Improvement of metal forming quality by motion design

Servo presses provide many advantages as formability, accuracy and productivity. A prototype of servo press with 50 ton capacity has been demonstrated by using a metal forming application in this study. The ram motion is programmed to have several desired profiles by introducing different case studies. Only one specific designed motion is included here as an example for sheet metal forming. The motion which is called soft motion is applied experimentally on Cr-Ni steel alloy sheet for material forming. Kinematics and dynamics from the simulations based on the experimental results are given. Soft ram motion with 20 strokes per minute (spm) and constant motor velocities (such as 5 spm, 10 spm and 20 spm) ram motions are experimentally compared. As a result of comparison; soft motion has given higher velocity with higher thickness and better surface quality on the material. Manufacturing performances of servo press are also experimented at 2-50 tons in laboratory. Stroke position error is found as ± 0.025 mm for the soft motion. This study is provided to be a research on servo crank press having 200 mm stroke.