Stamping 101: Anatomy of a Mechanical Press

A mechanical press is a popular machine used in the manufacturing industry. Its 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, itll 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.

 Theres 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 components function.

Theres 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. Heres 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 Rams vertical thrust during operations.

Bolster Plate

The bolster plate is a simple plate thats 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

Theres a simple metal road which connects the crank within the eccentric driven press thats called the pitman. The manufacturers can change the stroke rams position by changing the connecting rods length.

Driving Mechanism

The pitman and other driving mechanisms are the most crucial component of any mechanical presss design.

 With these driving mechanisms, the components 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 Rams 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 shafts 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 materials 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.

Machine tool that changes the shape of a work piece by the application of pressure

A forming press, commonly shortened to press, is a machine tool that changes the shape of a work-piece by the application of pressure.[1] The operator of a forming press is known as a press-tool setter, often shortened to tool-setter.

Presses can be classified according to

Shop Press

Typically consisting of a simple rectangular frame, often fabricated from C-channel or tubing, containing a bottle jack or hydraulic cylinder to apply pressure via a ram to a work-piece. Often used for general-purpose forming work in the auto mechanic shop, machine shop, garage or basement shops, etc. Typical shop presses are capable of applying between 1 and 30 tons pressure, depending on size and construction. Lighter-duty versions are often called arbor presses.

A shop press is commonly used to press interference fit parts together, such as gears onto shafts or bearings into housings.

Other presses by application

• A press brake is a special type of machine press that bends sheet metal into shape. A good example of the type of work a press brake can do is the back-plate of a computer case. Other examples include brackets, frame pieces and electronic enclosures. Some press brakes have CNC controls and can form parts with accuracy to a fraction of a millimeter. Bending forces can range up to 3,000 tons.[2][3][4]
• A punch press is used to form holes.
• A screw press is also known as a fly press.
• A stamping press is a machine press used to shape or cut metal by deforming it with a die. It generally consists of a press frame, a bolster plate, and a ram.[5]
• Capping presses form caps from rolls of aluminium foil at up to 660 per minute.

An example of peculiar press control: servo-press

A servomechanism press, also known as a servo press or an 'electro-press, is a press driven by an AC servo motor. The torque produced is converted to a linear force via a ball screw. Pressure and position are controlled through a load cell and an encoder. The main advantage of a servo press is its low energy consumption; its only 10-20% of other press machines.

When stamping, it is really about maximizing energy as opposed to how the machine can deliver tonnage. Up until recently, the way to increase tonnage between the die and work-piece on a mechanical press was through bigger machines with bigger motors.[6]

Types of presses

The press style used is in direct correlation to the end product. Press types are straight-side, BG (back geared), geared, gap, OBI (open back inclinable) and OBS (open back stationary). Hydraulic and mechanical presses are classified by the frame the moving elements are mounted on. The most common are the gap-frame, also known as C-frame, and the straight-side press. A straight-side press has vertical columns on either side of the machine and eliminates angular deflection. A C-frame allows easy access to the die area on three sides and require less floor space. A type of gap-frame, the OBI pivots the frame for easier scrap or part discharge. The OBS timed air blasts, devices or conveyor for scrap or part discharge.[7][8]

History

Historically, metal was shaped by hand using a hammer. Later, larger hammers were constructed to press more metal at once, or to press thicker materials. Often a smith would employ a helper or apprentice to swing the hammer while the smith concentrated on positioning the work-piece. Drop hammers and trip hammers utilize a mechanism to lift the hammer, which then falls by gravity onto the work.

In the mid 19th century, manual and rotary-cam hammers began to be replaced in industry by the steam hammer, which was first described in by James Watt, a British inventor and Mechanical Engineer who also contributed to the earliest steam engines and condensers, but not built until by British inventor James Nasmyth. By the late 19th century, steam hammers had increased greatly in size; in the Bethlehem Iron Company made an enhancement allowing a steam hammer to deliver a 125-ton blow.[9]

Most modern machine presses typically use a combination of electric motors and hydraulics to achieve the necessary pressure. Along with the evolution of presses came the evolution of the dies used within them.[10]

Safety

Machine presses can be hazardous, so safety measures must always be taken. Bi-manual controls (controls the use of which requires both hands to be on the buttons to operate) are a very good way to prevent accidents, as are light curtains that keep the machine from working if the operator is in range of the die.

References

Stamping 101: Anatomy of a Mechanical Press

Machine press