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Mechanical Presses
Mechanical Presses
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David Alkire Smith, 530 Hollywood Drive, Monroe, Michigan 48162-2943 Rev August 19, 2005
TYPES OF PRESSES
There are over 300,000 presses in use in the United States and many more worldwide.
Mechanical presses fall into two predominant press types: gap frame and straight side
types. The frame types used in mechanical presses are similar to those used in many
hydraulic presses. Here, we will limit our discussion to mechanical presses.
The drive systems, clutches, brakes, counterbalance systems, die cushions, electrical,
hydraulic and pneumatic features are similar in both the gap frame and straight side
types. The type and size of press selected is mainly determined by the work to be done.
Figure 1. A typical gap frame open back inclinable (OBI) mechanical press.
Verson Corporation
The main disadvantage of gap frame presses is that there is an unavoidable angular
misalignment that occurs under load. Limiting the amount of angular misalignment
requires very robust construction, which adds to the weight and cost of the machine.
Straightside Presses
Straightside presses derive their name from the vertical columns or uprights on either
side of the machine. The columns together with the bed and crown form a strong housing
for the crankshaft, slide and other mechanical components.
The housing or frame of most straightside presses is held together in compression by prestressed tie rods. Some straightside presses have solid frames. Generally a solid frame
straightside press is less expensive than one having tie rods. However, tie rod presses are
easier to ship disassembled and have better ability to withstand overloads.
Freedom from angular deflection under load is one reason for choosing a straightside
rather than gap frame press for work involving close tolerance dies. The part
dimensional accuracy and number of hits between necessary die maintenance often
improves by a factor of three or more.
Figure 2. A straightside mechanical press having double end drive gears and two
connections. Smith & Associates
In modern designs, the gears are fully enclosed and run in a bath of lubricant. Enclosing
the gears in separate enclosures from the rest of the machine permits using a heavier
viscosity lubricant than that used for other machine parts such as the bearings. The latter
are often supplied from a recirculating lubricant system. The separate gear housing and
lubricant bath system serves to lessen noise and insure long gear life.
The tie rods hold the housing assembly in compression. The pitman, connection, bolster
and other parts have similar functions in both gap frame and straightside presses.
N. Fisher. Principles of Mechanical Power Presses, SME Technical Paper MS76-285, The Society of
Manufacturing Engineers, Dearborn, Michigan, 1976. The author, N. Fisher, updates the material for
public presentations.
Figure 4. An example of a direct drive straightside press showing the flywheel and
clutch in a metal enclosure. Note the Eaton variable speed drive motor mounted on top
of the machine.
The high operating speeds provide much greater productivity than that of geared presses.
The direct drive press is very popular for precision progressive die and high speed
perforating operations. Two main factors limit the application of the direct driven press.
First, the full rated force of the machine is only available very close to the bottom of the
stroke; typically 0.060-inch (1.524 mm) from bottom dead center. A second
disadvantage is that the ability to deliver rated forces is substantially reduced if the press
is operated at less than full speed.
The nongeared press illustrated in Figure 4, built by the Minster Machine Company has
been in service for approximately 25 years. It is equipped with an Eaton variable speed
drive adjustable up to 300 strokes per minute. The machine still meets original
specifications for alignment and bearing clearances when regularly inspected. A
combination of good basic design and careful maintenance make long trouble free service
life possible.
Because these presses utilize a gear reduction, with the flywheel on the high-speed
backshaft, more flywheel energy can be provided for a given flywheel weight than in a
nongeared press. This greater amount of flywheel energy provides greater torque
capacity, thus making the single geared press better suited for drawing and heavy
forming operations than a direct drive press. A single end drive single gear reduction
press system is illustrated in Figure 5.
Single gear drive presses are often built in larger sizes than direct drive presses. Some
larger machines are built with force of 1,000 tons (8,896 kn.) or more and bed sizes of
204 inches (5.18 M). A machine of this type is excellent for high throughput blanking
operations.
