1、 Manufacturing StandardsFord Motor Company198207 STRAIGHT SIDE PRESSES DR-11Engineering Standards noresponsibility for this operation will be accepted by the FordCompany.The press supplier is responsible for the full installation ofall air receivers, oil tanks, etc. and must provide thenecessary fix
2、ing bolts, brackets, and support frames.The press supplier is responsible for loss or damage ofmaterial or equipment regardless of cause, until the completedmachine is accepted and handed over to production Ford MotorCompany cannot accept responsibility for the safekeeping ofany tools, tackle, or eq
3、uipment belonging to the presssupplier.A competent engineer is to be in attendance to supervise anddirect the installation of the press. The engineer should haveauthority to initiate through the offices of his company theorder or supply of equipment not supplied with the machine, orwhich has suffere
4、d damage in transit, and to organize laborrequired to correct faults found on the machine duringinstallation on site.Manufacturing StandardsFord Motor Company198207 STRAIGHT SIDE PRESSES DR-11Engineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 11 of 47All labor, t
5、ools, tackle, materials, equipment, andscaffolding, etc. required to erect the press is to beprovided by the press supplier. For safety and housekeeping onsite, the press supplier is to ensure that local nationalrequirements are complied with. These will be made availableby the Requisitioning Activi
6、ty before commencement ofinstallation.Erection can be sub-contracted to a reputable organization whoare fully experienced and equipped for this type of work.Sub-contractors general clause of contract which are contraryto the contents of this standard or the Ford contract will notbe accepted.It is th
7、e press suppliers responsibility to ensure that allequipment and work to fully erect and commission each machineis covered by their sub-contractors specifications.All fabrications, castings, etc. should be dressed to presentclean lines when assembled. The press should be thoroughlycleaned and free o
8、f rust, oil, or other foreign material, andfully prepared using filler where necessary before painting.Presses are to be painted in accordance with localrequirements.1.6.4 INSTALLATION BY OTHER THAN PRESS SUPPLIER: If the pressinstallation is to be carried out by Ford or others, the presssupplier mu
9、st provide technical representatives to assist inthe installation of presses and related equipment.1.6.5 FINAL ACCEPTANCE TESTS AND INSPECTION: The final acceptancetests for each press will be made at the designated Ford planton completion of installation. These will be comprised ofexaminations of a
10、ll functions, full dimensional checks,finish, and compliance with standards.After satisfactory testing all electrical functions, includingthe correct adjustment of limit and pressure switches, andsetting the slide(s) in the correct conditions for operatingwith respect to parallelism, vertical runnin
11、g and gibclearances, etc., electrical and mechanical service personnelin the press suppliers employ will be required to carry out a(48) hour test run.The 48 hour test run is to be made with the press control setto single stroke at 80% of its continuously rated speed,against a load of 80% of the rate
12、d tonnage. During the courseof the test run, the following items are to b checked:Manufacturing StandardsFord Motor Company198207 STRAIGHT SIDE PRESSES DR-11Engineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 12 of 47Friction block wear, temperature of clutch and
13、brake unit,bearings and air pipework, condition of gibs, lubrication, andair leaks.It is expected that on completion of the test run, allfunctions will be correctly set and adjusted, and that thepress will be fully ready for inspection and hand-over forproduction.2. MECHANICAL:2.1 RATINGS:2.1.1 LENG
14、TH OF STROKE: The stroke of a press slide (includingblankholder slide) is the actual lineal distance travelledduring the down-stroke (working stroke) from its upperposition (T.D.C.) to the bottom dead center (B.D.C.) position.2.1.2 SHUT HEIGHT: The shut height is the vertical distance (strokedown, a
15、nd slide adjustment up) between the slide surface andthe top surface of the bed bolster plate. When the press isequipped with sliding bolster, the shut height is specifiedfrom the upper surface of the sliding bolster. (See supplementPage 38).2.1.3 CLEARANCE BETWEEN UPRIGHTS: The clearance between up
16、rights isthe maximum unobstructed distance between the inside faces ofthe uprights, measured between the closest projecting items,such as gibbing, oil catchers, light fittings, etc. Thisrepresents the maximum width available for die loading.2.1.4 MAXIMUM TONNAGE: The rams or slides are to be rated f
17、ormaximum tonnage as follows:DISTANCE ABOVE BOTTOM OF STROKEEnglish System Presses Metric-System PressesRam or inner slide 12.5 mm Up (1/2“ Up) 25 mm Up (1“ Up)Outer slide 6.5 mm Up (1/4“ Up) 10 mm Up (2/5“ Up)Ram of Blanking presses 6.5 mm Up (1/4“ Up) 12.5 mm Up (1/2“ Up)2.1.5 ENERGY: The usable e
