NATIONAL UNIVERSITY OF TRUJILLO

SCHOOL OF MECHANICAL ENGINEERING

Stuffing Process
COURSE: MANUFACTURING PROCESSES II
PROF: Dr. ALCANTA ALZA VICTOR
MEMBERS
ALVA SANCHEZ KENYO
2. CASTRO GIL ANTONIO
3. JULCA CAVE FREDDY
4. LINCH PEÑA CÉSAR
5. RAMOS ESQUIVEL JORGE

2015
Technology of
process of
embellished
• The presses, known since ancient times, are
employed practically in all industries,
used to act on very different
materials, cold or hot, in any
operation that requires strong pressure:
["pack","squeeze","forge","stamp","embed"]
extrude, laminate, stretch... Even if we stick to
to metalwork, its vast variety
allows numerous classification systems. A
despite this, we will try to explore
continuation of some relevant milestones in the
exciting story of one of the machines most
most popular of all time.
Therockingpressandthe
coinminting
The dies or stamps of the obverse and of the
reverse were fitted to the spindle and the part
bottom of the box, placing between them the
gospel, which was printed by means of
successive blows. In 1783 it was
perfected by the Swiss engineer Jean
Pierre Droz, allowing the minting
simultaneous of obverse, reverse and edge.
This type of presses, with small
variations developed during the century
XIX remains in force until well
entered the 20th century. Let this be an example of
simple double-arm press-cutter that
appears in the catalog of Alfred Schütte of
1913, so similar to that of Briot, despite
the almost three hundred years that separate them.
The hydraulic press
Around 1650, the French physicist and mathematician
Blaise Pascal (1623-1662) made a
experiment that laid the foundations for the future
development of hydrostatics. Pascal
it was verified that when pressure is applied
to a contained and static liquid, said
pressure is uniformly transmitted to
all the particles of the fluid and with it to
the walls of the container.
based on that, he formulated the principle that carries his
name in the famous Treaty of Balance
of Liquids: the pressure exerted on a
confined and at rest liquid is transmitted
integrally to all the points of this.
Figure 2. Schematic of Bramah's first hydraulic press (1770)
Machines and Men Patxi Aldabaldetrecu
• At the beginning of the 20th century, the friction press
acquired a notable development, especially in
its application for object printing
massive like spoons, forks, shields,
medals, coins or even for folding
sheet metal parts.
• In the engraving, we can observe a model of
friction press of the first decade of the century
whose spindle, made of steel, with a three-thread screw, is
slides through a long bronze nut. This
model was supplied in different sizes,
varying the diameter of the spindle from 45 to
170 mm. The steering wheel has a coating of
leather intended to reduce wear
Figure 3. Friction press for stamping from the early 20th century.
General Catalog of Machine Tools 1913 Alfred H. Schütte
• During the 19th century, the punching of nails to
the departure from the branch was carried out using presses
seesaw, but this procedure resulted
not very efficient for manufacturing products
starting from sheet metal in large series. To alleviate
this problem, the American company
Bliss&Williams started marketing towards
1870 the first mechanical presses of
eccentric, suitable for punching
three-quarter inch holes with a
thickness of half an inch. They were designed
to work at 100 rpm. This type of presses,
in its different variants, frontals, collar
of swan, of arcade, became generalized with enormous
speed, progressively improving its
capacity and performance and making oneself
Figure 4. Excentric press for deep drawing. Catalog
General de Máquinas-Herramientas 1913 Alfred H. Schütte
PROCESS OF
sausage
Stuffing Process
• It is a sheet forming operation
metallic materials used to make shaped parts
stacked, box-shaped and other hollow forms
complex. It is done by placing a sheet of
metal over the cavity of a die and pushing
the metal into the cavity of this with a punch.
• A disk of diameter D is [Link] a die by means
of a punch with diameter DpThe punch and the die must have a
radius at the corners determined by Rpand Rd.

