Metal Forming Handbook

1 Introduction.- 2 Basic principles of metal forming.- 2.1 Methods of forming and cutting technology.- 2.1.1 Summary.- 2.1.2 Forming.- 2.1.3 Dividing.- 2.1.4 Combinations of processes in manufacturing.- 2.2 Basic terms.- 2.2.1 Flow condition and flow curve.- 2.2.2 Deformation and material flow.- 2.2.3 Force and work.- 2.2.4 Formability.- 2.2.5 Units of measurement.- 3 Fundamentals of press design.- 3.1 Press types and press construction.- 3.1.1 Press frame.- 3.1.2 Slide drive.- 3.1.3 Drive systems for deep drawing presses.- 3.1.4 Draw cushions.- 3.2 Mechanical presses 49.- 3.2.1 Determination of characteristic data.- 3.2.2 Types of drive system.- 3.2.3 Drive motor and flywheel.- 3.2.4 Clutch and brake.- 3.2.5 Longitudinal and transverse shaft drive.- 3.2.6 Gear drives.- 3.2.7 Press crown assembly.- 3.2.8 Slide and blank holder.- 3.2.9 Pneumatic system.- 3.2.10 Hydraulic system.- 3.2.11 Lubrication.- 3.3 Hydraulic presses 73.- 3.3.1 Drive system.- 3.3.2 Hydraulic oil.- 3.3.3 Parallelism of the slide.- 3.3.4 Stroke limitation and damping.- 3.3.5 Slide locking.- 3.4Changing dies 86.- 3.4.1 Die handling.- 3.4.2 Die clamping devices.- 3.5Press control systems 94.- 3.5.1 Functions of the control system.- 3.5.2 Electrical components of presses.- 3.5.3 Operating and visualization system.- 3.5.4 Structure of electrical control systems.- 3.5.5 Functional structure of the control system.- 3.5.6 Major electronic control components.- 3.5.7 Architecture and hardware configuration.- 3.5.8 Architecture of the PLC software.- 3.5.9 Future outlook.- 3.6Press safety and certification 106.- 3.6.1 Accident prevention.- 3.6.2 Legislation.- 3.6.3 European safety requirements.- 3.6.4 CE marking.- 3.6.5 Measures to be undertaken by the user.- 3.6.6 Safety requirements in the USA.- 3.7 Casting components for presses.- 4 Sheet metal forming and blanking.- 4.1Principles of die manufacture 123.- 4.1.1 Classification of dies.- 4.1.2 Die development.- 4.1.3 Die materials.- 4.1.4 Casting of dies.- 4.1.5 Try-out equipment.- 4.1.6 Transfer simulators.- 4.2Deep drawing and stretch drawing 156.- 4.2.1 Forming process.- 4.2.2 Materials for sheet metal forming.- 4.2.3 Friction, wear and lubrication during sheet metal forming.- 4.2.4 Hydro-mechanical deep drawing.- 4.2.5 Active hydro-mechanical drawing.- 4.3Coil lines 194.- 4.4Sheet metal forming lines 198.- 4.4.1 Universal presses.- 4.4.2 Production lines for the manufacture of flat radiator plates.- 4.4.3 Lines for side member manufacture.- 4.4.4 Destackers and blank turnover stations.- 4.4.5 Press lines.- 4.4.6 Transfer presses for small and medium sized parts.- 4.4.7 Large-panel tri-axis transfer presses.- 4.4.8 Crossbar transfer presses.- 4.4.9 Presses for plastics.- 4.4.10 Stacking units for finished parts.- 4.4.11 Control systems for large-panel transfer presses.- 4.5Blanking processes 268.- 4.6Shearing lines 284.- 4.6.1 Slitting lines.- 4.6.2 Blanking lines.- 4.6.3 High-speed blanking lines.- 4.6.4 Lines for the production of electric motor laminations.- 4.6.5 Production and processing of tailored blanks.- 4.6.6 Perforating presses.- 4.6.7 Control systems for blanking presses.- 4.7Fine blanking 330.- 4.7.1 Fine blanking process.- 4.7.2 Fine blanking materials, forces, quality characteristics and part variety.- 4.7.3 Fine blanking tools.- 4.7.4 Fine blanking presses and lines.- 4.8Bending 366.- 4.8.1 Bending process.- 4.8.2 Roll forming and variety of sections.- 4.8.3 Roller straightening.- 4.9Organization of stamping plants 389.- 4.9.1 Design.- 4.9.2 Layout.- 4.9.3 Quality assurance through quality control.- 5 Hydroforming.- 5.1General 405.- 5.2Process technology and example applications 405.- 5.2.1 Process technology.- 5.2.2 Types of hydroformed components.- 5.2.3 Fields of application.- 5.3Component development 413.- 5.3.1 User-oriented project management.- 5.3.2 Feasibility studies.- 5.3.3 Component design.- 5.4Die engineering 420.- 5.4.1 Die layout.- 5.4.2 Lubricants.- 5.5Materials and preforms for pr...