Press Equipment Research Articles

A study on the development of computer-aided process planning system for electric product with bending and piercing operations

This paper describes a research work of developing computer-aided design of product with bending and piercing operation for progressive working. Approach to the system is based on the knowledge-based rules. Knowledge for the system is formulated from plasticity theories, experimental results, and the empirical knowledge of field experts. The system has been written in AutoLISP on the AutoCAD with a personal computer. It is composed of four main modules, which are input and shape treatment, flat pattern layout, strip layout, and die layout modules. The system is designed by considering several factors, such as bending sequence by fuzzy set theory, complexities of blank geometry, punch profiles, and the availability of a press equipment and standard parts. The strip layout and die layout drawings automatically generated by formularization and quantification of experimental technology will make minimization of trial and error and reduction of period in developing new products. Results obtained using the modules enable the manufacturer for progressive working of electric products to be more efficient in this field.

Development of a System for Progressive Working of an Electric Product by Using Fuzzy Set Theory

This paper describes the development of a computer-aided design for a product with intricate bending and piercing operations for progressive working. The approach to the system is based on knowledge-based rules. Knowledge for the system is formulated from plasticity theories, experimental results, and the empirical knowledge of experts in the field. The system has been written in AutoLISP and AutoCAD on a personal computer. It is composed of four main modules, which are input and shape treatment, flat pattern layout, strip layout, and die layout modules. The system is designed considering several factors, such as bending sequence by fuzzy set theory, complexities of blank geometry, punch profiles, and the availability of press equipment and standard parts. The strip layout and die layout drawings, which are automatically generated by formulisation and quantification of experimental technology, will minimise trial and error and reduce the period for developing new products. The system could serve as a valuable system for experts and as a dependable training aid for beginners.

Fabrication of a first wall panel by diffusion bonding

Separated First Wall Panels mechanically attached to a shield block is now the reference concept for the Primary Wall Modules of RTO/RC ITER. The objective of the present work is to demonstrate the practical feasibility of a First Wall Panel utilizing a duplex round (steel) in square (copper) heat sink wound around a steel core and covered by Beryllium armour tiles. These three different materials (Be, Cu, steel) are joined together by diffusion bonding. The Copper alloy/stainless steel and Copper alloy/Beryllium joints were studied and developed selecting the optimal parameters for the related diffusion process. Several specimens were manufactured to be mechanically and thermally tested. The joints were mechanically tested using dedicated press equipment and investigated by micro-structural analysis with optical and SEM microscopy. Some thermal tests were finally carried out using an Electron Beam Facility. A dedicated R&D programme has led to the development of a co-drawing process, suitable for manufacturing the duplex Copper alloy-stainless steel heat sink. Two mock-ups were manufactured, the first in reduced-scale to test the thermal performance of the system, the second of larger scale and geometry better to represent the First Wall Panel.

An analysis of the forging processes for 6061 aluminum-alloy wheels

The metal forming processes of aluminum-alloy wheel forging at elevated temperatures are analyzed by the finite element method. A coupled thermo-mechanical model for the analysis of plastic deformation and heat transfer is adapted in the finite element formulation. In order to consider the strain-rate effects on material properties and the flow stress dependence on temperatures, the rigid visco-plasticity is applied to the simulation. Several process conditions were applied to the simulation such as punch speed, rim thickness, and the depth of die cavity. Experiment for a simplified small-scale model is carried out and compared with the simulation in terms of forging load to verify the validity of the formulation adapted in this study. Then, various processes with full-scale model for a 6061 aluminum-alloy wheel are simulated. Material flow, pressure distributions exerted on the die wall, temperature distributions and forging loads are summarized as basic data for process design and selection of a proper press equipment.

