Workshop

on
Increasing Press Line Efficiency in
Mechanical & Hydraulic Presses
INDEX
S.No. Description

Page No.

1.

Various types of Presses and their Application. Comparison of

capabilities and limitations of Mechanical & Hydraulic Presses.

2.

Introduction to various Sub Assemblies of Mechanical Presses

3.

Trouble shooting in Hydraulic Circuits

3-4

4.

Understanding the capability of Mechanical Presses w.r.t. Force,

Energy & Speeds

5-6

5.

Health checkup for Mechanical & Hydraulic presses.

6.

Quick Die Change System

7.

Servo Driven Mechanical Presses.

9-10

8.

Common Press problems and their remedies for Mechanical

Presses.

11-12

9.

Increasing Efficiency through Automation.

10.

Operation, maintenance and trouble shooting in Hydraulic Clutch

& Brake Units

11.

Lubrication & Pneumatic System for Mechanical Presses

17

12.

Electrical System Press Safety & Interlocks for Mechanical &

Hydraulic Presses.

18

**********

13
14-16

Various Types of Presses & their Application

A.

Classification of presses is based on following parameters:

1.

Motive Power
a) Hydraulic Press-Load Generation through motor drive hydraulic pumps.
b) Mechanical Press- Load generation through motor Flywheel gears & transmission
through connecting rods.
c) Servo Press-Load generation through Servo Motor, Gears and transmission through
connecting rods.

2.

Construction/Frame/Position type
a)
b)
c)
d)

3.

Gap Frame
4 Pillar
H Frame
Link Frame

Number of Dies used

a) Single Die Station- Stand alone Hydraulic & Mechanical Press, Tandem Press line
b) Multi Die Station
c) Progressive Dies Multiple operations like Punching , Blanking & notching are done
at high production rates
d) Transfer Presses- Multiple operations are done using specially designed transfer dies
and suitable transfer system as per requirement.

4.

Application based presses

a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)

B.

Forming, Draw & Deep draw

Hot Forming
Blanking & Trimming
Die Spotting & Tryout presses
Hemming Press
Rubber Pad Forming
Decorative Laminates
Close Die Forming
Composite SMC Moulding
Straightening Presses
Wheel & Axle Press for Railways

Limitations of presses based on motive power

1.
2.
3.

Hydraulic Presses
Mechanical Presses
Servo presses

****************

Sub-Assemblies in a Mechanical Press

A.

B.

C.

Crown Assembly
1.

Eccentric Gear Assembly

a) Eccentric Gear type
b) Eccentric Pin type
c) Link Drive type
d) Crank Shaft type
e) Eccentric Shaft type

2.

Intermediate Gear Assembly

a) With Integrated Pinion on Intermediate Shaft
b) With Removable Pinion on Intermediate Shaft

3.

Drive Shaft Assembly

a) Flywheel with Bearings
b) Pinion, Keys & Drive Shaft
c) Clutch Brake Unit with Rotary Union

Slide Assembly
1.

Slide adjustment assembly

a) Ball type
b) Plunger type
c) Pin type

2.

Gib Assembly
a) 8-Point Guided
b) 6-Point Guided
c) 4-Point Guided

3.

Hydraulic Over Load valve Assembly

a) Variable Tonnage
b) Fixed Tonnage

Die Cushion Assembly

1.
2.
3.
4.
5.

D.

Die Cushion with fixed stroke

Die Cushion with variable stroke
Single Stage Die Cushion
Two Stage Die Cushion
Die Cushion Adjustment & Damper Assembly

Moving Bolster Assembly

1.
2.
3.

Centre to Front / Rear

Centre to Left / Right
T-Track type
**********

Troubleshooting in Hydraulic Circuits

A.

Troubleshooting is a very important aspect of any maintenance team. Trouble shooting in

hydraulic circuits can only be done by trained maintenance personal. This requires the training
on the following aspects before actually working on the machines.
1.
2.
3.

B.

