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.PDF 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.
Mechanical Press Types and Nomenclature 1993-2005 C02.doc C02.PDF David Alkire Smith, 530 Hollywood Drive, Monroe, Michigan 48162-2943 Rev August 19, 2005
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.
Mechanical Press Types and Nomenclature 1993-2005 C02.doc C02.PDF David Alkire Smith, 530 Hollywood Drive, Monroe, Michigan 48162-2943 Rev August 19, 2005
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
Mechanical Press Types and Nomenclature 1993-2005 C02.doc C02.PDF David Alkire Smith, 530 Hollywood Drive, Monroe, Michigan 48162-2943 Rev August 19, 2005
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.
Figure 3. A nongeared drive illustrating a double-throw crankshaft directly driven by the flywheel through a frictional clutch. Energy is transferred from the motor to the flywheel by several V-belts.
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.
Mechanical Press Types and Nomenclature 1993-2005 C02.doc C02.PDF David Alkire Smith, 530 Hollywood Drive, Monroe, Michigan 48162-2943 Rev August 19, 2005
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.
Mechanical Press Types and Nomenclature 1993-2005 C02.doc C02.PDF David Alkire Smith, 530 Hollywood Drive, Monroe, Michigan 48162-2943 Rev August 19, 2005
Figure 5. A single geared drive illustrating a double-throw crankshaft driven by a single end gear and frictional clutch the flywheel drives the crankshaft end gear by means of a smaller pinion gear.
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.
Mechanical Press Types and Nomenclature 1993-2005 C02.doc C02.PDF David Alkire Smith, 530 Hollywood Drive, Monroe, Michigan 48162-2943 Rev August 19, 2005
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 6. Angular misalignment proportional to the torque transmitted through a crankshaft with two throws occurs in single end drive presses. This factor results in a ram tipping alignment error.
Mechanical Press Types and Nomenclature 1993-2005 C02.doc C02.PDF David Alkire Smith, 530 Hollywood Drive, Monroe, Michigan 48162-2943 Rev August 19, 2005
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.
Mechanical Press Types and Nomenclature 1993-2005 C02.doc C02.PDF David Alkire Smith, 530 Hollywood Drive, Monroe, Michigan 48162-2943 Rev August 19, 2005
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
Mechanical Press Types and Nomenclature 1993-2005 C02.doc C02.PDF David Alkire Smith, 530 Hollywood Drive, Monroe, Michigan 48162-2943 Rev August 19, 2005
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Mechanical Press Types and Nomenclature 1993-2005 C02.doc C02.PDF David Alkire Smith, 530 Hollywood Drive, Monroe, Michigan 48162-2943 Rev August 19, 2005
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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Mechanical Press Types and Nomenclature 1993-2005 C02.doc C02.PDF David Alkire Smith, 530 Hollywood Drive, Monroe, Michigan 48162-2943 Rev August 19, 2005
Figure 10. A full revolution clutch mounted on the press crankshaft. E. W. Bliss Company
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Mechanical Press Types and Nomenclature 1993-2005 C02.doc C02.PDF David Alkire Smith, 530 Hollywood Drive, Monroe, Michigan 48162-2943 Rev August 19, 2005
Figure 11. Single piston actuated combined clutch and brake system. Verson Corporation 2
C. Wick, J. T. Benedict, R. F. Veilleux, Tool and Manufacturing Engineers Handbook, Volume 2 Fourth Edition, pages 5-35 to 5-37, The Society of Manufacturing Engineers, Dearborn, Michigan 1984. This work is the source for Figures 10 and 11.