High-speed press crankshafts have short stroke lengths. These crankshafts have very low
amounts of torsional twist. Because the shaft diameter is large compared to the stroke
length, these are termed eccentric type crankshafts.
Figure 7. Providing a driving gear on either end of the crankshaft avoids the angular
misalignment under load illustrated in Figure 6.
Terms that describe the bolster size determine the maximum size die shoe that can be
accommodated in the machine. The minimum and maximum amount of vertical open
space between the ram and bolster must be known in order to know if a die will fit the
press. Of course, the force capacity is very important. It is illegal to overload a stamping
press.
Shut Height
The space available between the press bed or bolster and the slide or ram is called the
shut height. It is always measured with the press shut or at bottom dead center. It may
be specified as the vertical space between the ram and either the top of the bed or bolster
as illustrated in Figure 9.
When a die must be put in an existing press, the distance from the top of the bolster to the
bottom of the ram is the figure that should be used. This distance, specified with the
screw adjustment at maximum and minimum values, determines the range of closed
heights of the dies that will fit into the press.
At times, more shut height than that which can be accommodated with the press bolster
in place is needed. Some shops have removed the bolster and fastened the die directly to
the press bed. This is a poor practice. The bolster is needed to stiffen the bed and spread
the load evenly.
Figure 8. A typical style of clutch and gearing arrangement used on double gear
reduction presses.
Figure 9 illustrates two example of shut height measurement. Measurement (A) is taken
from ram to the bed and measurement (B) from ram to the bolster. Since the bolster is
needed to add stiffness to the press bed, measurement (B) is the one that should be used
when determining the allowable maximum die shut height.
Figure 9. Example of shut height measurement taken (A) from ram to the bed, and (B)
from ram to the bolster. Smith & Associates
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7. The connection, which connects the pitman(s) or eccentric strap(s) to the slide
through a bearing.
8. The slide or ram to which the upper die is fastened: it is guided by gibs attached
to the machine frame or housing.
9. The adjusting screw located at each slide connection point.
10. The counterbalance to counter balance the weight of the slide, upper die and
attached linkage.
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Figure 10. A full revolution clutch mounted on the press crankshaft. E. W. Bliss
Company
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Figure 11. Single piston actuated combined clutch and brake system.
Verson Corporation 2
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Brakes
A brake serves to stop and hold the press crankshaft or eccentric drive stationary when
the clutch is not engaged. In its simplest form, it is a drum attached to the crankshaft
having a metal band lined with frictional material attached to the press frame. A spring
with screw adjustment is used to apply constant braking action to the drum. Such brakes
are rarely used except on small presses having full revolution clutches. Since the inertia
of the moving parts is low, the braking action required is minimal.
Most mechanical power press brakes are applied by spring pressure. The brake is
released by applying air pressure to an air cylinder, which depresses the springs holding
the frictional surfaces in contact.
Piston actuated brakes are often combined with a friction clutch in an integral package.
Figure 11 illustrates an example of such a system.
The main advantage of a combined clutch brake is simplicity and lower cost compared to
that of a separate clutch and brake. The design insures that the clutch must release before
the brake can be applied. The combined unit is simple for a trained technician to service.
One design uses a fabric reinforced circular rubber air tube rather than a piston to
accomplish the function of air actuation. The tube does not require lubrication and is
leak free throughout its useful life. However, the safe reliable functioning of the air
valve still requires clean filtered air and may need an air line lubricator.
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Figure 12. Pneumatic piping tanks and controls installed on a straightside press that has
a separate clutch and brake mounted on opposite side of the press crown.
Verson Corporation
The clutch is engaged by applying a DC electrical current to the rotating coils through
slip-rings. The eddy currents set up in the clutch member attached to the press rotary
driven shaft produce a magnetic field that permits torque to be transmitted from the
flywheel to the driven shaft with very little slip.