This programme has been designed considering that the people attending the programme
have basic knowledge of understanding of hydraulic symbols. During the workshop, discussion
on working of few important valves used in hydraulic circuits of hydraulic presses, working of
hydraulic circuits of presses and finally some of the problems encountered during the working
of hydraulic presses will be discussed. Before actually working on the trouble shooting part,
one must understand the basic principles of hydraulics. While attending the problem one must
answer the following questions:
1.
2.
3.
4.
5.
6.

C.

Understanding of hydraulic symbols

Understanding of construction of the various elements used in the hydraulic circuits.
Understanding of working of hydraulic circuits.

What is the function of Hydraulic Pump?

What happens to the Pressure when it acts in a closed chamber?
What happens when there is a resistance to Flow?
Actuator speed is determined by what?
Oil under Pressure Takes what path in the hydraulic system?
What happens when oil moves from the area of high pressure to the area of low
pressure without performing any work?

All the above questions relates to one or the other problem we come across while working in
hydraulic presses. Hence understanding of the problem is must. Always start with the basics
and easy things first. The common problems encountered in the hydraulic presses are:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

No pressure build up.

Pressure build up time high.
Slide going up with very low speed.
Machine going down but not coming up.
Machine coming up but not building pressure during pressing
Jerk during fast approach to pressing change over.
Creep in the press.
Oil temperature going high
Leakage from the joints
Recurring hydraulic seal failure in the cylinder

D.

There are 3 types of valves used in hydraulic circuits. Conventional valves, logic elements and
proportional and servo valves. We have different hydraulic circuits for hydraulic presses
according to flow and control requirements. Manual setting of valves as well as setting of
valves thru operator panel is provided. We will discuss these circuits.

E.

You
1.
2.
3.
4.
5.
6.
7.

must keep the following DOs and Donts in your mind as maintenance personal.
Dont Jump To The Solution.
Observe Think And Brain Storm.
Establish Probable Causes.
Differentiate The Causes As Electrical Or Mechanical Or Hydraulic
Start With The Simplest Solution (Easy Things First)
Never Disturb Any Settings.
Conduct Failure Analysis.
3

8.
9.
10.
F.

Always Release The Pressure Before Opening Any Valve And Keep The Slide On Some
Positive Stop.
Check Oil Properties and filtration level At Regular Intervals. Never try to reuse paper
filter elements
Take Care Of Air Breathers. They should never be kept Open.

Most important part in any hydraulic system is hydraulic oil. That is generally overlooked by
maintenance team. Use of proper oil, maintaining the oil level and oil temperature in the oil
tank and checking of oil cleanliness at regular interval is a must. Oil cleanliness level required
is mentioned in the hydraulic circuits as well as in the operator manuals. There are some
valves and pumps which are very sensitive to contamination. Instructions regarding the
contamination level are to be followed in spirit and in totality to avoid a major breakdown. If
you find anything abnormal, establish the probable cause first. It is our experience that your
60% to 70% problems will be over, if you are taking CARE of hydraulic oil.

**********

Understanding the Capability of Mechanical Press

A.

Classification of Mechanical Presses (on the basis of drive mechanism)

1.

Eccentric/Crank Drive Press

a) Mechanism
i)
Based on Slider Crank Mechanism
b) Advantages
i)
Cheaper
ii)
Higher Rigidity of Linkage System
iii) Supports High Speed Operations
iv) Works for all general Stamping Operations
c) Slide Motion Analysis
i)
Sinusoidal (FBOS v/s Crank Angle)
d) Press Force Analysis

2.

Link-Drive Press
a) Mechanism
i)
Multiple Linkages System to obtain desired slide motion
b) Advantages
i)
Suitable for Draw Operations
ii)
Better Product Quality
iii) Increased Die Life
iv) Lower Vibrations
c) Slide Motion Analysis
i)
More Useful Time : Less Slide Speed from TDC to BDC
ii)
Lesser Idle Time : Higher Slide Speed from BDC to TDC
d) Press Force Analysis

B.