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Mechanical Press Types and Nomenclature 1993-2005 C02.doc C02.PDF David Alkire Smith, 530 Hollywood Drive, Monroe, Michigan 48162-2943 Rev August 19, 2005
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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Mechanical Press Types and Nomenclature 1993-2005 C02.doc C02.PDF David Alkire Smith, 530 Hollywood Drive, Monroe, Michigan 48162-2943 Rev August 19, 2005
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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Mechanical Press Types and Nomenclature 1993-2005 C02.doc C02.PDF David Alkire Smith, 530 Hollywood Drive, Monroe, Michigan 48162-2943 Rev August 19, 2005
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Mechanical Press Types and Nomenclature 1993-2005 C02.doc C02.PDF David Alkire Smith, 530 Hollywood Drive, Monroe, Michigan 48162-2943 Rev August 19, 2005
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Mechanical Press Types and Nomenclature 1993-2005 C02.doc C02.PDF David Alkire Smith, 530 Hollywood Drive, Monroe, Michigan 48162-2943 Rev August 19, 2005
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Mechanical Press Types and Nomenclature 1993-2005 C02.doc C02.PDF David Alkire Smith, 530 Hollywood Drive, Monroe, Michigan 48162-2943 Rev August 19, 2005
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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Mechanical Press Types and Nomenclature 1993-2005 C02.doc C02.PDF David Alkire Smith, 530 Hollywood Drive, Monroe, Michigan 48162-2943 Rev August 19, 2005
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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Mechanical Press Types and Nomenclature 1993-2005 C02.doc C02.PDF David Alkire Smith, 530 Hollywood Drive, Monroe, Michigan 48162-2943 Rev August 19, 2005
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Mechanical Press Types and Nomenclature 1993-2005 C02.doc C02.PDF David Alkire Smith, 530 Hollywood Drive, Monroe, Michigan 48162-2943 Rev August 19, 2005
These units required expensive maintenance. In addition, power wasting components such as resistor banks or rheostats were needed to achieve motor speed adjustment. Modern DC motors use solid state components such as large silicon controller rectifiers (SCRs) and high power transistors to replace both the motor generator set and inefficient speed adjusting systems. A physically small and efficient combined power supply and speed control is now used. Typical sizes for press applications range from five through 500 horsepower (3.729 to 372.9 kW). The high maintenance items on a DC drive motors are the brushes and rotating commutator. In addition, a fan is often required to cool the motor during low speed operation.
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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Mechanical Press Types and Nomenclature 1993-2005 C02.doc C02.PDF David Alkire Smith, 530 Hollywood Drive, Monroe, Michigan 48162-2943 Rev August 19, 2005
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.
One method of a variable frequency drive system is to convert the 60 HZ AC input to direct current. The DC is then efficiently converted to AC of the frequency required to drive the motor at the desired speed by solid state switching devices. While the electronic controls required to accomplish the conversion are complex, control designs employing modern solid state integrated circuit components permit the control package to be relatively small, cost effective and highly reliable.
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Mechanical Press Types and Nomenclature 1993-2005 C02.doc C02.PDF David Alkire Smith, 530 Hollywood Drive, Monroe, Michigan 48162-2943 Rev August 19, 2005
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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Mechanical Press Types and Nomenclature 1993-2005 C02.doc C02.PDF David Alkire Smith, 530 Hollywood Drive, Monroe, Michigan 48162-2943 Rev August 19, 2005
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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Mechanical Press Types and Nomenclature 1993-2005 C02.doc C02.PDF David Alkire Smith, 530 Hollywood Drive, Monroe, Michigan 48162-2943 Rev August 19, 2005
Gears are expensive press components. Proper lubrication is an absolute necessity. Where pairs of gears must work together such as the double end drive system illustrated in figures 2, 6 and 7, it is essential that the load be shared equally. Figure 17 illustrates how the gears shown in figure 2 are keyed to the press crankshaft. Tapered keys retained by keeper plates are superior to plain square keys in high torque and shock applications. Such keys usually have an L-shaped head to permit removal with a prybar. It is essential that tapered keys be correctly fitted. Should a careless maintenance mechanic drive a poorly fitted key into place, expensive damage can occur. The function of the keeper plate is to hold the key firmly in place. Welding should never be permitted to retain a key. The weld does nothing to improve the fit of a key and can cause extreme difficulty in servicing the machine.
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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Mechanical Press Types and Nomenclature 1993-2005 C02.doc C02.PDF David Alkire Smith, 530 Hollywood Drive, Monroe, Michigan 48162-2943 Rev August 19, 2005
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.
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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Mechanical Press Types and Nomenclature 1993-2005 C02.doc C02.PDF David Alkire Smith, 530 Hollywood Drive, Monroe, Michigan 48162-2943 Rev August 19, 2005
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