Stamping press

Power press with a fixed barrier guard Mechanical press

A stamping press is a metalworking machine tool used to shape or cut metal by deforming it with a die. A stamping press uses precision-made male and female dies to shape the final product. It is a modern-day counterpart to the hammer and anvil.

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Components

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A press has a bolster plate, and a ram.[1] Presses come in various types of frame configurations, C-Frame where the front & left and right sides are open, straight-side, or H-Frame for stronger higher tonnage applications. It is very important to size the press and tonnage based on the type of applications, blanking, forming, progressive, or transfer. Strong consideration should be given to avoiding off-center load conditions to prevent premature wear to the press.

A 440 ton progressive die stamping press

Bolster Plate

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The bolster plate is mounted on top of the press bed and is a large block of metal upon which the bottom portion of a die is clamped; the bolster plate is stationary. Large presses (like the ones used in the automotive industry) may be equipped with die cushions integrated in the bolster plate to apply blank holder or counter draw forces. This is necessary when a single acting press is used for deep drawing. The ram / slide is the moving or reciprocating member that the upper die is mounted to. Ram or Slide guidance is a critical element to assure long die life between die maintenance. Different types of slide guides are available, 4 point V-Gibs or 6 point square gibs on smaller presses and 8 point full length slide guides on larger straight side frame presses. The dies and material are fed into the press between the bolster and slide. Good press designs must account for plastic deformation, otherwise known as deflection when frame design and loads are considered.[2]

Ram / Slide

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The vertical motion of the slide acts like a hammer to an anvil. The most common Mechanical Presses use an eccentric drive to move the press's ram slide, length of stroke or slide travel depends on the crankshaft or eccentric, whereas hydraulic cylinders are used in hydraulic presses. The nature of drive system determines the force progression during the ram's stroke. Mechanical presses have a full tonnage rating point above BDC / Bottom Dead Center, normal full tonnage rating points are .187", .25" & .5". Hence a mechanical press has a tonnage curve and should be operated within the press capacity limits. Link Motion mechanical is yet another option, this provides a slide slow down near BDC / bottom dead center for soft touch tooling. This link feature can improve die life and reduce reverse-snap thru tonnage for blanking operations.[3]

On the contrary, Hydraulic Presses do not have a tonnage curve and can produce full tonnage at any point in the stroke. The trade-off is speed, a mechanical press is much faster when compared to hydraulic. On the other hand, Hydraulic Presses are much more practical for deep forming or drawing or parts or when dwell time at the bottom is desired.

Another classification is single-acting presses versus double- (seldom triple) acting presses. Single-acting presses have one single ram. Double-acting presses have a subdivided ram, to manage, for example, blank holding (to avoid wrinkles) with one ram segment and the forming operation with the second ram segment.[4]

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Other Components & Controls

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Typically, presses are electronically linked (with a programmable logic controller) to an automatic feeder which feeds metal raw material through the die. The raw material is fed into the automatic feeder after it has been unrolled from a coil and put through a straightener. A tonnage monitor may be provided to observe the amount of force used for each stroke. [5]

References

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A mechanical press is a popular machine used in the manufacturing industry. It&#;s most reputable for its high-end products and affordable operations.

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Before we move on to the mechanical press and its anatomy, you should know about metal stamping. Once you understand the metal stamping process, it&#;ll be easier to comprehend the anatomy of the mechanical press.

What is Metal Stamping?

Stamping or pressing is a method used in metal manufacturing. It primarily uses a plain metal sheet (either blank or in coil form) for stamping. It is where the machine and the die surface create the product shape in the raw metal added to the stamping machine.

The metal stamping processes are pretty versatile as they include multiple processes. These include: punching with a machine press

• Flanging
• Embossing
• Coining
• Blanking
• Bending

Each of these process differences may vary depending on the final product type required by a metal manufacturer.

 There&#;s a single-stage procedure on the sheet metal part in which every stroke within the press creates the desired result. Sometimes, the process may also be complete after passing through different processes.

 In most cases, professionals in the manufacturing industry may carry out the stamping on the metal sheet. However, you may also see stamping on other complex surfaces, such as polystyrene.

