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Many people may wonder, “What is press forming?” In this process, a pair of tools called a “die” is mounted inside a press, then a material such as metal is placed between the dies. High pressures (3000 tons of force or higher on large presses) are then applied by the press. The material is formed to match the shape of the dies. Since this process takes a very short time and can continuously produce the same product, presses are suited for mass production, and they are widely used by manufacturing factories around the world.
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| 1. The primary materials are metal alloys. | 2. The upper and lower sections of a die are mounted inside the press. | 3. The die sandwiches the metal and pressure is applied. |
●Click below to view the press process movie
Transfer operation / Progressive operation
【6-Stage Transfer Forming Example】Gas Tanks
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Due to environmental concerns, in recent years even more advanced technologies have been required for press forming, including technologies that use new types of materials which are difficult to form. Examples include titanium alloys that are gentle on the skin that are used for watch cases, and magnesium alloys used to make the light and easily portable cell phones and computers that consumers desire. Difficult-to-form materials which could not be formed using conventional press forming methods can now be formed and shaped using recently developed press forming processes. Another example is a motor core (electrode) used for the motor of a hybrid car. This requires a precise and delicate process technique to laminate multiple ultra-thin metal plates. This can only be achieved by a press. These next-generation press forming technologies support the enhanced performance and multifunctional abilities of all types of products.
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A wide range of products in different sizes can be formed using presses; ranging from a simple shape requiring a single process to a more sophisticated product requiring multiple processes. The flexibility of designs and sizes provided by press forming enables the manufacture of a diverse range of products in all shapes and sizes.
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The Japanese automotive industry manufactures the most diverse types of vehicles in the world. Recently, there has been a noticeable trend to promote differentiation by adding functions to meet the diverse needs of consumers in the world markets. The efficient and flexible manufacturing structure of the just-in-time production system is also a hallmark of the Japanese automotive industry. AIDA’s high-performance forming systems are instrumental in enabling the versatile and flexible manufacturing systems of this industry.
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The lead frames used to mount IC chips require micron-level accuracies (one micron = 1/1000 mm) and ultra-precise die assembly and press forming technologies. Many other electronic equipment components are manufactured by press forming, including computer components such as HDDs (Hard Disk Drives) and lithium-ion battery cases for cell-phones.
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Flat-screen TV body panels and built-in compressors for refrigerators, air-conditioners, and washing machines are manufactured by press forming. Utilizing the distinct advantages of press forming to achieve quick delivery and mass production, many products with diverse designs can be manufactured and placed on the market in rapid-fire succession.
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Products formed using presses turn up in the most unlikely places. For example, titanium eyeglass frames and wristwatch cases and stainless steel cooking pots, knives, spoons, and doorknobs. Even coins are made by presses.
