
- Curling
- Lock-seaming
- Ribbing
- Flange-punching