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A metal forming press, also known as a stamping press, is a machine tool used to precisely shape and cut metal typically using upward and downward movements. Metal, supplied in sheet, coil, or tube form, is pressed between two halves of a press tool. The top half of the tool, a punch, is attached to the ram, and the bottom half of the tool, a die, is attached to the bolster plate secured to the bed of the press. Posts and bushings are often used to guide the pressing motion.

In general, metal forming is a manufacturing process that reshapes metal by plastic deformation. Metal can be permanently bent, stretched, and compressed into complex geometric shapes with a press. The ability to reshape the metal is proportional to the type and amount of stress applied to the part.

Metal forming presses can be cam driven mechanically, powered via a flywheel and motor, or hydraulically, which uses fluid pressure to exert force during the forming process. Mechanical presses are able to reach high production speeds and are used regularly in assembly plants, however hydraulically powered metal forming presses offer much more versatility. A wide range of press tonnage, forming capabilities, and overall complexity of finished parts can be achieved with the use of hydraulically powered forming presses. Hydraulic presses can be used in a wide variety of applications as a standalone press, in an automated press line, or as a transfer press. For these reasons and more, hydraulic metal forming presses are often found in manufacturing plants around the globe.

Hydraulic presses, also known as Bramah presses after inventor Joseph Bramah, were first developed in the late ’s through his studying of fluid motion. A hydraulic press works by building up pressure within a closed system in order to generate and exert a powerful and steady force throughout the pressing process.

Hydraulic presses, which can be equipped with fully programable electrical control systems, are widely used in metal forming because of their efficiency, versatility, dependability, and the high level of force they are able to generate. They can come in either single or multi-action configurations allowing for multiple tools to be used to accomplish multiple operations simultaneously. Metal forming with hydraulic presses is used for various production applications that can range from large body panels to individual parts used in a wide variety of industries including; automotive, aerospace, packaging, consumer goods, defense, construction, electronics, medical devices, and many more.

Processes capable of forming and shaping metal which can go beyond the capabilities of a hydraulic metal forming press include:

Casting: Metal shapes can be formed by pouring molten metal into a mold, cooled, and then removed from the mold.  A wide range of metal alloys can be cast and complex shapes can be produced.

Rolling: Sheet metal rolling is a process where metal stock pieces are passed through one or more rollers.  Bending, forming, and flattening are a few of the forming processes that can be achieved through rolling.

Fabrication: For prototyping or small production runs, parts can be produced from multiple sheets via welding or other joining processes. In most cases, fabrication is only appropriate when production volume is not high enough justify the cost of dedicated tooling.

Laser Cutting: With the use of a high-powered laser, holes and cut-outs can be burnt through a sheet metal piece.  Laser cutting is a quick and precise metal forming process that can be handled with automated machines.

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Spinning: Spinning, also known as spin forming and metal turning, rotates a metal disc or tube at high speed transform it into a desired shape.  Depending on the material to be used, the process can be done hot or cold and produces an axially symmetric part. Cylinders, cones, and more complex geometries consisting of a combination of shapes can be produced via spinning.

A metal forming press can produce extremely complex parts, but the general process can be simplified to a few simple operations; shearing, bending, and stamping. A well configured press with the appropriate tools is capable of achieving a combination of these basic functions with a single stroke of the press. Let’s examine these basic operations, and the considerations of each that will result in a high a quality finished part.

Shearing: Shearing, also known as die cutting is a metal forming process in which straight lines are cut on flat sheet metal stock. A top and bottom blade are typically used to slice through the metal piece.  The top blade will come down and pierce through the part, while the bottom blade remains stationary. The process typically results in clean cuts with smooth edges.  It is a cost-effective method and a wide variety of metal materials are suitable for shearing.  The geometry and material of the tools used in shearing can affect the quality of parts produced. The press speed, use of lubrication, and clearances between tools and workpiece both pre and post shear, are also factors that contribute to process success.

Blanking: A die and punch are used to shear metal, typically in sheet or roll form, to produce flat shapes.  The geometry and size of the final piece is driven by the die and punch used. Blanking is a relatively straight forward, quick and cost-efficient method to produce large volumes of parts. Material waste can be minimized with strategic nesting of parts, and/or left-over metal can be reused for other applications. The process is best used for parts that are simple in geometry. If additional shaping is required, it can be accomplished in subsequent forming operations.

Punching: Punching is similar to the blanking process, however rather than leaving the outside of the part, punching removes material from the inside, like holes, via shearing forces. The metal removed is typically scrapped. A metal forming press can be configured to achieve both blanking and punching simultaneously.

Bending: Bending, a widely used method of forming sheet metal, gives the part an angular shape by deforming it with a punch. The bent metal will undergo a combination of compressive and tensile forces, beyond the material’s yield strength, resulting in the finished part.

Common bending methods including air bending and bottoming, are typically done on a brake press machine. Air bending allows the sheet metal to be bent to a specific angle by setting the stroke of the punch. Materials of different type and thickness can be bent to varying angles without needing to change the punch or die. Bottoming is a similar process, as it also uses a punch and die, however the punch will press the material against the contours of the die to define the bend angle.

Forming forces, accuracy, spring back, adequate bend radius to avoid risk of cracking the material, metal ductility, and material thickness are some of the factors that go into the design of bent parts and configuration of the press.

Deep Draw Presses: The deep draw process can be used to manufacture a wide variety of components such as body components, tanks and cans, cookware, and appliance panels. A deep draw press provides optimal control of pressing forces and material flow during forming, resulting in high quality finished parts with fewer defects compared to other forming techniques. Deep drawing reduces waste and minimizes production costs as the process results in the manufacture of a net shape using minimal material. Assembly costs can also be reduced by redesigning multiple components into one deep drawn part.

Forging Presses: Forging presses can provide precise high-speed performance, offering the optimal press control necessary to produce a wide array of open or closed die forged products for heavy industrial, automotive and aerospace applications such as, flanges, bearings, axles and gears. A hydraulic press can be specifically designed for the hot forging process with appropriate hydraulic and electrical control systems.

The processes discussed so far make up a small set of the types of metal forming that can be achieved with hydraulic presses. The dynamic nature of a hydraulic metal forming press allows for even more capabilities. So how to choose the right one? A large number of factors are involved when deciding on the right press. Technical requirements are very dependent on the specific product to be produced and production forecast. Additional requirements involve the press line itself, integrating into existing production and infrastructure, process control, and the availability of maintenance, service and spare parts for the press. These factors can have a significant impact on the cost of ownership of a metal forming press.

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