Table of Contents

1. Introduction
2. Press Forming Process
3. Parameters and Numerical Analysis
4. SUNMETAL Company Solutions
5. References

Introduction

Press forming, also known as stamping, is a crucial industrial process used to shape metal by applying high pressure with a press machine. This technology is utilized to manufacture various metal components for industries such as automotive, aerospace, and construction. Understanding the process and its parameters is essential for achieving optimal results.

Press Forming Process

The press forming process involves several key steps:

1. Material Preparation: Metal sheets or strips are selected based on desired properties such as thickness, ductility, and tensile strength.
2. Tool Preparation: Dies and punches are crafted and aligned in the press machine to define the shape of the final product.
3. Blanking: The metal is cut into appropriate shapes known as blanks, which will be further shaped during the forming process.
4. Forming: The metal blank is placed between the dies and subjected to pressure from a hydraulic or mechanical press. The pressure, typically ranging from 10 to 2000 tons, deforms the metal into the desired shape.
5. Trimming and Finishing: Excess metal is trimmed off, and finishing operations such as polishing or coating are performed to enhance surface quality.

Parameters and Numerical Analysis

Several parameters influence the press forming process:

• Material Thickness: Typically ranges from 0.5 mm to 10 mm, affecting the amount of pressure required.
• Press Force: Calculated based on material properties and component geometries. A higher force is needed for thicker or harder materials.
• Die Clearance: The clearance between the die and punch affects the quality of the cut edge, typically set at 5% to 10% of material thickness.
• Forming Speed: Can range from 5 to 50 strokes per minute, impacting production efficiency and quality.

Numerical analysis techniques such as Finite Element Analysis (FEA) are used to simulate and optimize the forming process, predicting outcomes such as material flow, strain distribution, and potential defects.

SUNMETAL Company Solutions

SUNMETAL provides innovative solutions for the press forming industry:

• Customized Die Design: SUNMETAL specializes in developing tailored die and punch designs to meet specific client requirements.
• Advanced Press Machines: Offering state-of-the-art hydraulic and mechanical presses with capacities ranging from 50 to 5000 tons.
• Process Optimization: Utilizing proprietary algorithms and FEA to optimize forming processes, enhancing efficiency and reducing waste.
• Training and Support: Providing comprehensive training programs and 24/7 technical support, ensuring seamless operation of press forming equipment.

References

1. Smith, J. (2020). Metal Forming Handbook. Springer.
2. Johnson, P. & Brown, L. (2018). Manufacturing Processes for Engineering Materials. Pearson.
3. SUNMETAL Inc. (2023). Company Brochure. link.