18、nergy of the press including energyrequired for cushions in accordance with its tonnage andrating distance must be available with a maximum permittedflywheel speed loss corresponding to the rated slip of themain drive.Manufacturing StandardsFord Motor Company198207 STRAIGHT SIDE PRESSES DR-11Enginee
19、ring Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 13 of 47Unless otherwise specified, the actual energy available forwork shall be equal to or greater than that calculated usingthe formula on Page 35. This formula assumes cushion tonnageof 1/6 rated press tonnage. Cush
20、ion tonnage in excess of thisamount will be treated as a special case.2.1.6 STROKES PER MINUTE: The rated strokes per minute f the pressare to be the number of complete cycles of the slide in oneminute, that can be maintained on a continuous basis whileusing on each stroke the maximum usable energy
21、as previouslydefined.On intermittent operation, the press has to provide 80% ofrated strokes per minute using the maximum energy on eachstroke.2.2 DEFINITIONS:2.2.1 STRAIGHT SIDED PRESS: The term “straight side press“ as usedin this specification refers to mechanical presses of tie-rodconstruction c
22、omprised of a bed, a crown, and two uprights(columns). The uprights may in fact be designed with openingsfor moving bolster equipment or other purposes, but must stillin effect comprise, with the other frame components, a rigid“box“ structure.2.2.2 SUSPENSION POINTS: Presses are also designated in t
23、erms ofthe number of suspension points. This is defined as the numberof slide connections to the eccentric drive gears. Forexample, a two point press would normally have two eccentricstrap connections to the slide. For double action presses, thenumber of suspension points is applicable to the ram.2.
24、2.3 FRONT TO BACK DRIVE: A front to back drive system is soarranged that the clutch/brake unit, eccentric gear shafts,etc., are designed so that their axis of rotation is alignedfrom front to back of the crown. Designs in which the axis ofrotation run from left to right are not acceptable withoutpri
25、or Ford approval.Transfer and progressive die presses do not require front toback drive.2.2.4 DRIVE LINKAGE: Eccentric drive is preferred to crankshaftdrive.When a link drive system is specified, slow down (reduction inslide velocity versus eccentric) shall be as follows:a) Blanking Presses: 67% red
26、uction at 12.5 mm (1/2“) frombottom of stroke.Manufacturing StandardsFord Motor Company198207 STRAIGHT SIDE PRESSES DR-11Engineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 14 of 47b) Other Presses: 50% reduction at 1/4 of the total slidestroke from bottom. (Inner
27、 slide only on double actionpresses.)c) Other Slowdown Values: Require prior Ford approval.2.2.5 BLANKING PRESS: A blanking press is a single action press asdescribed in Section 2.2.6 but primarily used for cutting ofblanks from sheet or coil.2.2.6 SINGLE ACTION PRESS: A single action press has onem
28、echanically driven slide, which may contain an integralpneumatic cushion unit, if specified. Pneumatic cushions mayalso be specified for installation in the press bed.2.2.7 DOUBLE ACTION PRESS: A double action press has two slides,both mechanically driven by the same system. The slides arearranged t
29、o run one within the other, such that the innerslide, or ram, passes through the outer slide or blankholder.The inner slide should b driven, either directly or through aslow down link system if specified, by eccentric gears.The outer slide is to be driven by a rocking link system toprovide a dwell p
30、eriod at the bottom of its stroke.The press may be provided with a pneumatic cushion in the bedif specified.2.2.8 TRIPLE ACTION PRESS: A triple action press has threemechanically driven slides. The upper slides are arranged asfor a double action press. The third action is in the form ofan upstroking
31、 mechanical drive operating from the bed of thepress, synchronized to run with the upper two slides whenrequired. Third action is to be provided if requested anddescribed in the specification.2.2.9 SLIDING BOLSTER PRESS: A sliding bolster press is equippedwith a system for rapid die change, which is
32、 comprised of oneor two powered bolsters which can be moved along rails to aposition outside the press. The system of operation, i.e. withmovement through openings in both or one uprights, forward orbackward between the uprights, and the position for parkingduring die change, will be detailed in the
33、 quotation.Construction of sliding bolster presses is described in aseparate section of this standard.Manufacturing StandardsFord Motor Company198207 STRAIGHT SIDE PRESSES DR-11Engineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 15 of 472.3 STRUCTURE:2.3.1 GENERAL
