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Objective: The research aims to develop alternative drivetrain designs for mechanical presses to enhance ram motion, focusing on maximizing joint force and efficiency. It prioritizes mechanical presses for their speed, cost-effectiveness, accuracy, precision, and energy efficiency. The goal is to optimize five designs, blending two established industry methods with three innovative approaches, to reduce processing time and energy use significantly.

Optimizing Novel High-Speed Mechanical Press Designs for

Improved Ram Dwell Limited by Joint Force Considerations

Press Machine

Products made by a press machine vary widely, including automotive parts[2] (top left), electronic components[3] (top right), construction materials such as beams and frames[4] (bottom left), coins and medals[5] (bottom middle), and beverage cans[6] (bottom right).

Tianze Xu

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Advisors: Andrew Murray & David Myszka

Department of Mechanical & Aerospace Engineering

Five Press Machine Structure Design

Different Press Machine Products

Common Defects of Press Products[7]

Tearing in pressed products occurs when pressure, speed, or temperature settings exceed the material's tensile limits. Wrinkling happens when pressing force is too low, causing material to bunch, or too high, leading to buckling. Springback is influenced by press holding time and force, with inaccurately calibrated parameters intensifying the material's elastic return to shape.

Five Press Machine Stroke Output

The commonality of the five structures mentioned is that they each have only one degree of freedom, enabling them to perform repetitive, efficient production tasks. Among them, the structures (a) Slider, and (b) Knuckle have already been utilized in actual industrial production. However, as mentioned in the left-hand section about defects, to enhance the presser with more stable and longer Press Holding Time, which produces higher-quality products and reduces the chance of defective products, we have designed (c) Knuckle with Ternary, (d)GFBS, and (e) GFBS with Ternary in our research. By comparing their stroke outputs, we can see that the improved structures indeed achieve a longer and more stable pressing process.

Numerical Optimization of Structure

Based on the structure of (c) Knuckle - Ternary, we used numerical methods to adjust the parameters of the links within its structure, resulting in a stable and more dwell holding output. This method can help us tailor our structural designs to meet the requirements of different production products. The same approach can also be applied to other structures

Numerical Optimization of Joint Force

The picture above shows the force analysis of the (b) Knuckle structure. In our research, one of our goal is by using numerical optimization method to find the structure result which satisfy with the MAX joint limit and resulting a longer dwell output

References

[1] Hydraulic Press of SCN Machinery, https://sites.google.com/scn-machinery.com/english/products

[2] Car Body Panel Press 2000Ton for Automotive Industry, https://www.youtube.com/watch?app=desktop&v=RgcGtlJ6R1w

[3] Laptop Picture, Google Picture Searching

[4] I-Beam Frame, Google Picture Searching

[5] Coin Picture, Google Picture Searching

[6] Can Shell, https://www.thefabricator.com/thefabricator/article/bending/high-speed-stamping-quenches-thirst-for-beverage-cans

[7] Hsu, C-W., A. G. Ulsoy, and M. Y. Demeri. "Development of process control in sheet metal forming." Journal of Materials Processing Technology 127.3 (2002): 361-368.