The amount of slip or difference in speed is controlled by the amount of DC current
supplied to the coils. This provides a useful way to slow the press speed during the
stroke while the flywheel runs at essentially full speed. This type of drive is called a
constant energy system or (CES) since full flywheel energy is available at any point in
the stroke.
This feature finds application in large presses where the slow down function is useful to
assist in deep drawing operations or to reduce moving die member impact problems. The
same principle may also be used to arrest the motion of the press with a set of brake coils
using eddy current action. If everything is functioning properly, the frictional holding
brake dissipates very little energy. The eddy current drive system is extensively used on
large presses that are single stroked. Many applications are found in non-synchronous
automotive tandem press lines.
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Welded repairs generally should never be attempted. The parts are subjected to cyclical
loading during operation as well as frequent heating and cooling cycles. The liability of
crack formation and propagation leading to sudden failure in the heat-affected zone of the
weld is unacceptable. Very serious pressroom accidents have occurred due to welded
clutch and brake repairs having been attempted.
Component Strength
The physical strength of the various parts of the press must be sufficient to withstand
long term cyclical loading at the rated force capacity of the machine. In addition,
deflection must not exceed accepted design tolerances. Standard mechanical engineering
formulas are used by press designers. The result is a robust machine that will provide
decades of normal service at full capacity without failure.
Flywheel
The motor furnishes energy to the flywheel. Once the flywheel is up to speed and not
being cycled, the motor need only supply enough energy to make up for frictional losses.
The flywheel stores the energy until some is used to perform work.
Torque Capacity
The press must have the ability to take the energy of the flywheel, and transmit it through
the clutch, gears (if a geared press), crankshaft, connection and slide to perform the
required work without exceeding the safe working capacity of any component. The
energy stored in the flywheel increases as the square of the flywheel rotational speed.
Thus, presses having variable speed drives vary greatly in the amount of flywheel energy
available depending upon the speed adjustment setting.
Reducing the flywheel speed reduces the total energy available. However, this does not
reduce the press tonnage capacity. The tonnage capacity is based on the strength of the
machine component parts.
When the flywheel speed is reduced below its standard rating, the flywheel energy is
reduced by the square of the speed reduction. Likewise, if the speed is increased, the
flywheel energy is increased by the square of the speed increase.
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The following calculations apply to a 60-ton (534 KN) nongeared press with a variable
speed drive, which is adjustable from 50 to 200, strokes per minute. The 60 tons of force
is available at a rated distance of 0.060-inch (1.5 mm) above bottom dead center at a
rated speed of 100 strokes per minute.
Doubling the speed to 200 strokes per minute will result in four times the usable flywheel
energy being stored. Because this press is designed with component strength and torque
capacity of 60 tons, the additional stored flywheel energy is not usable. The press
tonnage and torque capacity is the same.
If the speed is reduced by 50% to 50 strokes per minute, the flywheel energy is actually
reduced by 75% because at one-half speed there is only one-fourth the energy left in the
flywheel.
Figure 13. A graphical illustration of the relationship of flywheel speed to usable force
and energy.
The 60-ton (534 kN) press thus would supply 15 tons (133 kN) through 0.060-inch (1.5
mm) or 60 tons through approximately 0.015-inch (0.38 mm). At 50 strokes per minute,
the press is still a 60-ton press from a component strength and torque capacity standpoint,
but the flywheel energy is reduced to 25% of the standard rating. Thus, its ability to do
work at the 50 stroke per minute speed is greatly reduced. Figure 13 graphically
illustrates the relationship of flywheel speed to usable force and energy.
The speed range must be taken into account in selecting a press so this loss of energy at
slower speeds does not present a problem. Even if the press does not stall at slow speeds,
excessive drive belt and other drive component wear may result.
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Figure 14. V-belt variable speed drive illustrating the motor and variable pitch cone
pulleys set for minimum speed.
