Abstract
In sheet metal forming manufacturing operations the use of servo presses is gaining more interest due to the opportunity to improve process performance (quality, productivity, cost reduction, etc.). It is not yet clear how to proceed in the engineering process when this type of operating machine is used to achieve the maximum possible potential of this technology. Recently, several press builders have developed gap- and straight-sided metal forming presses adopting the mechanical servo-drive technology. The mechanical servo-drive press offers the flexibility of a hydraulic press with the speed, accuracy and reliability of a mechanical press. Servo drive presses give the opportunity to improve the productivity of process conditions and improve the quality of stamped parts. Forming simulation and numerical optimization can be useful tools to define beforehand the optimal process parameter set-up in terms of servo press downward curve properties. This is done by carrying out a sensitivity analysis of the forming parameters having influence on said curve. The authors have developed a numerical methodology able to analyze the influence factors, for comparison with the degrees of freedom made available by the usage of a servo press, in terms of stroke profile management, to obtain an optimized process parameters combination.
Highlights
Electro-mechanical servo-drives have been used in machine tools for several decades
The maximum and minimum reaction force values are obtained, respectively, for RUN8 and RUN16/20, while the maximum material recall in the die occurs for the RUN4, RUN11 and RUN25
The maximum and minimum reaction force values were obtained, respectively, for RUN5 and RUN17, while the maximum material recall in the die occurred for RUN1, RUN25 and RUN26
Summary
Electro-mechanical servo-drives have been used in machine tools for several decades. Recently, several press builders, mainly in Japan [1,2] and Germany [3], developed metal forming presses able to utilize the mechanical servo-drive technology. The mechanical servo-drive press offers the flexibility of a hydraulic press (infinite sliding-ram speed and position control, availability of press force at any slide position) with the speed, accuracy and reliability of a mechanical press [4]. The advantage of the servo motor is that it can control all the press motions, such as speed, stroke, slide motion and position. The mechanical servo press flywheel, clutch and brake are replaced by high-capacity motors, and the maintenance of the servo press is simplified. Compared with traditional presses that have been used for many years, the mechanical servo press allows users to obtain higher productivity, better product quality, simpler set up and maintenance, and high repeatability. One of the most important advantages of the servo press is the flexible slide movement [5]. The following advantages arise from choosing a motion suitable for each aim
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