Development of an integrated computer-aided process planning system for press working products

This paper describes research work in developing an automated computer-aided process planning system for a hot forging or blanking product by press working. The computer-aided process planning system written in AutoLISP on AutoCAD using a personal computer and in I-DEAS Drafting Programming Language on the I-DEAS Master Series Drafting with workstation in hot forging and blanking requires many kinds of technical and empirical skills. An approach to the computer-aided process planning system is based on knowledge-based rules and a process knowledge base consisting of design rules is built. Based on the investigation and collection of knowledge of the processes, the methodology adopted to develop this system is elaborated in this paper. This integrated computer-aided process planning system is composed of two main modules: hot forging and blanking modules. It is designed by considering several factors, such as the complexities of the blank geometry, the punch and die profiles, the availability of press equipment, and standard parts. Results obtained using the modules enable the designer and manufacturer of forging or blanking dies to be more efficient in this field.

An Integrated Design and CAPP System for Deep Drawing or Blanking Products

This paper deals with an automated computer-aided process planning system by which designers can determine operation sequences even if they have little experience in the process planning of sheet metal products by press working. The computer-aided process planning program written in AutoLISP for the AutoCAD using a personal computer, for deep drawing or blanking, requires many kinds of technical and empirical skills. The approach to structure of the system is based on knowledge-based rules, and a process knowledge base consisting of design rules is built. Based on the investigation and collection of knowledge about the processes, the methodology adopted to develop this system is described in this paper. An attempt is made to link programs incorporating a number of expert design rules to form a useful package for process planing. This integrated design and CAPP system is composed of two main modules and six submodules. It is designed considering several factors, such as the complexities of blank geometry, punch and die profiles, the availability of a press equipment, and standard parts. Results obtained using the modules enable the designer and manufacturer of deep drawing or blanking dies to be more efficient in this field.

An Integrated Design and CAPP System for Cold or Hot Forging Products

This paper deals with an automated computer-aided process planning system by which designers can determine operation sequences even if they have little experience in process planning of bulk metal products by press working. The approach to the system is based on knowledge-based rules and a process knowledge base consisting of design rules is built. Knowledge for the system is formulated from plasticity theories, empirical results and the empirical knowledge of field experts. Programs for the system have been written in AutoLISP for the AutoCAD using a personal computer. An attempt is made to link programs incorporating a number of expert design rules to form a useful package for process planing. This integrated design and computer-aided process planning (CAPP) system is composed of two main modules and nine submodules. It is designed considering several factors, such as the complexities of blank geometry, punch and die profiles, the availability of press equipment, and standard parts. Results obtained using the modules enable the designer and manufacturer of cold forging or hot forging dies to be more efficient in this field.

An integrated CAD system for the blanking of irregular-shaped sheet metal products

Abstract This paper describes research work into developing computer-aided design for the blanking and piercing of irregularly-shaped sheet metal products. This approach to an integrated CAD system is based on knowledge-based rules. Knowledge for the CAD system is formulated from plasticity theories, experimental results and the empirical knowledge of field experts. The system has been written in Auto LISP on the AutoCAD system with a personal computer. The system is composed of six main modules: input and shape treatment, production feasibility check, blank layout, strip layout, die layout and drawing edit module. Based on the knowledge-based rules, the system, STRTDES1, is designed by considering several factors, such as the complexities of the blank geometry and the punch profiles and the availability of press equipment and standard parts. This system can therefore carry out a die design for each process that is obtained from the results of an automated process-planning system and generate part drawings and the assembly drawing of the die set in graphic form. The developed system provides powerful capabilities for the process planning and dies design of irregularly-shaped products.

