Sac Şekillendirme Makinaları: Apkant Presler ve Diğerleri

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Bora Akbaş
8 yıl önce
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1 1 Sac Şekillendirme Makinaları: Apkant Presler ve Diğerleri 2.1 Apkant Preste Sac Bükme 2.2

2 2 CNC Hidrolik Apkant Pres 2.3 Tandem Apkant 2.4

3 3 Punch (panç) Pres 2.5 CNC Taretli Pres (Kesme( Kesme-Bükme Tezgâhı) CNC Press-Punch Punch [Murata Wiedemann, Salvagnini, Trumph] 2.6

4 4 Plazma Kesme 2.7 Plazma/Oksijenli Kesim 2.8

5 5 Lazerli Kesme 2.9 Hidromekanik Şekillendirme Hidrolik Şekillendirme Presi Kaynak : ThyssenKrupp Stahl/Schnupp 2.10

6 6 Schuler Aktive Hydro Mech Presi Çift etkili düz yanlı pres Şekillendirme kuvveti altta pres temeline bağlı sekiz silindir tarafından uygulanır. Maks. kuvvet: 5000 ton Pot çemberi kuvveti üst gövdeye bağlı altı silindir tarafından uygulanır. Maks. Pot kuvveti: 1600 ton 6 ayarlanabilir strok durdurma takozu Blank holder cylinder Stroke limiter Active hydromechanical die Slide Slide cylinders Kaynak: Schuler SMG GmbH 2.11 Schuler Aktive Hydro Mech Presi Kaynak: Schuler SMG GmbH 2.12

kuvvet: 5000 ton Pot çemberi kuvveti üst gövdeye bağlı altı Pot kuvveti: 1600 ton 6 ayarlanabilir strok durdurma takozu

7 Schuler Aktive Hydro Mech Presi Kaynak: Schuler SMG GmbH 2.13 Dortmund Univ. Yatay Presi Yatay pres yüksek basınçta şekillendirme için Base plate Tool Intermediate plate tercih edilir. İş parçası tutma ve aktarma elemanlarının pres dışında olması ile kısa stroklu ana silindir. Çelik teller sarılarak kuşatılmış öngerilmeli döküm gövde Spacer Tool change cart Locking cylinder Kaynak: (Kleiner, 1999)

edilir. İş parçası tutma ve aktarma elemanlarının pres dışında olması ile kısa stroklu ana silindir.

8 8 Dortmund Univ. Yatay Presi Kaynak: Universität Dortmund 2.15 Schnupp Hidrolik Şekillendirme Presi Kaynak: Thyssen Krupp Hydromechanics / Schnupp 2.16

9 9 Schnupp Hidrolik Şek. Presi Kaynak: (Friebe,2001) 2.17 Hidrolik Boru Şekillendirme: Taşıt Gövde Parçaları A. Roof Headers B. Instrument Panel Supports C. Radiator Supports D. Engine Cradles E. Roof Rails F. Frame Rails 2.18

Roof Headers B. Instrument Panel Supports C.

10 10 Hidrolik Boru Şekillendirme Video of Y-Shape Forming Kaynak : DaimlerChrysler 2.19 Challenges: Hidrolik Boru Şekillendirme için in Hidrolik Presler Load capacity High Pressure up to 5000 bar requires special pressure intensifier and controls Axial movement mechanism and control necessary Conventional Single Acting Hydraulic Press (DaimlerChrysler AG) 2.20

Pressure up to 5000 bar requires special pressure intensifier and controls Axial movement

11 11 Advantages: Hydraulic Presses with 2-Column Frame for THF Excellent accessibility Flexibility for different products Easily adaptable to existing plant layout (SPS GmbH) Accessibility of 2-Column Press 2.21 Principle: Tandem operation of two rams in a single press When one ram is up for loading, the other is clamping the die ( Single Mode ) Advantages: Hydraulic Tandem Presses Single Mode Double Mode One stroke of the press can do Preforming and Hydroforming Double mode allows couple both rams and handles higher clamping forces and larger dies (SPS GmbH) 2.22

21 Principle: Tandem operation of two rams in a single press When one ram is up for loading, the other is clamping the die ( Single Mode )

12 12 Functioning of Hydroforming Press (I) 3 pressure intensifiers (each 4,000 bar, volume: 4.0 liter) 1 pressure intensifier to fill and pre-form component (250 bar, volume: 500 liter) Slide plate and plate holding plate are hydraulically connected Max. 100,000 kn closing force 2.23 Functioning of Hydroforming Press (II) Slide Plate moves down, hydroform tool closes Horizontal cylinders: Frictional connection in the tool Build-up of the closing force Hydroforming 2.24

holding plate are hydraulically connected Max. 100,000 kn closing force 2.

