I. Introduction of Press Machine
A press machine, also known as a forming press, is a heavy industrial machine that uses pressure to change or adjust the size of the workpiece like steel, aluminum, or other materials. Press machines play a pivotal role in the sheet metal manufacturing industry.
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They are also known as forming presses or mechanical presses. Once a workpiece has been designed, operators use press machines to manufacture it. These machines work by applying pressure to bend and press the sheet metal.
A press machine consists of a frame and base, and it is equipped with punches and dies, which are located on the ram and workbench, respectively. The machine applies pressure to the metal plate through a power device that drives the punch.
There are different types of press machines, including hydraulic, pneumatic, and mechanical, and are differentiated based on their power system, capacity, and other factors. Different press machines operate through different dynamic mechanisms, and their design structure may include C-frame presses and screw presses.
There are numerous press manufacturing processes, such as die cutting, forging, and stamping. In this article, we will explore the definition of press machines and their various types.
II. The Driving System of the Power Press Machine
The driving system of a power press machine is a crucial component that powers the machine's operations. In a hydraulic press machine, the ram movement is driven by the hydraulic cylinder and the piston rod, which are typically located on both sides of the press machine.
The hydraulic system is capable of sustaining large loads and longer strokes continuously. The mechanical drive system, on the other hand, consists of components such as a crank, flywheel, eccentric, and knuckle joint. The flywheel rotates, connecting the crank to drive the movement of the ram, providing a strong mechanical driving force, which is ideal for blanking and stamping processes.
A pneumatic press machine operates on compressed air, and its structure is relatively simple. The power comes from the movement of compressed air, making it fast and capable of quickly driving the ram. In conclusion, each type of driving system has its own strengths and is suitable for different metalworking processes.
III. Type of Machine Press: Classification by Power Source
Press machines can be classified by different standards, including mechanical (hydraulic, pneumatic, etc.) and stamping (forging, punching, etc.).
1. Manual Press Machine
(1) Working Principle
A manual press machine is operated manually by the operator, who applies pressure to the machine through a handle. After the handle is rotated, the ram moves up and down, generating force through the lever to drive the punch to make a linear motion.
The hydraulic cylinder generates high pressure and slowly drives all components of the punch and die process of the workpiece. The manual press machine is suitable for small batches and simple production and can be used for bending, blanking, and punching.
The structure of the whole machine is very simple, including a C-frame, punch, die, handle, and guide rail. The larger the opening of the C-shaped frame, the better the feeding of metal plates.
It has an independent hydraulic system, which has the features of small volume and low operating cost. The manual press machine is very slow and suitable for one-time and light operation.
(2) Application Scenarios
Manual presses are commonly used for laboratory sample preparation, small-scale production, and repair work. They are suitable for metal stamping, marking, riveting, forming, and bending operations.
(3) Advantages
- Simple design and easy operation
- Low maintenance costs
- Precise control, suitable for various operations
- Low cost, ideal for small-scale use
(4) Disadvantages
- Slow operation speed, suitable for small batch production
- Requires manual operation, high labor intensity
- Limited pressure, not suitable for high-tonnage operations
(5) Technical Specifications
2. Hydraulic Press Machine
(1) Working Principle
Hydraulic press machine drives the ram through a series of hydraulic system components, with the oil cylinder usually installed on the top beam. The speed of the ram is determined by the circuit flow and oil quantity of the hydraulic system.
A hydraulic press operates based on Pascal's law, which states that pressure applied to a confined fluid is transmitted equally in all directions. Hydraulic presses typically consist of two pistons of different sizes. The fluid (usually oil) is pressurized in the smaller piston and then transmitted through pipes to the larger piston, generating a greater force.
By installing different punches and dies, the machine can work. To ensure operator safety, the hydraulic press machine is equipped with sensing devices and safety switches. With larger capacity, longer stroke, and adjustable tonnage, the hydraulic press machine is more suitable for manufacturing complex workpieces.
(2) Application Scenarios
Hydraulic presses are widely used in metal forming, forging, stamping, punching, mould manufacturing, deep drawing, die casting, and other sheet metal processes. They are also used for crushing cars, making cocoa powder, automotive parts manufacturing, the aerospace industry, and sword making.