The minimum number of induction motor poles (like the north and south poles of a
magnet) is a minimum of two. Thus, a two-pole induction motor operated from a 60 HZ
power source will run at 3,600 RPM minus the slip, a function of the developed torque.
In the same way, a four-pole motor will run at nearly 1,800 RPM, a six-pole motor at
1,200 RPM and an eight-pole motor at 900 RPM.
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The number of poles is determined by how the coils in the stator are connected. By
changing the connections with a switch or relay, the motor speed can be varied by two or
three discrete steps. This drive speed control system is little used. The mechanical
complexity of the switching required for a three-phase system is a disadvantage. In
addition, only a limited number of discrete speeds are available.
Figure 15. V-belt variable speed drives illustrating the motor and variable pitch cone
pulleys set for maximum speed.
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Some presses, especially those used in high speed perforating work, may have a
conventional induction motor which drives a V-belt variable speed drive built into the
press. In this case, one of the cone pulleys is attached directly to the flywheel.
Figure 16. A variable speed eddy current motor drive available as a packaged unit: it
contains a single speed motor and an eddy current coupling that changes the drive's
output shaft speed.
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The high current drawn when starting large motors can result in a momentary drop in
voltage that may disrupt other equipment on the same supply line. In addition, many
commercial users are charged a penalty by the utility company for the peak electrical
demand of the plant. If only one or two large press motors are in use, the starting surge
can result in substantial peak penalty charges. Even if many large press motors are
involved, it is wise to establish a procedure to stagger starting them at the beginning of
the day or shift.
If the starting voltage is reduced to half the running value, the starting current drops to
half the full voltage value. Since the torque is the product of the input power, the starting
torque is only one fourth the full voltage value.
Reduced starting torque substantially increases the amount of time required to bring the
flywheel up to speed. However, an advantage is that there is much less drive belt wear as
well as stressful torque reaction in the motor stator windings. Energy savings may also
be realized. The heating losses in the windings increases four times if the current drawn
is doubled.
Some reduced voltage starters operate by switching the winding connections with relays
in the case of multiple voltage motors. Because of the complexity of the circuit, this
method is seldom used.
A more common method makes use of a starter that reduces the starting voltage by means
of solid state switching devices. In addition, these starters often have a provision to
reduce the voltage supplied to the motor when reduced loads are experienced. This
feature reduces power consumption.
Gears
Figures 2, 4, 5, 7 and 8 illustrate the application of gears in press drive applications. In
mechanical press drive applications, gears are used extensively to permit an increased
flywheel speed and provide greater press torque capacity.
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Pitman
The English term pit man has long referred to any man who worked in a pit such as a
coal miner. Likewise, the man who worked in a saw-pit, cutting boards from logs with a
large two-man handsaw was called a pit man. The other end was pulled from above by
the top man.
Figure 17. Main drive gear double keyed to press crankshaft. The keys are subjected to
cyclical shear loading. Two keys provide a greater cross sectional area and torque
transmission capacity than a single key. Smith & Associates
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When waterpower was applied to the sawing operation, the connecting link between the
crank driven by the water wheel and the lower end of the saw was called a pitman. This
term was applied to emerging technologies employing a similar mechanical linkage, such
as the steam engine and stamping press as well. Thus, the link between the crank and
slide is generally termed a pitman. 3
When the press is driven by eccentrics, the link between the eccentric and connection is
called an eccentric strap. The flexible attachment of the pitman or eccentric strap to the
slide is called the connection. A means to accomplish shut height adjustment by an
adjustable screw mechanism is nearly always a part of the connection system.
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O. Evens, The Young Mill-Wright & Miller's Guide, Philadelphia, 1795. The work appeared in 15
editions between 1795 and 1860. A reprinted edition is available from the Oliver Evens Press,
Wallingford, Pennsylvania. This work served as the pattern for many water powered sawmills and
gristmills built throughout North America.
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