Fine Blanking Press Research Articles

Energy efficiency improvement of heavy-load hydraulic fine blanking press for sustainable manufacturing assisted by multi-stages pressure source system

The fine blanking process has the highest forming accuracy in the field of metal forming and its production volume has increased sharply. However, hydraulic fine blanking presses (HFBP) – the core equipment of the fine blanking process, have suffered from significant energy loss due to the inefficient hydraulic system. To enhance the energy efficiency of the hydraulic system, this study introduced a novel approach – a multi-stage pressure source system comprised of distinct pump-accumulator groups, each operating at varied supplied pressures to narrow the mismatch of the installed and demanded power. This adaptive system is capable of automatic adjustments to align with the required pressure, thereby mitigating energy losses while concurrently preserving superior dynamic working performance. First, this study commenced with a theoretical analysis of the system configuration and energy characteristics of HFBP. Subsequently, a comprehensive exploration into the inherent inefficiencies of the hydraulic system is undertaken by formulating a precise energy consumption model. Finally, a novel energy-saving optimization design was carried out on the fast-approaching subsystem. The results demonstrated that the implementation of the proposed system led to a notable reduction of 76.87% in energy loss within the flow-regulating module, and an overall diminution of 13.53% in energy dissipation compared to the conventional system. This study will significantly advance sustainable manufacturing practices within the metal-forming domain by reducing electricity consumption and production cost.

Optimization of Hydraulic Fine Blanking Press Control System Based on System Identification

Fine-blanking is a molding process based on the common blanking process, which obtains hydrostatic stress through blank holder reverse jacking, in order to increase material plasticity. It requires special equipment, namely a fine-blanking press, to complete the fine-blanking process. In this paper, the problem of the speed of the slide block fluctuation found in the actual use of a 12,000 kN hydraulic fine-blanking press after multi-stage pressure source optimization is studied. Firstly, the mathematical model of the motion of the slide block in the blanking stage of the hydraulic fine blanking press is established, and the accurate mathematical model in the blanking stage of the hydraulic fine-blanking press is obtained through the least square method system identification experiment. Aiming at the complex working situation of the fine-blanking press, a phased PID control strategy is creatively proposed. The optimal PID control parameters are obtained by a genetic algorithm, and established a fuzzy PID controller for the blanking stage to accurately control the movement speed of the slide block. The results show that the new control strategy is very effective in improving the movement accuracy of the slide block, effectively improving the machining accuracy and reducing the impact vibration of the hydraulic system.

Active Vibration Control of a Mechanical Servo High-speed Fine-Blanking Press

The fine-blanking process as an advanced sheet metal forming process has been widely applied in industry. However, specially designed equipment is required for this process. In this paper, a novel mechanical servo high-speed fine-blanking press with the capacity of 3200 kN is proposed, and the vibration control for this machine is researched to achieve the requirement of fine-blanked parts of high dimensional accuracy, since the vibration of the fine-blanking machine will cause the machining displacement error and reduce the machining accuracy. Self-adaptive feed-forward control is used to simulate the active vibration control of the mechanical fine-blanking machine. The vibration control principle of the fine-blanking machine is described, and the control algorithm is established. At the same time, the mechanical vibration model of the fine-blanking machine as the controlled object is established, and the parameters of the excitation input and the mechanical model are obtained by the fine-blanking finite element simulation and the experiments of the vibration measurement of the press. Finally, the numerical simulation and analysis of active vibration control based on MATLAB are carried out. The results show that the control effect is good, and the vibration response is effectively reduced, thus greatly increasing the processing accuracy, saving a significant amount of energy, and reducing the energy consumption and defective rate.

Structural Analysis and Size Optimization of a Fine-Blanking Press Frame Based on Sensitivity Analysis

The fine-blanking press, which has been widely used in the sheet-cutting industry, is high-end equipment. The frame is a core component of the fine-blanking press. In this paper, the sensitivity analysis and size optimization method were used to optimize a fine-blanking press frame. First, a shell element model of the frame was established to analyse the mechanical properties of the initial frame. Then, the mathematical expressions for sensitivity analysis and size optimization of the frame were formulated. Based on the established model, the response sensitivities for plate thicknesses were analysed, and a 12.94 % weight reduction was achieved through size optimization. Moreover, the effect of material distribution on dynamic performance was investigated. The result indicated that for a constrained structure, distributing material close to the constraint location increases the modal frequencies.

