Interactions in the workpiece-tool-press system

For numerical investigations a finite element model of the press has been set up including detailed modelling of the frame, kinematics mechanisms and guiding systems that take into account clearances. This enables relatively precise assessment of the vertical and horizontal deflections as well as tilting of the press parts in all stages of the cold forming process. The numerical model of the press was coupled with M5 numerical models of tools and workpieces, which were dedicated to stochastic analyses of product precision and tool service life.
Numerical investigations were extensively supported by statistical data obtained by industrial measurements. These included scatters of input parameters related to workpiece and tool geometry, material properties, surface conditions, tribology and forming machine characteristics as well as scatter of process responses including product tolerances and service life of tooling components.