A compact and practical CAD system for blanking or piercing of irregular-shaped sheet metal products and stator and rotor parts

This paper describes the development of a computer-aided design of blanking and piercing for irregular-shaped sheet metal products and stator and rotor parts. An approach to the compact and practical CAD system is based on the knowledge-based rules. Knowledge for the CAD system is formulated from plasticity theories, experimental results and the empirical knowledge of field experts. The system has been written in AutoLISP on the AutoCAD with a personal computer and is composed of six main modules, which are input and shape treatment, production feasibility check, blank layout, strip layout, die layout, and drawing edit module. Based on knowledge-based rules, the system, STRTDES, is designed by considering several factors, such as complexities of blank geometry and punch profile, availability of press equipment and standard parts, utilization ratio which minimizes the scrap in a single or a pairwise operation, bridge width, grain orientation and design requirements which maximize the strength of the part when subsequent bending is involved. Therefore, this system can carry out a die design for each process which is obtained from the results of an automated blank layout drawing with the best utilization ratio for the irregular shape of the product, which was successful in the production feasibility check module, and those of an automated strip layout drawing. It can then generate part drawings and the assembly drawing of the die set in graphic form. The developed system provides its efficiency and effectiveness for blank layout, strip layout, and die layout of irregular-shaped sheet metal products and stator and rotor parts.

Implementing an expert system for fault diagnosis of electronic equipment

The aim of this work is to develop a rule-based expert system to aid an operator in the fault diagnosis of the electronics of forge press equipment. It is a menu-driven package, developed in Turbo PROLOG on an IBM PC., to help the operator fix faults up to replaceable module level. The system has been broadly categorised into eight sub-systems, and the rules, based on fault cause relations, have been developed for each of the sub-systems. This modular development reduces the access time, and also facilitates the handling of the knowledge base.

Production of die steels by suspension molding

The ranges of application of traditional technologies of powder metallurgy, which include holding under a pressure of (5–7)·102 N/mm2, are limited by the necessity of using expensive press equipment and attachments. This paper investigates the structure and properties of heat-treated die steels produced by a new method of molding — from stabilized suspensions of metallic powders. Optimal suspension compositions and sintering conditions are proposed.

Joining of displays using thermosetting anisotropically conductive adhesives

This paper describes the reliability of using thermosetting anisotropically conductive adhesives for two applications: (1) joining LCD modules to rigid boards via flexible circuitry in a large panel video screen application; and (2) joining of LCD modules directly to flexible circuitry in a camera application. Three different types of thermosetting adhesive, one mixed type of thermosetting and thermoplastic anisotropically conductive adhesive and two heatseal connectors were used in the present investigation. The heatseal connectors are currently used in production and were used in the present investigation as reference materials. In the present study, ITO glass was used instead of real LCD devices. The interconnections were made using conventional heatseal press equipment for the two applications. The reliability of the adhesives was investigated in terms of a temperature-cycling test from −40 to 85oC for 1000 cycles using a temperature change rate of approximately 20oC/min, a constant-humidity test at 60oC, 95% RH for 1000 h, and a humidity-cycling test from 5 to 75oC at 95% RH for 1000 h. Both mechanical and electrical properties were measured before and after the environmental tests. The results indicate that control of process parameters such as bonding temperature, bonding pressure and time is critical for good bonding quality. Under the right process conditions, thermosetting anisotropically conductive adhesives are much better in environmental performance than heatseal connectors. The resistance change with time in the humidity test has been explained by oxidation of metal fillers or by oxidation of metallizations on interconnecting materials. It is shown that the oxide layer thickness and type control the rate of resistance change in a humid environment.

CADDS: an automated die design system for sheet-metal blanking

This article reports on the design and implementation of a Computer-Aided Die Design System (CADDS) for sheet-metal blanks. The system is designed by considering several factors, such as the complexity of blank geometry, reduction in scrap material, production requirements, availability of press equipment and standard parts, punch profile complexity, and tool elements manufacturing method. The interaction among these parameters and how they affect designers' decision patterns is described. The system is implemented by interfacing AutoCAD with the higher level languages FORTRAN 77 and AutoLISP. A database of standard die elements is created by parametric programming, which is an enhanced feature of AutoCAD. The greatest advantage achieved by the system is the rapid generation of the most efficient strip and die layouts, including information about the tool configuration.

