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Deep Drawing Transfer Press

Deep Drawing Transfer Press

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:

  1. 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.
  2. 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.
  3. 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.
  4. 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.
  5. 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:

  1. Blank Feeding: The blank is fed into the first station of the transfer press.
  2. Initial Forming: The first drawing ram descends, forming the blank into an initial shape.
  3. Transferring the Blank: The transfer system moves the partially formed blank to the next station.
  4. Subsequent Forming: The drawing ram at the next station applies force, further forming the blank into the desired shape.
  5. Trimming: The trimmer ram removes excess material from the edges of the drawn part.
  6. Ejecting the Finished Part: The finished part is ejected from the press.

Advantages of Using a Deep Drawing Transfer Press:

  1. High Productivity: The ability to perform multiple forming operations in a single press cycle significantly increases productivity.
  2. Reduced Material Waste: The transfer system ensures accurate positioning of the blank, minimizing material waste.
  3. Complex Shape Capability: The combination of drawing and transfer operations allows for the production of complex shapes with multiple draw stages.
  4. Consistent Quality: The synchronized ram movements and precise die alignment ensure consistent and high-quality parts.
  5. 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:

  1. Automotive Industry: Producing car body panels, fenders, hoods, and other automotive components.
  2. Appliance Industry: Manufacturing cooking pots, pans, sinks, and other appliance components.
  3. Aerospace Industry: Creating aircraft components, such as fuel tanks, fuselage sections, and engine housings.
  4. Electrical Industry: Producing electrical enclosures, housings, and components.
  5. 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.

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