Comparison between Eccentric Drive Press and Link Drive Press

C.

Work / Energy
1.

Definition
a) Work done (per stroke) = Press Force applied x Draw/Shear distance

2.

Understanding the use of Work/Energy concept in presses

a) In presses, energy is stored in the rotating mass of flywheel

3.

Specific Deformation Work (analysis based on different materials)

D.

Production Processes
1.

Metal Forming
a) Classification of various Metal Forming processes
i)
Bulk Deformation Processes : Rolling, Forging, Extrusion, Drawing
ii)
Sheet Metal Working Processes : Deep Drawing, Bending, Shearing
b) Understanding the process requirements and suitable presses

2.

Metal Parting
a) Classification of various Metal Forming processes
i)
Blanking, Shearing, Punching, Bite Cutting
b) Understanding the process requirements and suitable presses

**********

Health Check up for Mechanical Presses & Hydraulic Presses

A.

Parameters for Health check up for Mechanical Presses:

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

B.

Overall clearance.
Accuracy i.e. Flatness, Parallelism, Perpendicularity & leveling.
Jib clearance & condition.
Vibration
Lubrication , Hydraulic & Pneumatic systems
Oil condition & Make up rate.
Clutch & Brake system & Brake angle.
Hydraulic overload & slide adjustment system.
Gear condition
Die cushion working & snubbing action.
Electrical system, working of safety equipment & interlocks.

Parameters for health heck up for Hydraulic presses:

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Accuracy i.e. flatness, Parallelism, Perpendicularity & leveling.

Jib clearance & condition.
Pump condition , hydraulic & pneumatic systems
Oil condition & make up rate .
System leakages internal & external.
Cylinder & ram condition.
Electrical system.
Die cushion
Working of dampers (if fitted)
Accumulators pre-charge & condition.
Working of safety equipment & interlocks.
Vibration level

**********

Quick Die Change System & Auto Die Change System

A.

Why Quick Die Change System

1.
2.
3.
4.
5.
6.
7.
8.

B.

C.

Faster response for changing production schedules.

Reduce inventory
Reduce change over time- Increase equipment utilisation
Reduces cost per unit
Improve repeatability
Improve flexibility
Easier to train new operators
Increase operator safety

Elements of Quick Die Change System

1.

Die Clamps
a) Selection of Die Clamps
b) Type of Die Clamps based on application of Force
c) Type of Die Clamps based on Mode of Positioning

2.

Die Lifters
a) Selection of Die lifters

3.

Pre-rollers / die changing arms

a) Selection of Die change arms

4.
5.
6.

Die Carts / Die Change Tables

Dedicated Push Pull unit
Moving Bolsters

Auto Die Change System

1.
2.

Need
Requirements

**********

Servo Driven Mechanical Presses: Advantages & Trends

A.

Overview
1.

B.

Concept
1.
2.
3.

C.

Flexibility
Optimum adaptation to different forming processes
Reverse stroke motion
Try-out mode
Reduction in maintenance cost
Better energy balance

Composition
1.
2.
3.
4.
5.
6.

G.

Better quality of final product

Low environment pollution
Reduce noise
Reduce handling

Customer Benefits
1.
2.
3.
4.
5.
6.

F.

Less power consumption

Better Productivity
Less number of operators
Less maintenance Cost
Reduced number of rejections and less work
Improved Die Life
Reduced inventory ( No WIP)
Low Capital cost

Intangible Benefits
1.
2.
3.
4.

E.

Tailor made Slide Motion

Suitable for Progressive Die Application
Link Drive Servo presses suitable for high energy

Tangible Benefits
1.
2.
3.
4.
5.
6.
7.
8.

D.

No Clutch-Brake, No Flywheel, No dual Solenoid Valve.

Servo Motor
Power and other drives
Numeric control
Servo amplifiers
Capacitor Bank
Brake

Application in various stamping process

1.
Blanking
2.
Sheet Forming
3.
Draw Operation
4.
Transfer Press Applications
5.
Progressive
9

H.