• The sides of the punch and the die are separated by a space c.
This is approximately 10% greater than the thickness of the material.
• The punch applies a downward force to perform the
metal deformation, and the fastening of parts or shapes applies
a downward holding force Fh.
Stages in the Process
of Deformation
• Bending: When the punch starts to push the material
of work. The sheet is simply folded over the
corner of the punch and the corner of the die

• Straightening: As the punch advances, an occurrence happens.

straightening action, the metal that had been bent over
the die radius must be straightened so that it can
pulling inwards into the space and forming the wall of the cylinder.

• Stamping: The metal in the outer portion of the shape

take or insert into the opening of the die to replace the
previously bent and straightened metal that now forms
the wall of the cylinder. Of this type of metal flow through
from a restricted space is where it gets its name
stuffing process. During this stage of the process, the
friction and compression play important roles
Stages in the Process
Deformation
EngineeringAnalysis
of the Cold Cuts
• Relationship of sausage (DR): measure of the
severity of a sausage operation. It
define more easily for a cylindrical shape
as the relationship between the diameter of the shape
initialDband the diameter of the punch Dp.

An approximate upper limit of the relationship of

the embedding is a value of 2.0.

• Reduction: it is closely linked

with the relationship of sausage. Consistent with the
previous limit of DR (DR≤ 2.0), the value of the
reduction must be less than 0.50
• Relationship of thickness to diameter: thickness of the
initial shape divided by the diameter of the shape
Db. What percentage value is advisable that
greater than 1%.

In cases where the design of the stamped part

exceeds the limits of the sausage relationship, the
reduction and the relationship/D
B, the form must be embedded in two or more steps.

• Number of Operations (n): Not recommended

embed in an operation depths greater than
a radius of the part. For deeper parts, it
debe hacer en varias operaciones.
, for small diameter pieces
for large parts
• Required force of the punch to perform a
the given operation can be estimated approximately
by means of the formula

Where TS = tensile strength, MPa (lb/in2), The

constant 0.7 is a correction factor for the
friction. The previous equation estimates the maximum force
in the operation.

• Holding force is an important factor in the

stuffing operation.

Where: Y = resistance to the creep of the sheet of

metal, MPa (lb/in2) Rdcorner radio of the
die-cut, mm (in).
• Drawing Speed: it is the one that has the
puncture at the moment it attacks the sheet. In the
forging of 'cylindrical parts' their speeds
they are the following:
MATERIAL Punch Speed
Zinc and stainless steel: 200mm/s
Mild steel: 280mm/s
Aluminum: 500mm/s
Brass: 750mm/s

For non-cylindrical parts, small ones are preferable.

speeds, avoiding the risk of thinning
from the wall. But in this case, it can be determined the
speed with the following formula:
RUHRMANN formula

Where:
D = the diameter in mm of the first
d = the diameter in mm of the following stamping.
• Packer Pressure: The packer aims to
avoid the formation of folds towards the edge of the
primitive stamping through the action of a
correct pressure.
It is deduced that, as it disappears
unitIAL
the circular column (Fig. 6), the pressureMATER agardenpelKg/mm 2

stomper increases in proportion: Aluminum

Zinc
0.12
0.15
Duralumin 0.16
Brass 0.20
Steel 0.20
• Where: Stainless
Steel 0.25
p = Mean pressure of tread Stamp
Stained
0.30

D = Diámetro de la chapa
d = Stamping diameter of the sheet
• The presence of the stepper is necessary if:
Determination of
diameter of the sheet
• Rounded Corner Radius of the Matrix: For
Making a good sausage is vital to have
care of the draw radius or edge radius
rounded matrix.

Thus, the proposal by KACZMAREK is:

This expression is valid only for steel. Aluminum and

Their alloys take on a slightly greater radius (10%):

• Punch Rounding: To avoid the risk that the

punch drill the sheet, in no case, the radius of
the head of the punch must be lower than that of the die.
It generally becomes three to five times greater.
than that of the matrix
TOOLS
EMPLOYEES
PUNZON:
Element that forces the material to pass through a space
defined by itself and the matrix.

MATRIX:
Element that works as a mold. When the punch
move the sheet towards the die, the material of the sheet
flows along the edges of the walls of the matrix, whose
shape, except for the elastic recovery of the material, has
to be equal to the desired final shape of the sheet metal hole.
 PISA CHAPAS (holds sheets):
Element that has solely the function of
hold the plate object of the forming during
the entire process, with the aim that it does not
they form folds.
 TYPES OF
Cured meats
The study has focused on an operation
conventional coupled sausage that produces
a simple cylindrical shape in one step and use
a bra to facilitate the process is analyzed
some variants of this operation.