13 13 Long Stroke (Conventional) vs. Short Stroke Presses Short Stroke Press: Principle: In THF process, maximum ram force is needed only for clamping the die going along with a very small stroke during the hydroforming stage. However, maximum stroke length is needed to open and close the die for loading / unloading the die and the tube. Short Stroke Press separates the two operations. A small cylinder will handle long stroke needed for die opening / closing; Preforming (crushing) will be performed by this. One or more short stroke plunge cylinders will handle the clamping for pressure build up stage (hydroforming). Advantage: Cycle time reduced, thus increases productivity 2.25 Long Stroke (Conventional) Vs. Short Stroke Presses (Rexroth) IML Long-Stroke 451 Press Design Short-Stroke Press Design 2.26

However, maximum stroke length is needed to open and close the die for loading / unloading the die and the tube. Short Stroke Press separates the two operations.

14 B 14 Short-Stroke Press Schematic (IFU, U. Stuttgart) Arrangement: Two short-stroke 600 bar cylinders that provide the clamping stroke of 50 mm and the clamping force of 35,000 kn Long-Stroke Press and Short-Stroke Press Preform cylinder Cams for locking Main cylinder (long stroke) Main cylinder (short stroke) 2.28

clamping stroke of 50 mm and the clamping force of 35,000 kn. 2.

15 15 Locking Mechanism for Die / Bayonet Locking (Anton Bauer GmbH) 2.29 Locking Mechanism for Die / Bayonet Locking (Anton Bauer GmbH) 2.30

16 16 THF Press with Bayonet Locking / Bauer Closing force: to 60,000 kn Internal Pressure: to 6,000 bars up up Die installation area: 3,700 x 2,000 x 1,200 mm Floor-mounted (Anton Bauer GmbH) 2.31 Different Press Designs / THF system - Schuler Clamping force: tons Axial cylinders: tons Counter cylinders: tons Pressure Intensifier: 1-12 times increase in pressure bars (15,000-60,000) psi 2.32

31 Different Press Designs / THF system - Schuler Clamping force: 700-5000 tons Axial cylinders: 100-500

17 17 10,000 Ton Press at Schuler Hydroforming ,000 Ton Press at Schuler Hydroforming 2.34 Sac Şekillendirme Truck Makinaları side rail Ekim 2007

18 18 THF system Interlaken 2.35 C-Frame Press / Pollock Features: Excellent Accessibility of parts and dies Useful for THF of long structural parts The table can be pulled out for loading and unloading The table with the lower die is brought in the press and clamped with the upper die for hydroforming 2.36

dies Useful for THF of long structural parts The table can be pulled out for

19 THF system Benteler hydroforming sequence 2.37 Process Control & Monitoring / Typical Pressure Cycle Press control: X Axis: Axial stroke in mm Y Axis: Internal pressure in bar

20 20 Process Control: Internal Pressure vs. Axial Feed Build up pressure Internal pressure ( bar ) Start of forming ( ~ 300 bar) 80% formed (~ 600 bar) Calibration ( ~ 1600 bar) 600 bar 300 bar 0 5 mm Stroke (Axial cylinder, mm) mm 2.39 Typical Axial Force Curve 2.40

forming ( ~ 300 bar) 80% formed (~ 600 bar) Calibration ( ~ 1600

21 21 Cycle Times for Various Components Component Part/Stroke Cycle Time Exhaust manifolds Side-rail for pick up truck Instrument panel beam sec 2 40 sec 1 35 sec T shapes up to sec 2.41 Manufacturing Cells: Flexible Manufacturing / Modular Press System Flexible Manufacturing Production of variety of parts Parts can be of different applications, size, shape, material etc. (ThyssenKrupp Drauz) Modular Press Useful for parts requiring several steps of production Multiple rams can be locked İmalat together Makinaları for large parts 2.42 (AP&T)

22 22 Improving Efficiency: Multi-Station Press Hydrofroming Press with two Loading Stations, achieving shorter cycle times (AP&T) 2.43 Improving Efficiency: Automation / Robotics Over-head Feeder for Pre-bent Tube: Linear feed system Designed to minimize time consumed in part handling Robotics Multi-task system Bridges gap between preforming stations and 2.44 hydroforming stations (AP&T)

23 23 Boru/Tüp Hidroform Presi Clamping force: tons Axial cylinders: tons Counter cylinders: tons Pressure Intensifier: 1 to 12 times increase in pressure bars (15,000-45,000) psi 2.45 Sorular 2.46

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