Comparison of various types of presses

1.
2.
3.
4.

I.

Key Features to suit process requirement

1.
2.
3.
4.
5.
6.
7.
8.

J.

Productivity vs formability : Link Press, Crank Press, Hydraulic Press and Servo Press
Drawing :Pressure vs time ( Pneumatic Cushion) ;Conventional Press vs Servo Press
Drawing :Pressure vs time (Hydraulic Cushion) ; Conventional Press vs Servo Press
Blanking : Pressure vs time ( Pneumatic Cushion) ;Conventional Press vs Servo Press

Adjustment of Stroke Length and Operating Speed

Programmable Slide Motion
Slide Dwell for benefit of Complex Jobs
Optimized Press Stroke for Automation Cycle
Crank Motion
Knuckle Motion
Programmable Dwell at BDC
Multiple Dwell

Energy Buffer/Regeneration
1.
2.

Energy BUFFER using Flywheel

Energy BUFFER using Capacitor Bank.

K.

Capacitive Energy Buffering

L.

Isgec References
1.

400T Servo Press installed at Brandl, Romania

**********

10

Common Problems in Mechanical Presses related to various Sub-Assemblies

A.

Hydraulic Over Load Assembly

1.
2.

It is used to protect the dies & press from overloading in most of the cases.
It is very large size fast acting relief valve to drain the oil in-case of development of high
pressure in the system due to high load.
Most common problem in the overload system & their remedies are

3.

S.No.
Problem
a) Charging time
very high
b)

Over load
dumping without
actual overload

c)

Haskel pump
pumping
continuously

d)

Over load not

charging at all

i)
ii)
i)
ii)
iii)
i)
ii)
iii)
iv)
i)
ii)
iii)
iv)
v)

B.

Cause
Air pressure low
Rolling diaphragm worn
out/punctured
Air pressure low
Rolling diaphragm worn
out/punctured
Missing electrical signal
Leakage from main
cartridge
Rolling diaphragm worn
out/punctured
Leakage from ball seat
Haskel pump faulty
Precondition not ok
Oil level low
Air entrapped in the system
Rolling diaphragm worn
out/punctured
Leakage from the cylinder

Remedy
i) Correct the same.
ii) Replace the same.
i) Correct the same
ii) Replace the same
iii) Correct the signal
i)
ii)
iii)
iv)
i)
ii)
iii)
iv)
v)

Clean the cartridge &

reassemble
Replace the rolling
diaphragm
Check the ball seat
Service it or replace it
Correct as per HMI
Check & fill correct grade
of oil
Bleed the air
Replace the same
Chances of leakage from
main cylinder/seal are
less so the system must
be checked before seal
replacement

Slide Adjustment Assembly

1.
2.

It is used to accommodate different die heights on the press.

The basic components of the slide adjustment assembly are worm, worm wheel, nut &
screw.

S.No.
Problem
a) Jamming of slide
adjustment
b)

Motor tripping &

high current

c)

Variation in actual
& displayed value

Cause
i) Failure of coupling
ii) Jamming of worm wheel &
worm shaft
i) Wrong setting of MPCB
ii) Jamming of adjustment
Failure of encoder coupling

Remedy
i) Replace the same
ii) Correct the same.
i)

Correct the same as per

relevant circuit.
ii) Correct the same
Replace the encoder

11

S.No.
Problem
d) Over travel of
slide
e) Abnormal sound
during the slide
adjustment
f)

C.

Torque Coupling
failure /Slippage.

Remedy
Rectify the same
i) Check & correct
ii) Check & replace if
required
iii) Correct the same
Correct the bore size/
fitment.

Die Cushion Assembly

1.
2.
3.

Die cushion is used to provide counter force during the draw operations.
It can be single stage, double stage with fixed stroke or with adjustable stoke.
Snubber & delayed return are the other features

S.No.
Problem
a) Die cushion not
coming up Check
precondition
b) Die cushion
movement non
parallel
c) Height of die
cushion not equal
to the reading
d) No Snubbing
Action
e) Die Cushion
adjustment
jammed.
D.

