FORMING

Q1: What is an air cushion?

 It is basically of an air cylinder, a piston, and a surge tank. The air cushion is
attached to the die shoe or in some application maybe attached to the frame of
the press and it is a type of pad used to help keep the W.P in place.

Principal of air cushion.

Q2: What is the advantages of air cushioning?
1. can hold more constant pressure for long strokes than spring pads
2. although its pressure is not constant it can vary within limits
Disadvantages of air cushions
1. Low pressure only up to 100 psi.
2. The pressure varies.
3. Must be located on the die shoe because of the space limitations of the
punch.
Q3: What is curling die? What is the purpose of curling?
 A curling die rolls a raw edge of metal into a roll or curl
 The purpose is to strengthen the raw edge, provide a protective, and
improve the appearance of the product. The curl is often applied over a
wire ring for increased strength.

Q4: What is the major difference between coining and embossing?

 Is that in coining the metal flows whereas in embossing the metal does not
change in thickness to any great extent.
 a) Principle embossing die b) Embossed part

Q5: What are the major advantages of coining?

1) Ornate detail can be reproduced.
2) Excellent surface finish.
3) Very close tolerance can be held.
Q6: Why is rubber or urethane preferred as a pressure dispersing
agent in bulging operations?
 Because they are clean and are easy to use and may have high productivity and
require follow-ups after the process.
Q7: Why must coining dies highly polished and free from scratches?
 As the scratches and marks maybe stress-concentration points which will
cause the die to split under heavy weight.
 The surface finish of the die affects the quality of the surface of the product,
so a polished surface is required to give a good surface finish.
Q8: what is a bulging operation?
 Bulging is an internal forming operation used to expand portions of the drawn
shell or tube and as such the forming force is applied from the inside to allow
the cross section to expand the force is applied through a medium that flows
but doesn’t compress such as rubber, urethane, water, oil, and grease.
 Principle of bulging die

Q7: What are the advantages of hydro pneumatic dies?

1- Full pad pressure from the start.
2- Constant pressure throughout the stroke of the press.
3- Small piston can fit in spring hole.
4- Easy adjustment of the pressure.
5- Elimination of pumps and motors.