Within the molding process, we can distinguish

between:
• Cold curing, practiced at temperature
environment.
• Hot embutido, for which the sheet is
heat to forging temperatures (800°C to
850°C) para el acero suave.
IN HOT
• When, due to the thickness and the
characteristics of the surface of the sheet, the
cold forging requires a force
superior to the capacity of the press
available.
• When, in small series, it is desired to limit
the tool costs, always high, that
it involves cold stamping (material of
more expensive work, more careful finish.
IN COLD
• Whenever the fabrications of are necessary
large series of pieces, and because it is a
procedure that improves productivity
regarding the hot extrusion system.
• Why the properties are not modified or changed
of the materials due to heating.
REIMBURSED:
If the change of form required by the design of
the piece is too severe, the shaping
complete piece may require more than one
sausage stuffing step. To the second sausage stuffing step
and to any subsequent one, if needed, it
stuffed llama.
INVERSE EMBEDDING:
Although it may seem that the sausage could
to produce a more severe deformation than the
reembodied, it is actually easier in metal.
The reason is that in the reverse stuffing the sheet
metal bends in the same direction in the
outer and inner corners of the die,
while in the re-embossing the metal is bent
in opposite directions at the two corners
Form Molding
NON-CYLINDRICAL:
• Many products require stuffing of
non-cylindrical shapes. The variety of shapes
embedded include square shapes, boxes
rectangular (washbasins), stepped cups,
cups with spherical bases rather than flat ones and
irregular curved shapes (like in the panels)
of automobile bodies). Each one
in these ways represents a problem
unique technician in sausage making.
EMBUTIDO WITHOUT
BRA
• One of the main functions of the bra
it consists of preventing the wrinkling of the flange
while the piece is stuffed. The trend towards
wrinkling is reduced by increasing the ratio
between the thickness and the diameter of the shape
initial.
FORGING OF
SIMPLE EFFECT
Stamping without a lid press, called 'stamping'
of simple effect", which only allows for execution
of shallow embedded parts.
• The tool consists of:
• P=punch for stamping whose section has the
forms of the embutition to be carried out.
M=embedding matrix equipped with a hole
that allows the passage of punch, having
a space equal to the thickness of the metal
DOUBLE FORGING
EFFECT
• By double acting injection is understood as
the operation that transforms a flat sheet,
in a curved shape piece, maintaining
the thickness of the sheet significantly
constant.
• That type of deformation is achieved through
a press, whose main elements are:
the punch, the stamper and the die.
DEFECTS OF
Cured meats
The metal sheet stuffing is a
more complex operation than the cut or the
folded; therefore, there are more things that can
fail. Numerous defects may arise in
a type of sausage product.
Wrinkling in the flange or tab.
Wrinkling on the wall
c) Tear
d) Eared
e) Superficial scratches
LUBRICATION IN
sausage
CONCEPT

• It is about the interposition

of a medium (Lubricant)
between two surfaces in
sliding contacts,
in order to reduce the
friction between them
Lubrication is essential in this.
operation by:

• Lubrication of the plate only by the

side of the matrix.
• Lubrication of both sides of the
iron trying not to lubricate the part
corresponding to the base of the punch.
• No lubrication.
• Lubrication of the plate throughout the
surface only on the side of the punch.
ThecontactzonesoftheroughnessesAandA'aregenerationzonesof
hightemperaturesandthereforeexposedtoscratchesanddetachments.
TYPES OF LUBRICATION
There are several lubrication systems,
but among the most used
we highlight the following:

• HYDRODYNAMIC LUBRICATION
• CONTACT LUBRICATION
• Extreme pressure lubrication
TYPES OF LUBRICATION
• HYDRODYNAMIC LUBRICATION
The sliding surfaces are separated.
totally by a thick and continuous layer of
thicker lubricant than the height of
the roughness of both surfaces.
TYPES OF LUBRICATION
• CONTACT LUBRICATION
In this case, the thickness of the fluid is
inferior to that of the hydrodynamic system
TYPES OF LUBRICATION
• EXTREME LUBRICATION
PRESSURE
It is characterized by the existence of
chemical activity between the lubricant and the
metal, the fluid layer being similar or
inferior to that of the previous case.
CHOICE OFLUBRICANT

