Copyright 1997 Society of Manufacturing Engineers FUNDAMENTAL MANUFACTURING PROCESSES PUNCH PRESSESSHEARING AND BENDING NARRATION (VO): MACHINE...

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1 FUNDAMENTAL MANUFACTURING PROCESSES PUNCH PRESSESSHEARING AND BENDING SCENE 1. CG: REVIEW white text on black tape 63, 12:00:15-12:03:49 review music SCENE 2. tape 312, 00:03:30-00:03:36 punch press punching large hole SCENE 2. PUNCH PRESSES ARE EQUIPPED WITH PUNCHES AND DIES DESIGNED EXPRESSLY FOR HOLE PUNCHING OPERATIONS, PERFORMED PRIMARILY IN SHEET METAL. A SHEAR CONSISTS OF A FIXED LOWER BLADE..., WHICH IS MOUNTED ON THE TABLE OR BED OF THE MACHINE..., AND AN UPPER BLADE..., WHICH IS SECURED ONTO A VERTICALLY MOVABLE CROSSHEAD. SCENE 3. tape 347, 01:01:05-01:01:20 ANI: punching process, ram contacting punch, pushing slug through mating die SCENE 3. c.u. bending with thin stock c.u. bending with thick stock HOLES ARE PRODUCED BY A RAM PUSHING THE PUNCH THROUGH THE WORKPIECE, FORCING THE RESULTING SLUG THROUGH THE MATING DIE. BENDING IS A FAST, ECONOMICAL WAY TO PRODUCE AN ENDLESS VARIETY OF PARTS FROM SHEET METAL AND PLATE, OFTEN WITHOUT THE NEED FOR SECONDARY FORMING OPERATIONS. --- FTB --- SCENE 4. continue previous shot tape 327, 04:01:00-04:01:09 manual punching operation CG, SUPER: MANUALLY MECHANICALLY THE PUNCH PRESS RAM IS POWERED IN ONE OF THREE WAYS:

2 HYDRAULICALLY EITHER MANUALLY, MECHANICALLY, OR HYDRAULICALLY. SCENE 5. tape 351, 01:34:58-01:35:08 wide, c-frame punch press CG, SUPER: C-FRAME tape 344, 01:40:57:00 freeze, wide of bridge-frame punch press CG, SUPER: BRIDGE-FRAME SCENE 5. pan of slitting line, from payoff reel, through slitter, to recoiler SCENE 6. tape 346, 04:15:16-04:15:30 single station punch press operating CG, SUPER: SINGLE-STATION PRESS tape 327, 03:19:06-03:19:22 turret punch press operating CG, SUPER: TURRET PUNCH PRESS SCENE 6. PUNCH PRESS FRAMES ARE CLASSIFIED AS EITHER C- FRAME, OR BRIDGE-TYPE FRAME. SLITTING IS A SHEARING PROCESS IN WHICH SINGLE WIDTH COILED STOCK IS REDUCED LENGTHWISE INTO MULTIPLE NARROWER COILS ON SLITTING LINES. THERE ARE TWO TYPES OF PUNCH PRESSES: THE SINGLE-STATION PRESS, AND THE TURRET PUNCH PRESS. BENDING IS THE CREATION OF THREE-DIMENSIONAL SHAPES OUT OF TWO-DIMENSIONAL MATERIAL. SCENE 7. tape 327, 03:21:32-03:21:43 tools rotating through sequencescene 7. A TURRET PUNCH PRESS CAN HOLD UP TO 70 PUNCHES IN THE UPPER TURRET AND CORRESPONDING DIES IN THE LOWER TURRET. THERE ARE SEVERAL KINDS OF BENDING MACHINES, WITH THE MOST COMMON BEING THE PRESS BRAKE. SCENE 8. tape 326, 02:09:42-02:09:50 turret punch press turret punching then turning to new tool and punching tape 326, 02:11:07-02:11:23 turret punch press turret, punching then turning to new tool and forming TURRET PUNCH PRESSES CAN PUNCH A VARIETY OF HOLE SHAPES AND SIZES IN A WORKPIECE AS FAST AS THE WORKPIECE CAN BE REPOSITIONED AND THE TURRET INDEXED.

3 SCENE 9. tape 342, 01:03:03-01:03:14 c.u. punching operation tape 352, 01:04:34-01:04:39 c.u. punching operation SCENE 9. MOST PUNCH PRESSES ARE RATED BY THE PUNCHING FORCE THEY CAN GENERATE AND THE MAXIMUM HOLE SIZE THEY CAN PUNCH IN A GIVEN MATERIAL THICKNESS.NARRATION (VO): THERE ARE THREE MAJOR CATEGORIES OF BENDING: AIR BENDING..., BOTTOM BENDING..., AND COINING. SCENE 10. tape 342, 01:02:54-01:03:01 pan up of punch and ram tape 328, 06:02:00-06:03:00 blue background CG: HOW THE RAM IS DRIVEN THE SPEED OF WORKPIECE POSITIONING THICKNESS OF PUNCHED MATERIAL SCENE 10. THE NUMBER OF STROKES PER MINUTE FOR A PUNCH PRESS DEPENDS ON HOW THE RAM IS DRIVEN, THE SPEED OF WORKPIECE POSITIONING, AND THE THICKNESS OF MATERIAL BEING PUNCHED. NINETY-DEGREE V -SHAPED DIES ARE THE MOST COMMON TYPE OF BENDING DIE, BUT MANY OTHER TYPES ARE USED TO PRODUCE SHAPES, SUCH AS: ACUTE ANGLE DIES, GOOSENECK DIES, OFFSET DIES, AND ROTARY BENDING DIES. SCENE 11. tape 353, 01:20:54-01:21: strokes per minute on mechanical press tape 351, 01:16:13-01:16:26 hydraulic punch press punching thick material SCENE 11. MECHANICAL PRESSES PERMIT A HIGHER OPERATING SPEED, BUT HYDRAULIC PUNCH PRESSES HAVE A MORE EVEN PUNCHING FORCE. THE ADDITION OF COMPUTER CONTROLLED GAGES TO PRESS BRAKES HAS GREATLY EXTENDED THEIR ACCURACY AND