(3) Advantages
- Can generate enormous pressure
- Suitable for high-tonnage operations
- Simple design with low maintenance costs
- Low noise levels
- Built-in overload protection
- Small footprint
- Long tool life
(4) Disadvantages
- Pressure is limited and cannot exceed the set value
- Some hydraulic oils are flammable
- Requires more maintenance
- Potential for hydraulic oil leaks
- Slower operation speed
- High energy consumption
- Unpleasant odors
- Noise
- Significant heat generation
(5) Technical Specifications
3. Mechanical Press Machine
(1) Working Principle
Mechanical press machines use mechanical energy to process sheet metal and come in various types. The power source of the mechanical press machine is the motor, which transfers energy to the ram. Compared to hydraulic press machines, mechanical press machines have a faster speed and are suitable for stamping.
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A mechanical press operates by using an electric motor to drive a flywheel, which stores kinetic energy. This energy is then transferred through a clutch and crank mechanism, converting rotational motion into linear motion to drive the ram and apply pressure to the workpiece.
They are characterized by the rapid and repeated application of pressure within a limited stroke. However, the stroke of the mechanical press machine is unstable because force is applied at different speeds, making it unsuitable for manufacturing complex workpieces.
Currently, the press capacity of the mechanical press machine can reach 12,000 tons. Mechanical press machines provide fast and repeatable operations, reducing the cost of mass production.
(2) Application Scenarios
Mechanical presses are commonly used for metal stamping, forming, and extrusion operations, suitable for mass production. They are widely used in electronics, industrial manufacturing, automotive parts, construction, and aerospace industries.
(3) Advantages
- Capable of achieving high cycle rates
- Suitable for mass production
- Robust structure for high-strength operations
- Fast operation speed
(4) Disadvantages
- Requires regular lubrication and maintenance
- High noise levels
- Complex structure with high repair costs
(5) Technical Specifications
4. Pneumatic Press Machine
(1) Working Principle
A pneumatic press machine is powered by compressed gas, which is compressed and expanded to increase the pressure in the cylinder. The pressure in the pneumatic press machine is consistent throughout the entire stroke, and there is no need to adjust the pressure.
The machine moves quickly and can carry out multiple cycles rapidly. The maximum force of the pneumatic press machine is determined by the cylinder aperture and the regulated working pressure.
During use, the pneumatic press machine must maintain the operating pressure; otherwise, the stroke of the press will be intermittent, which is not conducive to process monitoring.
To prevent air supply failure, pneumatic check valves and shaft locking devices are required to ensure stroke accuracy and operator safety.
(2) Application Scenarios
Pneumatic presses are widely used for bending, stamping, forming, and cutting metal sheets. They are used in automotive manufacturing, metalworking, and electronics manufacturing industries.
(3) Advantages
- Fast operation speed, ten times faster than hydraulic presses
- High adaptability with adjustable pressure, speed, and position
- Low energy consumption and environmentally friendly
- Low maintenance costs and easy operation
- Low noise levels
(4) Disadvantages
- Limited pressure, not suitable for high-tonnage operations
- Requires a stable supply of compressed air
- Potential for air leaks
(5) Technical Specifications
5. Servo-Electric Press Machines
Features
- Energy Efficiency: Servo-electric presses consume energy only during the active pressing cycle, significantly reducing overall energy consumption compared to hydraulic presses. Advanced designs, such as those using roller screw actuators, can save up to 50% in energy costs.
- Low Noise: The absence of hydraulic pumps and valves ensures quieter operation, creating a more comfortable work environment and reducing noise pollution in manufacturing facilities.
- High Precision: Servo-electric presses offer precise control over force, speed, and position through programmable motion profiles. This precision is critical for applications requiring high accuracy and repeatability.
Applications
- Medical Device Manufacturing:
- Cleanroom environments benefit from the servo-electric press's oil-free operation, ensuring contamination-free production of medical implants and surgical tools.
- Precision Stamping in Aerospace Industries:
- Used for forming lightweight and intricate aerospace components with tight tolerances, enhancing material efficiency and reducing waste.
Innovations
- Programmable Motion Control:
- Advanced servo motors enable real-time adjustments to ram speed, force, and position for complex forming tasks. This reduces scrap rates and improves productivity.
- Energy Savings:
- Servo-electric presses reduce energy consumption by up to 70% compared to traditional hydraulic systems by using power only when pressing occurs.
- Reduced Maintenance:
- With fewer mechanical parts and no need for hydraulic oil, these presses have lower maintenance costs and longer operational lifespans.
IV. Classification by Application
1. Punching Press Machine
(1) Working Principle
A Punching Press Machine, also known as a punch press or punching machine, operates by shearing and deforming materials. It uses force generated by mechanical, hydraulic, or pneumatic systems to drive a punch into the workpiece, creating holes or specific shapes in metal sheets or other materials. The basic components of a punching press include the frame, bed, punch, die, and power source.
