SHEET METAL
Ready-to-Install parts straight from the press
Combination of precision blanking and sheet metal forging reduces number of process steps as well as material and energy costs
complex: they are now expected to fulfill several functions at once in order to save weight. Until recently, such sophisticated parts had to be manufactured in several intermediate steps, pushing the possibilities of conventional forming processes to their limits. One possible solution is the combination of precision blanking and forging in a single die. “At present, components which have different material thicknesses in different areas are generally produced by joining several individual components,” explains Schuler Managing Director Jochen Früh, who heads the company’s Industry division. “Long process chains to produce these components and additional steps for storing, separating and loading – as well as the necessary joining processes – all result in high part costs.” In addition, surfaces often have to be reworked, e.g. to remove the burr. Shortening process chains including all press operations for producing components in a single press therefore offers a huge potential for savings.
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Schuler’s sheet metal forging process for progressive or transfer dies has been developed to facilitate the economic production of components with varying material strengths. First, a pre- form shape of the component is produced in a classic sheet metal forming process. Next, one area is thickened or embossed by means of cold forging, e.g. to increase rigidity. Such parts can be produced with a high level of repeat
10 IMT March 2015
The PSK precision blanking and forming presses of Schuler subsidiary Gräbener Pressensysteme are ideally suited for this task.
accuracy and close tolerances. For components requiring a higher degree of deformation, Schuler offers hot forming processes.
Toothed flange produced in one pass In the case of a flange component, for example, the required torque transmission in the toothing can
be achieved by increasing the sheet thickness from 3.1 to 5.0 millimeters. First, the component is pre-formed in a progressive die before the sheet thickness is increased over several stages. Next, the collar is drawn, perforated and thickened in further steps by means of upsetting. Once the component has been cut from the strip, the
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downstream transfer system takes it, turns it by 180 degrees, places it in the bending station and after that in the station for precision blanking.
Precision blanking – also a development of Schuler – guarantees a high smooth cut ratio and rounds off the burr in the same process. With the aid of
öppingen, February 23, 2014 – Automotive components are becoming increasingly
Photo: Schuler
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