4 MADE POSSIBLE THE ECONOMICAL PRODUCTION OF MULTIPLE-BEND, MULTIPLE-STROKE PARTS IN A SINGLE SETUP. SCENE 12. tape 347, 01:01:35:00 freeze, punch tooling punch CG, SUPER: PUNCH tape 347, 01:01:41:00 freeze, punch tooling die CG, SUPER: DIE tape 347, 01:01:47:00 freeze, punch tooling stripper CG, SUPER: STRIPPER PUNCH PRESS TOOLING CONSISTS OF A PUNCH, A DIE, AND A STRIPPER. SCENE 13. tape 339, 02:02:10-02:02:20 ANI: punch with flat tip tape 339, 02:02:40-02:02:50 ANI: punch with shear ground tip tape 339, 02:04:10-02:04:20 ANI: punch with rooftop inverted shear ground tip tape 339, 02:05:40-02:05:50 ANI: round punch shape tape 339, 02:06:40-02:06:50 ANI: square punch shape tape 339, 02:07:40-02:07:50 ANI: double d punch shape tape 339, 02:08:10-02:08:20 ANI: rectangle punch shape tape 339, 02:08:40-02:08:50 ANI: hexagon punch shape tape 339, 02:09:40-02:09:50 ANI: five-hole mount punch shape tape 339, 02:10:10-02:10:20 ANI: radius-corner rectangle punch shape PUNCHES VARY IN TIP CONFIGURATION AND THE SHAPE OF THE HOLE TO BE PUNCHED. BOTH STANDARD, AND SPECIAL HOLE SHAPES ARE AVAILABLE. SCENE 14. tape 356, 00:04:10-00:04:22 nibbling operation NIBBLING IS USED WHEN A HOLE LARGER THAN AN EXISTING PUNCH, OR A CONTOURED SHAPE, MUST BE PRODUCED. SCENE 15. tape 341, 00:22:32-00:22:40 wilson wheel using roll shearing wheels tape 361, 01:07:45-01:07:49 c.u. wilson wheel roll forming RECENT PUNCH PRESS TOOLING INNOVATIONS INCLUDE THE SHEARING WHEEL TOOL FOR PRODUCING A CONTINUOUS

5 tape 361, 01:01:23-01:01:30 wilson wheel roll forming SCENE 15. STRAIGHT OR CONTOURED CUT, AND THE ROLL-FORMING WHEEL TOOL FOR PRODUCING A CONTINUOUS RIB SHAPE IN SHEET METAL. THE FOLDING MACHINES IS ANOTHER TYPE OF MACHINE USED IN BENDING, AND IS ESPECIALLY SUITABLE FOR LARGE OR COMPLEX PARTS REQUIRING MULTIPLE BENDS. --- FTB --- SCENE 16. tape 344, 01:39:00-01:39:20 c.u. ram cycling through multitool, punching part MULTI-TOOLS USED IN AUTOMATIC PROGRAMMABLE INDEX STATIONS PERMIT UP TO 30 SMALL PUNCHES TO BE USED IN ONE TOOL HOLDER POSITION ON A TURRET. SCENE 17. tape 342, 01:07:32-01:07:46 multiple shots, tools being radially rotated as they are punching SPECIAL ROTARY ADAPTERS ALLOW PUNCHES AND DIES TO BE ROTATED RADIALLY, PERMITTING STANDARD TOOLS TO PRODUCE SPECIAL HOLE SHAPES. SCENE 18. tape 354, 01:39:07-01:39:42 plasma cutting contour on turret punch press PLASMA ARC CUTTING, AND LASER CUTTING ATTACHMENTS PERMIT CNC PUNCH PRESSES TO MAKE LARGE CUTOUTS AND CONTOURS NOT PRACTICAL WITH PUNCHING TOOLS. SCENE 19. tape 351, 01:08:58-01:09:14 workpiece load/unload system overhead rail suction cups picking part up, loading to worktable tape 353, 01:10:48-01:11:03 pull back, work done on sheet metal, work clamps moving, regripping material, moving it into position for punching tape 353, 01:01:23-01:01:31 punch press operation WORKPIECE LOAD/UNLOAD SYSTEMS, AS WELL AS WORKPIECE REPOSITIONING SYSTEMS, ADD GREAT VERSATILITY TO PUNCH PRESSES AND PERMIT UNTENDED OPERATION. --- FTB ---

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