Metal Forming Handbook, Softcover reprint of the original 1st ed. 1998

Following the long tradition of the Schuler Company, the Metal For­ ming Handbook presents the scientific fundamentals of metal forming technology in a way which is both compact and easily understood. Thus, this book makes the theory and practice of this field accessible to teaching and practical implementation. The first Schuler "Metal Forming Handbook" was published in 1930. The last edition of 1966, already revised four times, was translated into a number of languages, and met with resounding approval around the globe. Over the last 30 years, the field of forming technology has been rad­ ically changed by a number of innovations. New forming techniques and extended product design possibilities have been developed and introduced. This Metal Forming Handbook has been fundamentally revised to take account of these technological changes. It is both a text­ book and a reference work whose initial chapters are concerned to pro­ vide a survey of the fundamental processes of forming technology and press design. The book then goes on to provide an in-depth study of the major fields of sheet metal forming, cutting, hydroforming and solid forming. A large number of relevant calculations offers state of the art solutions in the field of metal forming technology. In presenting tech­ nical explanations, particular emphasis was placed on easily under­ standable graphic visualization. All illustrations and diagrams were compiled using a standardized system of functionally oriented color codes with a view to aiding the reader's understanding.

1 Introduction.- 2 Basic principles of metal forming.- 2.1 Methods of forming and cutting technology.- 2.1.1 Summary.- 2.1.2 Forming.- 2.1.3 Dividing.- 2.1.4 Combinations of processes in manufacturing.- 2.2 Basic terms.- 2.2.1 Flow condition and flow curve.- 2.2.2 Deformation and material flow.- 2.2.3 Force and work.- 2.2.4 Formability.- 2.2.5 Units of measurement.- 3 Fundamentals of press design.- 3.1 Press types and press construction.- 3.1.1 Press frame.- 3.1.2 Slide drive.- 3.1.3 Drive systems for deep drawing presses.- 3.1.4 Draw cushions.- 3.2 Mechanical presses 49.- 3.2.1 Determination of characteristic data.- 3.2.2 Types of drive system.- 3.2.3 Drive motor and flywheel.- 3.2.4 Clutch and brake.- 3.2.5 Longitudinal and transverse shaft drive.- 3.2.6 Gear drives.- 3.2.7 Press crown assembly.- 3.2.8 Slide and blank holder.- 3.2.9 Pneumatic system.- 3.2.10 Hydraulic system.- 3.2.11 Lubrication.- 3.3 Hydraulic presses 73.- 3.3.1 Drive system.- 3.3.2 Hydraulic oil.- 3.3.3 Parallelism of the slide.- 3.3.4 Stroke limitation and damping.- 3.3.5 Slide locking.- 3.4Changing dies 86.- 3.4.1 Die handling.- 3.4.2 Die clamping devices.- 3.5Press control systems 94.- 3.5.1 Functions of the control system.- 3.5.2 Electrical components of presses.- 3.5.3 Operating and visualization system.- 3.5.4 Structure of electrical control systems.- 3.5.5 Functional structure of the control system.- 3.5.6 Major electronic control components.- 3.5.7 Architecture and hardware configuration.- 3.5.8 Architecture of the PLC software.- 3.5.9 Future outlook.- 3.6Press safety and certification 106.- 3.6.1 Accident prevention.- 3.6.2 Legislation.- 3.6.3 European safety requirements.- 3.6.4 CE marking.- 3.6.5 Measures to be undertaken by the user.- 3.6.6 Safety requirements in the USA.- 3.7 Casting components for presses.- 4 Sheet metal forming and blanking.- 4.1Principles of die manufacture 123.- 4.1.1 Classification of dies.- 4.1.2 Die development.- 4.1.3 Die materials.- 4.1.4 Casting of dies.