Energy improvement of fineblanking press by valve-pump combined controlled hydraulic system with multiple accumulators

To improve the useful energy efficiency of a hydraulic fine-blanking press (HFBP), a hydraulic system using a combined valve-pump combined with multiple accumulators and comprising a valve-controlled circuit and pump-controlled circuit, was presented based on the working-process load characteristics. By adopting multiple accumulators, the slide block mechanical energy was recycled and the system dynamic response speed was improved. The system operation principle was first presented, and the system parameters were calculated based on the energy conservation law. Then, a simulation model was established to analyze the system energy dissipation and distribution. Finally, the proposed system was validated on a 1000-ton HFBP. The results demonstrate that, in comparison with the conventional system, the novel system performs well, while simultaneously achieving a high working speed, high precision and large tonnage. Moreover, the total dissipation energy of this novel system was decreased by approximately 100 kJ in a working cycle, while the energy utilization efficiency was increased by an average of 20% under different load conditions. This novel system can be generalized to any hydraulic press to improve energy efficiency and especially hydraulic presses having a large tonnage.

Energy analysis and optimization of main hydraulic system in 10,000 kN fine blanking press with simulation and experimental methods

In this paper, a low-high pressure double oil hydraulic system with accumulators was presented with the features of high working efficiency, high control precision and large working capacity. To analyze the hydraulic system energy characteristic, a novel analytical approach, based on the mathematical energy dissipation model of hydraulic components, was proposed to calculate the system energy dissipation by establishing high accuracy simulation model. A test rig with a 10,000 kN hydraulic fine blanking press was built up and used to validate the proposed system and the energy analytical approach. Finally, the system energy dissipation of the 10,000 kN hydraulic fine blanking press was analyzed and the pump output pressure was optimized to minimize the energy dissipation with the genetic algorithm. Results indicate that the energy efficiency of the hydraulic fine blanking press hydraulic system is low, and especially under low-load conditions it is (0–50% full load rate) less than 15%. About 50% of the total input energy is consumed in the form of valve dissipation resulted from the imbalance of installed and demanded energy. After optimization, the total input energy decreases by nearly 50% and the energy efficiency increases by 10%, especially under low-load conditions.

Evaluation of the fine blanking tool for the precise clutch cam of automobile seat lifter pumping device

In this paper, the multi-step forming process was studied with the fine blanking (FB) tool and the FB experiments for the precise clutch cam of automobile seat lifer pumping device (PCC). In order to form the PCC, the multi-step compound FB tooling system was taken; the three forces were directly gained from the rams of the FB press and the other force was gained from the auxiliary hydraulic device in the FB press. The FB tool was optimally designed through the FB simulation and fabricated. From the FB experiments with the FB press (Mori Iron Co., Ltd, FB400), the 5 samples of the PCC were taken and measured. All samples fulfilled the tolerance conditions.

Model and Simulation Analysis of a High Speed Hydraulic System in a Fineblanking Press

As a key component of a hydraulic fineblanking press, a high speed hydraulic system is used to achieve the rapid movement of the slider in the noncutting stage, which is important for improving the processing efficiency. It is important to study the various properties of a high speed hydraulic system as the rapid movement affects the precision of the machine as well as the quality of the stamping parts. In this paper, a high speed hydraulic system model was established, and the static and dynamic characteristics of the key components in the system were simulated and analyzed. The system control logic was designed according to the blanking process, and the changes in the speed, displacement, pressure and flow of the high speed cylinder in the blanking process were analyzed. A strategy using PID feedback control of the system was proposed to improve the blanking precision and provide a reliable basis for the control system design.

Transient performance analysis of the master cylinder hydraulic system of a 6.3 MN fineblanking press

The master cylinder hydraulic system is the core component of the fineblanking press that seriously affects the machine performance. A key issue in the design of the master cylinder hydraulic system is dealing with the heavy shock loads in the fineblanking process. In this paper, an equivalent model of the master cylinder hydraulic system is established based on typical process parameters for practical fineblanking; then, the response characteristics of the master cylinder slider to the step changes in the load and control current are analyzed, and lastly, control strategies for the proportional valve are studied based on the impact of the control parameters on the kinetic stability of the slider. The results show that the kinetic stability of the slider is significantly affected by the step change of the control current, while it is slightly affected by the step change of the system load, which can be improved by adjusting the flow rate and opening time of the proportional valve.