Cause
Adjustment motor brake not
working
i) Brake not release properly
ii) Worm wheel/bearing worn
out
iii) Fan cover fouling
Loosen of key/bore worn out.

Cause
Check precondition

Remedy
Correct the same as per HMI

Uneven clearance

i) Encoder coupling failure

ii) Counter meter cable broken

Correct the same in the

presence / supervision of
Isgec engineer.
i) Replace the coupling
ii) Replace the cable

Oil level low

Fill the correct grade of oil

Jamming in worm shaft &

worm wheel

Correct the same.

Moving Bolster
Moving bolsters are used to change the dies quickly & safely, the next die change set up can
be made ready off line while present part is under production. We can achieve less 10
minutes die change, when the press is equipped with two moving bolsters.
S.No.
Problem
Cause
a) Moving bolster not i) Precondition not ok
lifting
ii) Pump not built up the
pressure
b)

c)

Moving bolster not i) Non alignment

seating properly
ii) Foreign particle entrapped
between bolster & bed area
No movement or
Non alignment
erratic movement

Remedy
Check the precondition as
per HMI
ii) Check the pump &
replace if required
i) Correct the alignment
ii) Remove the foreign
particle.
Correct the alignment
i)

**********

12

Increasing efficiency through Automation

A.

B.

Press Automation
1.

Why Press Automation?

2.

Type of press automation

a) Die Automation & Pneumatic Ejection
b) Robotic Automation Pick & Place
c) Transfer bar for inter station transfer
d) Cross Bar Transfer (single and double)
e) Robot Beam Transfer

3.

Productivity Measurement

4.

Compact robotic automation

Robotic Tandem Press Line

1.

C.

D.

Elements of Robotic Automation

a) Front of Line Equipment
b) Robot for Press Linking
c) Automation tooling (grippers and fingers)
d) End of Line Equipment

Transfer Presses with Automation

1.

Front of Line Equipment

2.

Transfer bar for Inter Station Transfer and Grippers & Tooling for components

3.

End of Line Equipment

Important features of Isgec Transfer Presses

**********

13

Clutch and Brakes

A.

Principle of Operation

B.

Types:
1.
Mechanical
2.
Electromagnetic
3.
Pneumatic
4.
Hydraulic

C.

Cooling types:
1.
Dry
2.
Wet

D.

Mechanical Press Drive

E.

Hydraulically actuated clutches and spring-applied brakes

F.

Hydraulic Clutch & Brakes

G.

Clutch Brake Liners

H.

Construction

I.

Clutching Operation
Hydraulic oil moves the piston against the force of the springs, which release the brake plates
and bring the friction clutch plates together which activates the clutch.

J.

Braking Operation
Springs press piston in the cylinder to bring the friction brake plates together which activates
the brake.

K.

Fitment
1.
Clutch/Brake Combined Unit
2.
Housing
3.
Rotary Unit
4.
Flexible Hose
5.
Throttle
6.
Press safety valve
7.
Check valve
8.
Accumulator
9.
Pressure gauge
10. Stopcock
11. Hydraulic unit

L.

Advantages
1.
Hydraulically engaged, spring-released multi-plate Clutches combined with the
hydraulically released spring-applied multi-plate Brakes require small space and have low
moment of inertia of the rotating parts.
2.
Permitted for the high application frequencies.
3.
To a large extent they require no maintenance.
4.
Cylinder and piston are protected against rust.

14

M.

Conventional Hydraulic Circuit

N.

Fast Engagement with Accumulator

O.

Modified Hydraulic Circuit

P.

Hydraulic Module

Q.

Single Brake

R.

Double Brake

S.

Checking for wear prior to Dismantling

T.

Parts Single Brake

U.

Parts Double Brake

V.

Enemy of Clutch Slip

Reasons of Slip:
1.
High Torque
2.
Poor Friction
a) Moisture
b) Contamination

W.

3.