34、 The structure forming the main frame ofstraightsided presses is to consist of four (4) basic units,comprised of one crown, two uprights, and one bed. The wholeassembly is to be rigidly held together by four (4)pre-stressed tie rods.Frame components, slides, and auxiliary structures are to beconstr
35、ucted as weldments from mild steel plate and sections.Each fabrication is to be fully stress relieved after weldingand shot blasted before inspection for mark-out. Welds must bcontinuous for the full length of all joints. Plat abutmentsand welding shall be finished to present a clean and planesurfac
36、e. Standards for the deposition of weld material andpreparation for plate joints must not be inferior to thosespecified in the relevant National Standards.Press components should be designed to make optimum use of thebuilding and relevant overhead crane capacity. Each componentis to be provided with
37、 facilities for the attachment of tacklefor purpose of lifting, transporting, and moving by means ofoverhead crane, etc. The facilities shall be arranged toprovide a balanced lifting condition without the use ofspecial equipment or odd-legged slings. Lifting holes shallnot be less than 60 mm (2 1/2“
38、) diameter.Adjacent to each lifting point on the major frame components,the weight shall be metal stamped in characters at least 12 mm(1/2“) high, stating the weight of the component in bothstripped and assembled conditions. The press serial number andsuitable orientation marks to assist in assembly
39、 shall besimilarly stamped on metal on all frame components.2.3.2 BED: If specified, the press bed is to be machined forinstallation of a pneumatic die cushion unit, which will beordered with the press or at a later date for retro-fit. Inthis case, the press main drive shall be designed with anenerg
40、y rating to include bed cushion operation. The bolsterplate on presses not equipped with sliding bolster equipmentis to be fixed by socket head screws to facilitate removal andpermit dismantling of bed cushion unit through the bedopening.The maximum deflection of the center of the bed must notexceed
41、 0.125 mm per meter length of bed (or 0.0015 inches perfoot) when subjected to the full press tonnage uniformlydistributed over two-thirds of the specified left-to-right beddimension.Manufacturing StandardsFord Motor Company198207 STRAIGHT SIDE PRESSES DR-11Engineering Standards & Printed copies are
42、 uncontrolled.Systems Engineering (ESSE) Page 16 of 47Lifting facilities with holes not less than 60 mm (2 1/2“)diameter are to be provided to allow the bed to be liftedwithout the use of special slings. Covers are to be providedover holes in area of die cushion travel.2.3.3 BOLSTER HOLES: All bolst
43、er pin holes are to be provided withreplaceable inserts, material, hardness and method ofretention to be approved by the specifying activity.2.3.4 UPRIGHTS: The press uprights are to be constructed to housethe following components so that no part of them projectsbeyond the face of the uprights:a) Ma
44、in operators control panelb) Bed cushion control panelc) Complete air control compartmentd) Stroke position indicatore) Power outletsf) Electrical main control panel, etc.Where specified, mounting pads for automation equipment andfor mechanical guards are to be provided, in accordance withrelevant d
45、rawings.2.3.5 CROWN: The top face of the crown, where suitable for walkingon, shall be kept clear of electrical conduits, pipework, andother equipment which might constitute a tripping hazard.Expanded metal grid walkways are to be provided to covercrown-mounted equipment to prevent damage by mainten
46、ancepersonnel requiring access.The top of the crown is to be provided with a handrail aroundthe outer edge, arranged so that there is at least 500 mm(20“) clearance space for access between clutch and brakehousings and the nearest handrail. The use of overhanging orsuspended platforms to achieve thi
47、s must be approved by Ford.To facilitate dismantling of clutch and brake, easilyremovable sections of handrailing are to be provided.All vent and drain holes in the top face of the crown are tobe filled with wire gauze covers to prevent ingress of dirt,etc. The crown is to be provided with a drip le
48、dge around theedge at the top face to prevent oil running down the exteriorsurface of the press frame, and also to act as a toe-plate forthe handrail.Removable covers are to be provided for access to the crowninterior where required for maintenance and inspection. Coversshould be oil and dust tight,
49、 and transparent wherepracticable and provided with suitable handling facilities.Covers which require frequent removal for regular inspectionor preventative maintenance should be hinged.Manufacturing StandardsFord Motor Company198207 STRAIGHT SIDE PRESSES DR-11Engineering Standards & Printed copies are uncontrolled.Systems Engineering (ESSE) Page 17 of 472.3.6 TIE RODS: Tie rods shall be designed for hydraulic tensioningduring the press installatio
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