Analysis and Optimization of the Control System of a Hydraulic Fine-Blanking Press

Analysis and Optimization of the Control System of a Hydraulic Fine-Blanking Press

자동차용 고정밀 시트 리클라이너의 기어성형 공정에 관한 연구

In the automotive seat industry, the use of a fine blanking press is important for manufacturing of high precision products. Among them, a gear part which is a main component of an automotive seat recliner is generally manufactured by fine blanking press. However, the use of conventional mechanical press has been increasing in manufacture of gear part because of low productivity of fine blanking press. In this study, new forming process is suggested to fabricate the gear part with high precision by using mechanical press. The effect of flow restriction die (FRD) which has the restriction of blank edge on dimensional accuracy is investigated by FE-analysis. FE-analysis results for different conditions of FRD indicated that FRD has high dimensional accuracy with the lowest roll-over and the highest perpendicularity of gear part. After application to fabrication of the gear part using mechanical press, the measured dimensional characteristic was compared with the required specification of final product. In addition, results of the performance test showed that the product fabricated by developed process satisfied the required strength and durability. The results show that the suggested forming process by using FRD and mechanical press can replace fine blanking on the viewpoint of dimensional accuracy and productivity.

Finite element analysis and topology optimization of a 12000KN fine blanking press frame

Fine blanking press frame is one of the core components of the fine blanking press. Good performance of the frame is of great importance to ensure blanking precision. Simultaneously, lightweight of...

The Static and Modal Analysis of 12000KN Fine Blanking Press Frame

The fine blanking press supports huge impact load and high-speed stamping frequency in the work process, and the deformation of the molds and the precision of components are significantly influenced by the deformation and vibration of the press. The frame under impact load and stamping frequency, thus the frame structure is the key factor to ensure the reliable work. To make the virtual prototype of the 12000KN fine blanking press frame meet requirements in the best way, the concept design of the frame was built. And optimal interval of the frame stiffness and first order natural frequency were find according to finite element analysis, which can lay the foundation for the design of an ideal frame.

An Experimental Study on the Effect of Die Chamfer Shape and V-Ring Position on Die Roll Height in the Fine Blanking of a Special Part with Various Corner Shapes

In this paper, a change of die roll height according to the die chamfer shape and V-ring distance of a fine blanking tool was studied by experiments on a special part with various corner shapes. Three guide plate inserts with different V-ring positions and three die inserts with different die chamfers were machined, and then a fine blanking tool was manufactured for the fine blanking experiments. Nine experiments were conducted on a 650-ton fine blanking press. Each die roll height was measured and analyzed. It would be noticed that the die roll heights on the corner shapes of the fine blanked parts increased with increasing V-ring distance and die chamfer angle, but it decreased with increasing corner radius and angle. The results in this study can be used to minimize the die roll height of fine blanked parts with corner shapes when designing the V-ring and die chamfer of a fine blanking tool.

An Experimental Study on the Die Roll Height According to the V-Ring Distance of the Fine Blanking Tool for the Seat Recliner Holder with Various Corner Shapes

In this paper, the relation between die roll height and V-ring distance of a fine blanking tool was studied by experimenting on a special designed seat recliner holder with various corner shapes. Three guide plate inserts with different V-ring distances and a die insert with constant die chamfer were machined, and a fine blanking tool was manufactured for the experiments. Three experiments were conducted on a 650-ton fine blanking press. Each die roll height on the sample from the experiments was measured and analyzed. It should be noticed that the die roll heights on the corner shapes of fine blanked parts increase with increasing the distance between the V-ring distance, and decrease with increasing corner radius and angle. These results can be used to minimize the die roll height of fine blanking parts with corner shapes when designing the V-ring of a fine blanking tool.

An Experimental Study of V-Ring Position on the Die Roll Height in the Fine Blanking of Special Part with Corner Shapes

In this paper, the relation between die roll height and V-ring position of a fine blanking tool was studied by experimenting on a special part with various corner shapes. Three guide plate inserts with different V-ring positions and a die insert with constant die chamfer were machined, and a fine blanking tool was manufactured for the fine blanking experiments. Three experiments were conducted on a 650-ton fine blanking press. Each die roll height was measured and analyzed. We found the tendency of the die roll heights on the corner shapes of fine blanked parts to increase with increasing the distance between the V-ring position and the contour of the special part, and to decrease with increasing corner radius and angle. These results can be used to minimize the die roll height of fine blanking parts with corner shapes when designing the V-ring of a fine blanking tool.

高精度ＦＢ型のメンテナンス技術の構築と金型製作

高精度ＦＢ型のメンテナンス技術の構築と金型製作