Punching machines have punches and dies of different sizes and shapes. During processing, the plate is placed under the punch, and the pressure of the machine causes the punch to move downward. The punching press machine has two types: C-frame and H-frame.
The C-frame drives the ram through the hydraulic cylinder to operate the punch, while the H-frame is designed to place the metal plate in the center of the machine without protruding. The C-shaped frame occupies less space and is flexible to use, while the H-frame is suitable for large-scale manufacturing.
(2) Application Scenarios
The forming technology of the punching press includes blanking, punching, perforating, and bending. Punching presses are widely used in the automotive, aerospace, electronics, and construction industries. They are used to manufacture automotive parts, electronic device enclosures, building metal structures, metal frames, and brackets. Punching presses can also be adapted for custom applications, meeting unique needs in industries such as furniture and signage.
(3) Advantages
- Versatility: Capable of performing various operations, including punching, forming, and bending, suitable for metalworking.
- High Efficiency: Capable of high productivity due to fast operation and automation capabilities.
- High Precision: Provides excellent accuracy and repeatability, ensuring consistent results.
- Cost-Effective: Suitable for mass production due to its efficiency and versatility.
- Flexibility: Can handle various sizes and types of materials, allowing flexibility in the manufacturing process.
(4) Disadvantages
- Limited Pressure: Certain types of punching presses (e.g., pneumatic punching presses) have limited pressure and are not suitable for high-tonnage operations.
- Maintenance Requirements: Requires regular maintenance and inspection to ensure the machine is in good working condition.
- Noise Issues: Mechanical punching presses can generate significant noise during operation.
(5) Technical Specifications
2. Stamping Press Machine
(1) Working Principle
The stamping press machine forms metal sheets by applying pressure on them. It features interlocking punch and work table devices that secure the plate for cutting or punching into the final shape. Due to its large size and complex operation, it requires a great amount of power for driving.
The surface of the workpiece produced by the stamping press machine may have defects, and the punching holes may not be clean enough. The stamping machine only forms the metal sheet and may not handle details well.
(2) Application Scenarios
Stamping presses are widely used in the automotive manufacturing, electronics, household appliances, construction, and aerospace industries. They are used to produce automotive body parts, electronic device enclosures, household appliance components, and building metal structures.
(3) Advantages
- High Material Utilization: The stamping process efficiently utilizes materials, reducing waste.
- High Productivity: Suitable for mass production, capable of quickly manufacturing large quantities of parts.
- High Precision: Hydraulic stamping presses provide high-precision stamping operations, suitable for high-precision applications.
- Versatility: Capable of performing various operations, including punching, bending, and drawing.
(4) Disadvantages
- Material Limitations: Certain materials (e.g., very hard metals) are not suitable for stamping and may require heat treatment to increase ductility.
- Thickness Limitations: Thicker materials require greater force to stamp, necessitating larger machines and more robust dies.
- Complex Tooling Requirements: Typically requires complex tooling for each part, increasing initial costs and preparation time.
(5) Technical Specifications
3. Bending/Press Brake Machines
Functionality
- Press brake machines are designed to bend or deform sheet metal into specific angles or shapes using a punch and die setup.
- CNC (Computer Numerical Control) press brakes enhance precision by automating the bending process, ensuring repeatable and accurate results.
Examples
- Aerospace Industry:
- CNC press brakes are used to manufacture intricate components like wing sections, fuselage panels, and brackets for aircraft and spacecraft.
- High-precision bending ensures lightweight yet robust structural elements critical for aerospace applications.
- Kitchen Equipment Fabrication:
- Press brakes are widely used to create custom components for ovens, grills, stoves, and refrigeration units in commercial kitchens.
- Stainless steel countertops, trays, and other catering equipment are bent into precise shapes using hydraulic or CNC press brakes.
Innovations
- Multi-Axis CNC Systems:
- Advanced CNC press brakes feature multi-axis controls for complex bending operations, such as tapered bends or multiple sequences.
- Automation and Tooling:
- Automated tool changers and adaptive bending technologies ensure precision while reducing material waste.
- Sustainability:
- Accurate bending reduces rework and scrap, contributing to eco-friendly manufacturing processes.
4. Forging Press Machines
Functionality
- Forging press machines shape metal through the application of compressive forces at high temperatures.
- The process refines the grain structure of the metal, enhancing its strength, ductility, and resistance to impact or fatigue.
Examples
- Automotive Industry:
- Forging presses are used to produce durable components like drive shafts, gears, and suspension parts.