Insufficient Force
a) Low Pressure
b) Internal leakage

4.

High rpm

Fault finding

Fault
Clutch Slips

Reason
Oil pressure too low

Remedy
Set the working pressure to the
required figure: 63 bar
Repair hydraulic system

Fault in the hydraulic system

(dirt, leaks)
Friction linings worn down
Get customer service to change
(max. permissible size of the air gap the plates
reached)
Reason cannot be established
Obtain technical service
Brake slip
Friction linings worn down
Get customer service to change
(braking angle (max. permissible size of the air gap the plates
increased)
reached)
Reason cannot be established
Obtain technical service
X.

Oil Inlet

Y.

Oil Inlet With Encoder

Z.

Oil Inlet - Construction

15

AA. Slip Control

1.
Machine Controller (PLC)
2.
Sensor Pads on Flywheel
AB. Braking Angle
AC. Pneumatic Clutch & Brake
AD. Mounting Types
AE. Pneumatic Clutch & Brake Fitment
AF. Pneumatic Clutch & Brake Circuit
AG. Mounting on Shaft
AH. Pneumatic Clutch & Brake Construction
AI. Air Inlet
AJ. Wet Clutch & Brake
1.
Application of the brake
2.
Engagement of the clutch
AK. Version with key
AL. Version with locking assemblies
AM. Applications
1.
Machine Tools
2.
Construction Machines
3.
Marine Transmission
4.
Vehicles
5.
Textile Machine
6.
Paper Industry

**********

16

Lubrication & Pneumatic System for Mechanical Presses

Construction & Working principles of Various Elements
A.

Oil lubrication System for Mechanical Presses.

1.
2.
3.
4.
5.
6.

B.

Grease Lubrication System.

1.

2.
C.

Generally die-cushion guides (liners) in the press-bed are lubricated with grease.
Grease pump operated with pneumatic solenoid valve forces greases to progressive
block which delivers metered quantity of grease at pre-defined interval.

Pneumatic System for Counter Balance Cylinder and Die-Cushion

1.
2.
3.
4.

D.

Various Bearings, bushes, gears in the press crown and slide-guides needs lubrication oil
at different quantities based on speeds and area.
Lubrication system ensures lubricant supply to all the points.
Lubrication system mainly consists of hydraulic pump, filter and progressive distributors.
The oil is collected back in the tank through inbuilt trap for contamination and recirculated through filters to ensure clean oil supply.
Progressive distributor ensures a metered quantity of oil at every point. The working of
progressive feeder is monitored with inbuilt proximity switch and press PLC.
Normally gear oil of viscosity grade 150 is recommended for mechanical presses.

Variety in upper die-weights need different air pressure settings based on the pressure
v/s weight chart displayed on the machine.
There may be a manual or automatic pressure setting.
Automatic pressure data can be fed in tool data and the circuit ensures to maintain the
pressure as per specified data.
Similar system is taken for various pressure settings for die-cushion.

Air Saving Valve:

1.

Air saving valve saves the compressed air of die-cushion reservoir from draining when
the cushion cylinder is drained for a die change.

**********

17

Electrical Systems
A.

Electrical Systems- Safeties & Interlocks in Presses

1.

B.

C.

Electrical Systems- Machine Parameter Settings

1.

Mechanical Presses
a) Parameter settings
b) Tuning
c) Diagnosis

2.

Hydraulic Presses
a) Parameter settings,
b) Tuning
c) Diagnosis

Electrical Systems- VFD (Working & Parameterization)

1.

D.

Safeties & Interlocks

a) Mode Selection
b) Emergency & Immediate Stops
c) Two Hand
d) Light Curtain
e) Cam box System
f) PSV actuation & feedback monitoring
g) Hydraulic Module Sensor Monitoring

VFD
a) Components Working,
b) Parameter settings
c) Tuning
d) Diagnosis

Electrical Systems- Troubleshooting in Electrical System

1.

Control & Power circuit

a) Architecture, Diagnosis

**********

18