• The following must be taken into account

factors:

A. Type of material of the part.

B. Difficulty of the embedding.

C. Desired antioxidant protection.

[Link] and interval of degreasing

SELECTION OF THE LUBRICANT
• A. THE TYPE OF MATERIAL
Depending on the material of the piece, it is
the coefficient of friction between the piece and
useful and the respective attack or adsorption.

• B. DIFFICULTY OF THE EMBEDDING

The difficulty is measured by the
total reduction carried out, this is the
relationship between initial measurement and measurement

final.
IF R < 0.40 The embutition
it is light.
0.60 > R > 0.40 The molding
it is average.
IF R > 0.60 The molding
it is deep.

The greater the reduction, the greater the

pressures and stresses and of course, greater
the function of separating the lubricant.
SELECTION OF
LUBRICANT
• C. ANTIOXIDANT PROTECTION
If the parts are to be stored for a long time or
they will be treated superficially, the lubricant
it must have good antioxidant action.
• D. FORM AND INTERVAL OF DEGREASING
If the piece is chemically attacked by the
lubricant, in order to fulfill its function, (as
it happens with sulfurized lubricants, golden,
, it is important to foresee the form, and
the degreasing medium to avoid increasing the cost
final product. If there are intermediate anneals, the
the layer is damaged and corrosion may occur.
APPLICATIONMETHODS:

The methods used to impregnate the

lubricant are:
A. Application with fogs or gun base
sprayer.
B. Application by means of rollers
impregnants.
C. Immersion application of the whites.
D. Application with brushes or highlights.
 CONCLUSIONONLUBRICATION

• In the deformation of the sheet metal in processes of

pressed, the contact lubrication regime
is the one that widely predominates over the
above all due to the high pressures,
the high slipping coefficients that
they need and to the lateral loss of lubricant without
replacement possibilities.
• For the same reason of the high severity of the
conformation work, high pressures
necessary and the high temperature developed, the
lubricants must contain additives in quantities
high.
Conclusions

• The reactivity that may be of interest for forming the

lubricant cover by combination with the
metal, it can cause tool corrosion and
attack of the pieces, if left uncleaned.
• The intermediate operations and the
manipulations can force a choice
lubricants that are not the most suitable in
regarding lubrication qualities.
SOLVED EXAMPLES
• PROBLEM 1
A stuffing operation is used to form a
cylindrical glass with an inner diameter of 75 mm and
a height of 50 mm. The size of the initial shape
it is 138 mm and the thickness of the material is 2.4
Mm. Based on this data, is it feasible the
operation?
SOLUTIONPROBLEM1

• analyze the feasibility, the ...

To
relationship of sausage, the reduction and the
thickness-diameter ratio.
• According to these measures, the operation of
stuffing is feasible. The relationship of stuffing is
less than 2.0, the reduction is less than 50%, and the
The thickness-to-diameter ratio is greater than 1%. These
these are the general guidelines that are used
frequently to indicate technical feasibility.
• Now we find the required piercing force.
to perform a given operation, it can be estimated
approximately by means of the formula:
• With tensile strength TS=300 MPa

• Now we calculate the holding force using the

equation:
With Y=175 MPa
SOLUTIONPROBLEM2

•
According to Equation 20.14,

Because the sheet is quite thick,

we will use volume instead of area for
determine if there are sufficient metals in a
3.75 inches in diameter in white. The cup made.
consists of three sections:
• walls of the cup
• toroid at the base
• the base
•
V2 = (cross section of the toroid) x (circle made)
by sweeping of the centroid)

Cross section of the toroidal sweep

Circle made by sweeping the centroid has a diameter

Now we find volume 2 and volume 3:

 • we have the total volume equal to:
So

Therefore, the diameter of 3.75 calculated from

according to equation 20.14, it does not provide
the sufficient metal to complete the cup.