- Advanced materials like Thyrotherm steel improve wear resistance and performance under high stress.
- Aerospace Industry:
- Hydraulic forging presses create high-strength parts such as turbine shafts and landing gear for aircraft.
- Industrial Machinery:
- Forged rollers, gears, and other components ensure durability in heavy-duty equipment.
Innovations
- Hydraulic Forging Presses:
- These presses offer precise control over force application, enabling uniform pressure across dies for consistent quality.
- Radial Forging Technology:
- Used in automotive applications to produce lightweight hollow gear shafts with optimized wall thickness for e-mobility.
- Servo-Controlled Systems:
- Modern forging presses integrate servo technology for enhanced precision in stroke length and force application while reducing material waste.
V. Classification by Frame Design
Gap Frame (C-Frame) Presses
Features
- Open sides provide easy access to the die space for material loading, unloading, and maintenance.
- Compact design minimizes floor space requirements.
- Typically supports light to medium-duty operations with tonnage capacities ranging from 1 to 250 tons.
- Offers cost-effective solutions compared to other press types.
Applications
- Stamping and Forming: Common in automotive industries for small to medium components.
- Electronics Component Assembly: Ideal for precision assembly tasks requiring accessibility.
- General Metalworking: Used for punching, blanking, bending, coining, and embossing.
Example
- A custom C-frame press used for forming corrugated steel in manufacturing processes.
Advantages
- Three open sides allow versatile material handling and tooling adjustments.
- Minimal deflection ensures precision for light-duty applications.
- Cost-effective and adaptable to various industries like aerospace, appliance manufacturing, and medical devices.
Inclinable Frame (OBI) Presses
Features
- Inclining capability allows scrap or finished parts to slide out of the back of the press via gravity.
- Compact and versatile design suitable for high-speed operations.
Applications
- Punching and Blanking: Commonly used in high-speed stamping tasks in automotive and consumer goods industries.
- Shallow Drawing: Suitable for forming shallow parts with minimal complexity.
Advantages
- Optimized for rapid production runs with easy material ejection.
- A space-efficient design ideal for smaller workspaces.
Straight Side Presses
Features
- Rigid vertical columns minimize deflection, ensuring high precision and stability during operation.
- Designed for heavy-duty applications with tonnage capacities up to 4,000 tons or more.
Applications
- Progressive Die Applications: Used in automotive manufacturing for large-scale production of body panels or structural components.
- Heavy-Duty Forming: Ideal for deep drawing, blanking, and transfer stamping operations requiring high tonnage.
Example
- Straight-side presses are extensively used in EV battery housing production due to their ability to handle large workpieces with high accuracy.
Advantages
- Superior alignment reduces wear on dies and tools during prolonged operations.
- Suitable for off-center loading and high-volume production environments.
H-Frame or Pillar Presses
Features
- H-shaped frame provides excellent stability and balanced load distribution during pressing operations.
- Accommodates larger tooling setups with open front, back, left, and right sides for easy material pass-through.
Applications
- Forging: Commonly used in heavy industries for shaping metal components like gears or shafts.
- Assembly Operations: Effective for pressing bearings or gears into place in automotive or industrial machinery.
Advantages
- High tonnage capacity supports heavy-duty tasks like compression molding or straightening.
- Versatile design allows customization for specific industrial needs.
Adjustable Bed Frame Presses
Features
- Vertical bed adjustment allows flexibility in handling workpieces of varying sizes and shapes.
- Compact design suitable for prototyping setups or low-volume production runs.
Applications
- Prototyping setups requiring variable workpiece positioning.
- Small-scale manufacturing processes where adaptability is crucial.
Advantages
- Offers enhanced versatility for experimental or custom manufacturing tasks.
- Efficient use of space while maintaining operational flexibility.
VII. Conclusion
Today, many mechanical and hydraulic press machines are being enhanced with computer numerical control (CNC) systems. Press machines are essential in the sheet metal industry, as they can perform various metal processing tasks such as cutting, bending, stamping, and forming.
The most effective machines for workpiece bending are press brakes and panel benders. These industrial processing machines have been around for decades and continue to be popular. With 20 years of professional experience in sheet metal machine production, ADH offers a wide range of products, including press brakes, panel benders, laser cutting machines, and shearing machines.
Our sales team can help you select the right machine that meets your needs while ensuring the most cost-effective solution. Browse our products or contact our sales team to learn more about our products and their pricing.
Are you interested in learning more about Servo Press and Automatic Stamping Line? Contact us today to secure an expert consultation!