- 4.1.5 Try-out equipment.- 4.1.6 Transfer simulators.- 4.2Deep drawing and stretch drawing 156.- 4.2.1 Forming process.- 4.2.2 Materials for sheet metal forming.- 4.2.3 Friction, wear and lubrication during sheet metal forming.- 4.2.4 Hydro-mechanical deep drawing.- 4.2.5 Active hydro-mechanical drawing.- 4.3Coil lines 194.- 4.4Sheet metal forming lines 198.- 4.4.1 Universal presses.- 4.4.2 Production lines for the manufacture of flat radiator plates.- 4.4.3 Lines for side member manufacture.- 4.4.4 Destackers and blank turnover stations.- 4.4.5 Press lines.- 4.4.6 Transfer presses for small and medium sized parts.- 4.4.7 Large-panel tri-axis transfer presses.- 4.4.8 Crossbar transfer presses.- 4.4.9 Presses for plastics.- 4.4.10 Stacking units for finished parts.- 4.4.11 Control systems for large-panel transfer presses.- 4.5Blanking processes 268.- 4.6Shearing lines 284.- 4.6.1 Slitting lines.- 4.6.2 Blanking lines.- 4.6.3 High-speed blanking lines.- 4.6.4 Lines for the production of electric motor laminations.- 4.6.5 Production and processing of tailored blanks.- 4.6.6 Perforating presses.- 4.6.7 Control systems for blanking presses.- 4.7Fine blanking 330.- 4.7.1 Fine blanking process.- 4.7.2 Fine blanking materials, forces, quality characteristics and part variety.- 4.7.3 Fine blanking tools.- 4.7.4 Fine blanking presses and lines.- 4.8Bending 366.- 4.8.1 Bending process.- 4.8.2 Roll forming and variety of sections.- 4.8.3 Roller straightening.- 4.9Organization of stamping plants 389.- 4.9.1 Design.- 4.9.2 Layout.- 4.9.3 Quality assurance through quality control.- 5 Hydroforming.- 5.1General 405.- 5.2Process technology and example applications 405.- 5.2.1 Process technology.- 5.2.2 Types of hydroformed components.- 5.2.3 Fields of application.- 5.3Component development 413.- 5.3.1 User-oriented project management.- 5.3.2 Feasibility studies.- 5.3.3 Component design.- 5.4Die engineering 420.- 5.4.1 Die layout.- 5.4.2 Lubricants.- 5.5Materials and preforms for producing hydroformed components 423.- 5.5.1 Materials and heat treatment.- 5.5.2 Preforms and preparation.- 5.6 Presses for hydroforming.- 5.7 General considerations.- 5.7.1 Production technology issues.- 5.7.2 Technical and economic considerations.- 6 Solid forming (Forging).- 6.1General 433.- 6.2Benefits of solid forming 441.- 6.2.1 Economic aspects.- 6.2.2 Workpiece properties.- 6.3 Materials, billet production and surface treatment.- 6.3.1 Materials.- 6.3.2 Billet or slug preparation.- 6.3.3 Surface treatment.- 6.4Formed part and process plan 464.- 6.4.1 The formed part.- 6.4.2 Process plan.- 6.5 Force and work requirement.- 6.5.1 Forward rod extrusion.- 6.5.2 Forward tube extrusion.- 6.5.3 Backward cup extrusion and centering.- 6.5.4 Reducing (open die forward extrusion).- 6.5.5 Ironing.- 6.5.6 Upsetting.- 6.5.7 Lateral extrusion.- 6.6Part transfer 478.- 6.6.1 Loading station.- 6.6.2 Transfer study.- 6.7Die design 485.- 6.7.1 Die holders.- 6.7.2 Die and punch design.- 6.7.3 Die and punch materials.- 6.7.4 Die closing systems (multiple-action dies).- 6.8Presses used for solid forming 505.- 6.8.1 Choice of press.- 6.8.2 Mechanical presses.- 6.8.3 Hydraulic presses.- 6.8.4 Supplementary equipment.- 6.8.5 Special features of hot and warm forming lines.- 6.8.6 Sizing and coining presses.- 6.8.7 Minting and coin blanking lines.

* Kompakte Einführung in die Grundlagen der Umformtechnik und des Pressenbaus * Anschauliche Darstellung der wichtigsten Umformverfahren * Berechnungsbeispiele geben Auskunft über den Kenntnisstand der Umformtechnik * Zahlreiche vierfarbige Abbildungen erleichtern das Verständnis der Zusammenhänge