The dies that operate in stages or multiple progressions utilize steel coils, the coils used for unwinding the coils and then adding them to a feeder that advances the raw materials to the press and dies and the required length.

The manufacturers add this length in advance to avoid any errors in manufacturing. The number of die stations required may vary based on the final designs of the metal pressing.

Stamping Mechanical Press Function

Since we are discussing the basics of a mechanical press, one should consider the function of the stamping process to better understand each component&#;s function.

There&#;s a variety of mechanical processes that you might use in manufacturing. Professional utilizes the press in metal forging and manufacture. In other cases, it may also be used for sheet metal work. The requirement of force determines the best option for the mechanical press type.

The extrusions can usually produce longer, consistent force through a larger area. However, the mechanical press may also be a good option for professionals looking for an impact extrusion. It is because the mechanical process provides a repeatable, quick and efficient use of force over a certain distance.

The exact distance required may vary according to the product the manufacturers wish to get. On average, the machine presses used in commercial manufacturing have a pressing capacity ranging up to 12,000 tons (or 24,000,000 lbs).

The Anatomy of the Mechanical Press: Parts you should know

The mechanical process is a relatively more straightforward setup used by commercial manufacturers. Each part within the mechanical press has a progressive role and can determine the overall efficiency of these parts. Here&#;s a quick list of the parts in the mechanical press:

Base

The base is a support area for the machine press, allowing clamping and titling within the press setup. You may find the base mainly in the inclined press, which serves as the foundation for the whole mechanism.

Frame

The frame is the primary design in which all the mechanical press components are fit. Most of the presses used in commercial manufacturers have this frame design. You will find it on the straight side type with a C-shaped frame. The C-shaped frame handles Ram&#;s vertical thrust during operations.

Bolster Plate

The bolster plate is a simple plate that&#;s on the base to add support for the die block and the other components set on the mechanical press.

Ram

Ram is a component within the mechanical press that slides into the press and moves the guide fitted onto the bottom of the setup. With the Ram, the mechanical press operates freely and can better operate for the process.

Pitman

There&#;s a simple metal road which connects the crank within the eccentric driven press that&#;s called the pitman. The manufacturers can change the stroke ram&#;s position by changing the connecting rod&#;s length.

Driving Mechanism

The pitman and other driving mechanisms are the most crucial component of any mechanical press&#;s design.

 With these driving mechanisms, the component&#;s movement converts to the reciprocating movement of various parts. These parts include:

• • • • • • The Ram by crank
          • Eccentric and connecting rod
          • Connecting rod
          • Other mechanisms set within the mechanical press

Fly Wheel

The flywheel is the component on the driving shaft end and connects to the rest of the setup with a clutch. You will find a flywheel that stores all the remaining energy. This wheel stays idle and uses Ram&#;s speed. The speed is used when the punch presses into the work.

The flywheel connects and couples to the electric motor, allowing flawless operations within the mechanical press.

Clutch

The clutch primarily maintains and cuts off the connection between the driving shaft and the flywheel when the manufacturers need to stop or start the movement of the Ram.

Brakes

The mechanical press brakes help control the driving shaft&#;s movement as soon as a user shuts it off during operations. With the brakes, the mechanical press operates appropriately for maximum efficiency within the mechanical press.

Operating the Mechanical Process: How to do it?

Mechanical presses are large-sized machines, which might be a little intimidating for some users. However, with a bit of proper training, anyone can use them.

If you wish to use the mechanical press, you need to learn a three-step process that begins with placing the material on the die to keep it in place.

The operator can add pressure and change the material&#;s shape as required. Once all of this is done, the final product leaves the machine.

Users should know all the mechanical press parts should be appropriately lubricated and performed correctly to avoid any issues during the performance. With the steps mentioned above, manufacturers can use the mechanical press efficiently and avoid any performance issues.

Bottom Line

A mechanical press is a fundamental and practical machine used in manufacturing. It is a large and complex machine that might be challenging to understand. You can use the info in this guide and use the mechanical press better for future manufacturing needs.

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