Deep Draw Technology 02

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Deep Draw Technology

IMPROVE YOUR PRESS SHOP TECHNOLOGY1


www.hydraulico.com


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Part IDeep drawing of rectangular parts

Part IIElectronic Shimming TM


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Hydraulico Profile:

Innovative, state-of-the-art technologies in deep drawing

Continuous development of products, know-how, and technologies

Competences:

Product development

Simulation of process

Tool and press design

Automation and line layout manufacturing

Running in and training

Service


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1000 tons PressLubricatorRobot

Tool


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Deep Drawing of Rectangular Part

Corner

Compressing

Bending

Stretching

Sidewall

Bending

Stretching


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Food pan made in One draw

Dimension

L = 500 mm

W = 300 mm

D = 165 mm


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Dimension

L = 350 mm

W = 250 mm

D = 250 mm

Sink made in One Draw


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Bath tub made in One Draw

Dimension

L = 1300 mm

W = 600 mm

D = 450 mm


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Successful Sink Produktion

Five steps to consider

1. Material

2. Blank shape

3. Lubrication type and machine

4. Protecting film

5. Press and tools with Electronic Shimming


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FormabilityMaterial Range


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Chemical composition of austenitic stainless steel


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Mechanical properties of austenitic stainless steel


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Influence of Blank Shape

Square

Diamond

Round

Developed


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Lubrication

Type

Soap - high friction and progressive Oil - medium friction Protective films PVC/PE - low friction Dry lube Combination


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Our traditional contact lubricators are

valuable for full size or sectorial appli-cating of blanks, coils and profiles.

Different types of rollers (Felt, Brush,Cellpor) for different applications,speeds and lubricants.

Wide range of standard devices:- from 15 mm mini roller to

2000 mm sector lubricator.- from motor driven roller to

mobile blank lubricator.

Roller lubricator


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Non-contact spray lubricator


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10mm/min

10m

m/min

Different products produced with tapes


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Surface contact adhesive- substrate

Topography of the metal

Surface finishing 2B-2D-3D-BA-struktural


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Lubrification

Combination of the right oil /grease with protection tape givesexcellent results.

Problem

Waste treatment

Time for preparation

Scrap/ production defaults

Advantage tape

Less processing oil.

Easier handling

Higher yield/Less polishing

Only oil Combination

Benefit by us of tape


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SPV 224P ~ SPV 225P PVC tapes

30804 ~ 308LA5 ~ 3104H5 Rubber based PE

9205 ~ 6065E5 Easy peel acrylic based

3100H5 Laserguard

Different types of tape


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Upper tool plate

mild steel or cast

Lower tool plate :

mild steel or cast

Draw ring :

cast or aluminium bronze

Blank holder :

cast or aluminium bronze

Punch :

hardened steel or

aluminium bronze

Sink tool


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Draw Process in 3 Steps

Stretch Deep Drawing Final Stretch

1. step 2. step 3. step


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Draw Tool in press

Critical dimensionCorner radiiPunch & draw radii

Die clearance app. 1,10-1,15 *thickness of plate


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Part II

Electronic ShimmingComputerized control of blankholding force

for deep drawing of extreme components

New patented technology


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Traditional shimming (what shimming used to be):

Manual shimming with metal foil


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What our customers wanted:

Optimized blank hold control during deep draw

Improved product quality

Scrap reduction!

Increased productivity

Deeper draws without annealing

Flexibility many tools on the same press

Shimming tools that work with existing dies

Shimming tools that can be fitted to existing presses


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Why is Shimming needed?

1. The press frame and the die are deflected during deep draw

2. The blank thickness is changing during deep draw


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Electronic Shimming How it works

The Electronic Shimming Plate allows precise compensation for:

die deformation

change in blank thicknesscomputer-controlled

blank hold

electronicshimming plate


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How it works

The Electronic Shimming Plate is placed directly under the blankholder

electronicshimming plate


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How it works: Computer animation


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Result: No wrinkles, no buckles

Without ES With ES


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Products created with Electronic Shimming


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Extreme blank hold control

The Electronic Shimming Plate offers flexibility and adaptabilityfor a range of deep draw operations


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Control Unit

Advanced Control Unit allows:

real-time monitoring

adjustments on-the-fly

quick tool changes


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A complete solution


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Shimming plates can be designed for many purposes


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Forming of future products can be simulated

Simulation results


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and tools can be perfected to meet requirements

Finished product


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Summary, benefits:

Better Products No wrinkles or buckles and less tension in the final product Allows up to 12 deep draw, without annealing

Increased Productivity

Short start-up time Extreme blank hold control 50% scrap reduction Reduced wear on active tool plates

Cost efficiency Adapts to existing dies and presses Payback time: typically 3-6 months


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Thank you for watching this presentation

Hydraulico asRaadhusgade 87 8300 Odder Denmark

Tel.: +45 8780 2000 Fax: +45 8780 2001E-mail: [email protected]

www.hydraulico.com

Deep Draw Technology 02

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