1 Introduction.- 2 Basic principles of metal forming.- 2.1 Methods of forming and cutting technology.- 2.1.1 Summary.- 2.

1.2 Forming.- 2.1.3 Dividing.- 2.1.4 Combinations of processes in manufacturing.

- 2.2 Basic terms.- 2.2.1 Flow condition and flow curve.- 2.2.2 Deformation and material flow.

- 2.2.3 Force and work.- 2.2.4 Formability.- 2.2.

5 Units of measurement.- 3 Fundamentals of press design.- 3.1 Press types and press construction.- 3.1.1 Press frame.- 3.

1.2 Slide drive.- 3.1.3 Drive systems for deep drawing presses.- 3.1.4 Draw cushions.

- 3.2 Mechanical presses 49.- 3.2.1 Determination of characteristic data.- 3.2.2 Types of drive system.

- 3.2.3 Drive motor and flywheel.- 3.2.4 Clutch and brake.- 3.2.

5 Longitudinal and transverse shaft drive.- 3.2.6 Gear drives.- 3.2.7 Press crown assembly.- 3.

2.8 Slide and blank holder.- 3.2.9 Pneumatic system.- 3.2.10 Hydraulic system.

- 3.2.11 Lubrication.- 3.3 Hydraulic presses 73.- 3.3.1 Drive system.

- 3.3.2 Hydraulic oil.- 3.3.3 Parallelism of the slide.- 3.3.

4 Stroke limitation and damping.- 3.3.5 Slide locking.- 3.4Changing dies 86.- 3.4.

1 Die handling.- 3.4.2 Die clamping devices.- 3.5Press control systems 94.- 3.5.

1 Functions of the control system.- 3.5.2 Electrical components of presses.- 3.5.3 Operating and visualization system.- 3.

5.4 Structure of electrical control systems.- 3.5.5 Functional structure of the control system.- 3.5.6 Major electronic control components.

- 3.5.7 Architecture and hardware configuration.- 3.5.8 Architecture of the PLC software.- 3.5.

9 Future outlook.- 3.6Press safety and certification 106.- 3.6.1 Accident prevention.- 3.6.

2 Legislation.- 3.6.3 European safety requirements.- 3.6.4 CE marking.- 3.

6.5 Measures to be undertaken by the user.- 3.6.6 Safety requirements in the USA.- 3.7 Casting components for presses.- 4 Sheet metal forming and blanking.

- 4.1Principles of die manufacture 123.- 4.1.1 Classification of dies.- 4.1.2 Die development.

- 4.1.3 Die materials.- 4.1.4 Casting of dies.- 4.1.

5 Try-out equipment.- 4.1.6 Transfer simulators.- 4.2Deep drawing and stretch drawing 156.- 4.2.

1 Forming process.- 4.2.2 Materials for sheet metal forming.- 4.2.3 Friction, wear and lubrication during sheet metal forming.- 4.

2.4 Hydro-mechanical deep drawing.- 4.2.5 Active hydro-mechanical drawing.- 4.3Coil lines 194.- 4.

4Sheet metal forming lines 198.- 4.4.1 Universal presses.- 4.4.2 Production lines for the manufacture of flat radiator plates.- 4.

4.3 Lines for side member manufacture.- 4.4.4 Destackers and blank turnover stations.- 4.4.5 Press lines.

- 4.4.6 Transfer presses for small and medium sized parts.- 4.4.7 Large-panel tri-axis transfer presses.- 4.4.

8 Crossbar transfer presses.- 4.4.9 Presses for plastics.- 4.4.10 Stacking units for finished parts.- 4.

4.11 Control systems for large-panel transfer presses.- 4.5Blanking processes 268.- 4.6Shearing lines 284.- 4.6.

1 Slitting lines.- 4.6.2 Blanking lines.- 4.6.3 High-speed blanking lines.- 4.

6.4 Lines for the production of electric motor laminations.- 4.6.5 Production and processing of tailored blanks.- 4.6.6 Perforating presses.

- 4.6.7 Control systems for blanking presses.- 4.7Fine blanking 330.- 4.7.1 Fine blanking process.

- 4.7.2 Fine blanking materials, forces, quality characteristics and part variety.- 4.7.3 Fine blanking tools.- 4.7.

4 Fine blanking presses and lines.- 4.8Bending 366.- 4.8.1 Bending process.- 4.8.

2 Roll forming and variety of sections.- 4.8.3 Roller straightening.- 4.9Organization of stamping plants 389.- 4.9.

1 Design.- 4.9.2 Layout.- 4.9.3 Quality assurance through quality control.- 5 Hydroforming.

- 5.1General 405.- 5.2Process technology and example applications 405.- 5.2.1 Process technology.- 5.

2.2 Types of hydroformed components.- 5.2.3 Fields of application.- 5.3Component development 413.- 5.

3.1 User-oriented project management.- 5.3.2 Feasibility studies.- 5.3.3 Component design.

- 5.4Die engineering 420.- 5.4.1 Die layout.- 5.4.2 Lubricants.

- 5.5Materials and preforms for producing hydroformed components 423.- 5.5.1 Materials and heat treatment.- 5.5.2 Preforms and preparation.

- 5.6 Presses for hydroforming.- 5.7 General considerations.- 5.7.1 Production technology issues.- 5.

7.2 Technical and economic considerations.- 6 Solid forming (Forging).- 6.1General 433.- 6.2Benefits of solid forming 441.- 6.

2.1 Economic aspects.- 6.2.2 Workpiece properties.- 6.3 Materials, billet production and surface treatment.- 6.

3.1 Materials.- 6.3.2 Billet or slug preparation.- 6.3.3 Surface treatment.

- 6.4Formed part and process plan 464.- 6.4.1 The formed part.- 6.4.2 Process plan.

- 6.5 Force and work requirement.- 6.5.1 Forward rod extrusion.- 6.5.2 Forward tube extrusion.

- 6.5.3 Backward cup extrusion and centering.- 6.5.4 Reducing (open die forward extrusion).- 6.5.

5 Ironing.- 6.5.6 Upsetting.- 6.5.7 Lateral extrusion.- 6.

6Part transfer 478.- 6.6.1 Loading station.- 6.6.2 Transfer study.- 6.

7Die design 485.- 6.7.1 Die holders.- 6.7.2 Die and punch design.- 6.

7.3 Die and punch materials.- 6.7.4 Die closing systems (multiple-action dies).- 6.8Presses used for solid forming 505.- 6.

8.1 Choice of press.- 6.8.2 Mechanical presses.- 6.8.3 Hydraulic presses.

- 6.8.4 Supplementary equipment.- 6.8.5 Special features of hot and warm forming lines.- 6.8.

6 Sizing and coining presses.- 6.8.7 Minting and coin blanking lines.