Kinetic Chain Exercise in Knee Rehabilitation

Rehabilitation is recognised as a critical component in the treatment of the anterior cruciate ligament (ACL) injured athlete, and has been the subject of intense research over the past decade. As a result, sound scientific principles have been applied to this realm of sports medicine, and have improved the outcome of both surgical and nonsurgical treatment. Possibly the most intriguing of these principles is the use of the kinetic chain concept in exercise prescription following ACL reconstruction. The hip, knee, and ankle joints when taken together, comprise the lower extremity kinetic chain. Kinetic chain exercises like the squat recruit all 3 links in unison while exercises such as seated quadriceps extensions isolate one link of the chain. Biomechanical assessment with force diagrams reveals that ACL strain is reduced during kinetic chain exercise by virtue of the axial orientation of the applied load and muscular co-contraction. Additionally, kinetic chain exercise through recruitment of all hip, knee, and ankle extensors in synchrony takes advantage of specificity of training principles. More importantly, however, it is the only way to reproduce the concurrent shift of 'antagonistic' biarticular muscle groups that occurs during simultaneous hip, knee, and ankle extension. Incoordination of the concurrent shift fostered by exercising each muscle group in isolation may ultimately hamper complete recovery. Modifying present day leg press and isokinetic equipment will allow clinicians to make better use of kinetic chain exercise and allow safe isokinetic testing of the ACL reconstructed knee. Reconstruction of the ACL with a strong well placed graft to restore joint kinematics, followed by scientifically sound rehabilitation to improve dynamic control of tibial translation, will improve the outcome after ACL injury.

Temperature field of high-pressure apparatus and its influence on the structure formation of material of wurtzite boron nitride

The authors study the effects of the temperature distribution in the press equipment on the crystallization, lattice structure, and microstructure of boron nitrides during their hot pressing. The calculation procedures use coefficients of the electrical and thermal conductivity of the nitrides. Structural phase transformations resulting in a wurtzite lattice are also analyzed.

An ergonomic approach to designing a manufacturing work system

This paper highlights the methodology that was applied systematically to incorporate ergonomics principles and data to design a manufacturing work system. The manufacturing task comprised of drilling four holes on a prepared steel plate. The components of the manufacturing work system included: manufacturing task, power-feed drill press, jig, fixture and other equipment, workplace layout, operator training and (hard) production standard and feedback. The ergonomically designed manufacturing work system proved to be effective and efficient in terms of manufacturing processing time, safety, training time, and worker productivity, satisfaction, and job attitudes.

Comparative analysis of the characteristics of press equipment with electromagnetic drive

Comparative analysis of the characteristics of press equipment with electromagnetic drive

Current developments and trends in press equipment for the refractories industry

Current developments and trends in press equipment for the refractories industry

Automation comes to the printing and publishing industry Production and distribution of magazines, periodicals, and books

Existing information retrieval systems, hardware and software for automated publication, and newly developed press and bindery equipment* are the precursors of ever more dramatic and sophisticated systems now in the R&D stages. For example, a fully automated web offset press could be in commercial production within the next few years. At the same time, there is a quiet revolution in bookbinding, based upon plastics technology, that is rendering obsolete conventional binding methods. The day is not far distant when almost completely automatic satellite plants will be operated for producing and distributing periodicals, indexes, catalogs, and books.

Pressure Lubricated Deep Drawing : 5th Report, The Sub-shop-scale Experiments Using a Hydraulic Press Equipment

An intermediate equipment between the laboratory scale and the actual press shop scale is constructed and tested for the Pressure lubricated deep drawing. By its hydraulic system, the fluid pressure can be controlled between 0 and 1000kg/cm2, which may be necessary to obviate the difficulties encountered in press shop practice. Through the experiment, it is clarified that the pressure formulae previously proposed are also consistent with the new lager equipment, and that the pressure lubricated deep drawing system can be applicable to the practical working rather satisfactorily. To realize the importance of controlling pressure in that system, its effect on drawing result is proved by showing the certain drawn examples of cylindrical cups.