die-mounting surface of the ram and that of the press bed.

This deviation from

parallel
is called angular deviation, or angular distortion, and it is usually expressed in
differences
in parallelism between the two surfaces. To properly evaluate this condition, the
deviation
must be measured not only in an environment free from press force, but in
situations where
a centrally located force is applied to the tested surfaces, as well as an off-
center located
force, as shown in Table 5-2.
Another variable affecting the firmness/rigidity of the press, which has a standing
effect
on the angular deviation of its mounting surfaces is the material from which all
forceaffected
parts are made. Generally, it can be stated that the greater the modulus of
elasticity
of given materials, the greater deflection and issuing angular deviation can be
expected.
A less rigid press, made from more elastic materials, will be subject to greater
deflection,
up to the point where a considerable portion of its output energy will be wasted on
the
deformation work of its elements. The angular deflection further dictates the
working tolerances
in press components� assemblies. The press tolerance ranges must always be
greater than any dislocation that may result from the lack of parallelism between
the press
bed and the ram.
There will always be some amount of detrimental influences already present in the
function
of a press that will affect the angular deformation. There may be nonsymmetrical
parts
produced in the press, or a progressive diework with less-than-perfect centering of
the utilized
work force. Other times, the progressive die will be perfectly centered, but not
all of
its stations will engage in the predetermined operation at the same time, which, in
itself,
will surely shift the center of the utilized press force elsewhere.
Already the differences in material thickness or material hardness may produce a
shift
off the central axis of the work force even in perfectly symmetrical parts. Another
reason
for work force shift are differences in wear of die segments, which are always
followed by
variation in friction, in force usage and its distribution.
METALWORKING MACHINERY 231
TABLE 5-2 Acceptable Angular Deviation Between the Ram and the Press Bed
Type of
angular deviation C-press frame O-press frame
Inches
No press force applied Side-to-side 0.00015 in./linear inch 0.00015 in./linear inch
Front-to-back 0.0003 in./linear inch 0.00015 in./linear inch
Centrally applied force Side-to-side 0.0004 in./linear inch 0.00025 in./linear inch
along the press axis Front-to-back 0.002 in./linear inch 0.00025 in./linear inch
Off-center force applied* Side-to-side 0.002 in./linear inch 0.0005 in./linear inch
Front-to-back 0.001 in./linear inch 0.0005 in./linear inch
Millimeters
No press force applied Side-to-side 0.0045 mm/linear 30 mm 0.0045 mm/linear 30 mm
Front-to-back 0.0090 mm/linear 30 mm 0.0045 mm/linear 30 mm
Centrally applied force Side-to-side 0.0120 mm/linear 30 mm 0.0075 mm/linear 30 mm
along the press axis Front-to-back 0.060 mm/linear 30 mm 0.0075 mm/linear 30 mm
Off-center force applied* Side-to-side 0.060 mm/linear 30 mm 0.0150 mm/linear 30 mm
Front-to-back 0.030 mm/linear 30 mm 0.0150 mm/linear 30 mm
* The off-center force should be located in 1/4 of the width of the press (left-to-
right), and in 1/4 of the depth
(front-to-back). The force should be equal to 1/4 of the max. press force.
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METALWORKING MACHINERY
5-3-5 Press Controls
There are quite a few diverse elements involved in the press control. Previously, a
single
motor equipped with a starter and a disconnect switch was all that was used. Today,
the
complexity and intricacy of press control systems and its components is dependent
on
pneumatic, hydraulic, electronics, electrical, and electro-mechanical enhancements.
Where
before the operator simply pressed a �Start� button and terminated the press
operation by
pressing a �Stop�, a wide range of commands, with sequences of predetermined loops
of
operation, supported by an array of limit switches, sensors, relays, air or
hydraulic cylinders,
motors, and other components are used (see Fig. 5-18 for the size and complexity of
the
control panel).
Programmable logic controllers (PLCs) can nowadays be programmed to respond to
every
need of the press operator, or even guide the press in an automatic production
environment.
The automatic function of a press can be adjusted to any scenario such a machine
can
encounter. Should a valve need be opened to provide for a shift within a press
mechanism,
the PLC can be programmed accordingly and the desired shift will occur precisely,
on time,
with dependence on the parameters given.
232 CHAPTER FIVE
FIGURE 5-18 Verson 1000 ton Link Drive Blanking Press, model LE4-1000-180-96T
and integrated blanking line control console. Link drive provides fast advance and
slow
down during the blanking portion of the stroke to increase production while
reducing the
shock associated with the blanking operation. This press is typical of automotive
blanking
presses with 12 in. stroke and speed ranging from 20�60 SPM. (Reprinted with
permission
from Verson and Danly Division of Enprotech Mechanical Services, Inc., Lansing,
MI.)
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METALWORKING MACHINERY
Automatic punching machinery, or numerically-controlled (NC) presses, sometimes
also
called �turret presses� are operating on the basis of NC commands, previously
contained on a
punched paper, or mylar, tape, today transmitted to the machine via computer
network. For
some strange reason, NC presses are sometimes erroneously called CNC presses. In
the U.S.
industry, the term �CNC� is reserved to rotating, numerically-controlled machinery,
such as
milling centers, lathes, and similar. The meaning of both acronyms, numerically-
controlled
(NC) and computerized numerically controlled (CNC), is the same, yet the
distinction is kept
to separate the two groups of machines, punch presses as NCs and rotating machines
as CNCs.
5-4 PRESSES, ACCORDING TO THEIR
OPERATION
After classifying presses according to various aspects of their construction and
use, differentiating
them according to the type of their operation is the final point of distinction of
this
type of equipment.
5-4-1 Single-Action Press
Single-action presses are used for general press work throughout the industry. The
number
of �actions� is given by the number of slides, or rams, operating on a common axis
and
mounted within the same frame.
5-4-2 Double-Action Press
A double-action press (Fig. 5-19), as its name implies, has two slides operating
along the
same axis yet independent in their movements. Where the first slide may be actuated
by the
usual means, the other slide has a different operating arrangement. Quite often, a
camdependent
movement tied to the first slide�s function is utilized.
METALWORKI