The General Design And Core Components Development Of 1000 Ton Four-point Heavy Mechanical Press

Mechanical press is the main equipment in metal sheet forming.In recent years,a new generation of high-strength stamping materials and composite stamping materials were put into use;the complexity in the shape of stamping products increased daily;users’ requirement in the added value of stamping products grew continuously;the society became more aware of the conservation of raw materials and energy.These factors created a new level of requirements for the design and performance of mechanical presses.Developing the next generation of large-scale mechanical press,which has improved rigidity,precision,composite processing ability,and efficiency,will create huge economic and social benefits.Funded by “The 2009 Cooperation Project of Guangdong and Hong Kong,Large Precision Stamping Equipment of Special Steel”,the overall design of machine met the demand of the market and complied with national technical standards.Main parameters,such as number of strokes,area of bolster plate,and length of stroke,were determined based on knowledge in modern mechanical design theory,mechanical manufacturing systems engineering,product design and management,and digital design and manufacturing.To finalize the design of the force energy system,geometric kinematics calculation was applied to.Thirdly,apply finite element analysis on the strength of welded components,so we could finalize the design of the fuselage welding structure.Lastly,complete product trial and debugging based on data processing and trouble-shooting procedures,complete heat coefficient calculation and check of clutch and brake,analysis on the synchronization precision of the drive system,and tightening method and finally,test body stiffness.Prototype of this design,named as “GP4-1000 Closed Four-point Mechanical Press”,was successful manufactured and tested by Guangdong Forging Machine Tool Factory.Comparing to the average of existing products,the prototype achieved significant improvement in rigidity and precision,30% improvement in production rate,and a weight reduction of 10%.This paper not only puts forward the corresponding countermeasures,and suggestions for the technical problems and potential risks that may arise in the future design,and use of GP4-1000 four point mechanical press,but also summarize the technical difficulties of large mechanical press manufacture and debugging process,the technical development trend and the application prospect of the large mechanical press are analyzed and predicted.