A tryout press is a stage in the tool's engineering and manufacturing process when the tool is first loaded into the press to perform an initial test of manufacturing the part. During testing, the shaping method then undergoes thorough tuning, an expensive and time-consuming step towards the efficient development of a high-quality instrument. Because corrective work and adjustments are unavoidable, in terms of time and resources, any correction loop that can be stopped has an immediate gain. Any enhancement of component efficiency during testing immediately boosts the productivity of the company.
These corrective loops are usually unlikely, following today's trial and error theory. Nowadays, without using emulation, it's impossible to consider testing out instruments. A structured strategy that is not confined to the limits of particular operating units guarantees success. Therefore the efficient development of tools is focused on correctly tested, consistent simulation outcomes that lead to a substantial reduction in the number of correction loops.
In the tool room, engineering, including stamping simulation and experimentation, are independent operational departments. In terms of facilities and organization, but also the time of their use during the creation of the method, these divisions vary. The technical team is usually already on the latest designs when the milling tool is released, while the test team is just getting started. In reality, the same questions are discussed by both departments: where are the sensitive areas, in part?
● Minimized correction loops and associated trial costs
● Sample - parts of the required quality
● The test team must perform several correction loops on the tool until the tool can be used to produce the required quality parts.
To achieve a successful test, both operational departments must coordinate their activities with each other. Basically, before the tool can be used to generate a portion of the desired standard, the test team needs to run multiple correction loops on the tool. Engineering implements simulation-based trial support at this stage.
In the simulation model, all potentially feasible remedial steps that can be done in the real trials are integrated and these simulations run in tandem with the output of the instruments. Prior to a tool update, findings are available, enabling you to manage simulation-based trials. The cause can be seen on the machine if a problem arises during the test, and it soon becomes apparent which steps have a beneficial impact on the outcome of the molding. The tool shop can effectively cope with the complicated geometry of components, high-strength steel materials, short timelines with quality specifications, due to the effective and systematic testing of instruments.
Whether they are a punch press or a conventional test press, hydraulic presses are best suited for die testing and commissioning before series production begins.
During the test, the press operator has full press capacity available, allowing him to precisely control the closure of the upper and lower dies.
Regarding size, capacity, performance specifications and detailed equipment options, tryout presses can be customized to meet special die testing, trial and production needs.
● Programmable speeds and forces
● Return slide possible at any time during the jump
● The joystick allows you to gently control Tryout Pressthe movement of the slide
● Full rated capacity available across the entire stroke
● Simple adaptation to different die heights
● Double and single-sided operation at the touch of a button
One of the challenges with die construction is the time spent trying the die to get a satisfactory part. The trial process may take several minutes or several months to complete depending on the complexity and tolerancing of the part’s geometry.
Advanced tools such as molding simulation software can certainly help you reduce your press time. But while creating a simulation can help you establish a process electronically, it usually doesn't take into account many of the variables that exist in the real world of stamping. Factors such as heat, press and die deflection, forming speed, and friction changes during forming are usually not included in the simulation, but they have a profound effect on the ability to obtain a satisfactory extruded part.
1. Eject problems from the process and tools
When I was a young toolmaker, we didn't have mold simulation software. The die engineers and designers made thoughtful guesses to determine the best die design and part manufacturing process, so they spent a lot of time in the press, changing and modifying tooling as needed. We joked that we design dies in the press.Today we have neither the time nor the resources for this.
To speed up the die trial process, the die designer or process engineer must not leave any stone on the stone. Every detail of the matrix structure must be defined. Using molding simulation, analyze the part deformation levels to equalize and distribute the deformation as evenly as possible to prevent cracking and wrinkling during stretching or stretching.
Once you get there, focus on preventing springback, not correction. And remember: no effort, no profit. Significant changes in strain intensity typically cause parts to twist and tilt. Knowing the true properties of the material is essential. I recommend that you investigate the actual tensile strength of a test material to determine the mechanical values.
2. Create a formability report for tool builders
The formability report usually includes the material parameters used for the simulation, so the tool manufacturer can verify that the correct trial material is being used. The report also shows the applied coefficient of friction, the required holding and forming pressures, and may also show the boundary diagram of the forming process and the blank dimensions. The test technician or toolmaker should use exactly the same blank size and shape that was used during the molding simulation process.
For parts that are formed by the drawing process, the report should also include the specified draft measurements around the perimeter of the blank and the part being drawn. Most simulation reports show the part that is applied to the blank. These pull-in measurements will determine how the metal flows inward toward the pull punch to get a satisfactory part.
During the die trial process, the manufacturer or technician can compare the feed measurements on the report with the actual measurements on the tool. If the simulation report shows 35 mm inward flow in a given part area and the die shows only 30 mm inward flow, the gardener or technician must adjust the tool to obtain 5 mm of additional inward flow.
If the inward flow rates on the die are identical to those reported in the formability report, there is likely a difference in the applied friction or the mechanical properties of the metal do not match what was used in the simulation. So a tryout press is an integral part for metal stamping operations to speed up their engineering stages for mass production.
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