Manually Fed Press

Manually Fed Press Image The following lesson outline details the tasks needed to be an operator and die-setter machinist on a Manually Fed Press. Some of these tasks require the trainee to explain how something works to insure they have the required understanding of the processes and are not simply memorizing procedures. All of the tasks listed will be a part of the Performance Test within each lesson. To learn more about these tests and the training process itself, see the Philosophy section.

This program was specifically designed to train setup operators of a Manually Fed Press. The instructional technique employed will enable individuals to learn to setup and operate the machines with little difficulty. The trainee will also learn the measurement techniques needed by press setup operators. The last lesson includes setup of both "Posson's" and "Safeguard" Pullbacks. Both existing personnel and new trainees can utilize these training materials to develop or improve their performance.

Lesson 1: Basic Components [ Top ]

After completing this lesson the operator will be able to:

  1. Use the correct terminology to describe blanks, slugs or scrap and piece parts.
  2. Locate, identify and explain the purpose of the bed, the frame, and all major components of the press drive mechanism.
  3. Locate, identify and explain the purpose of the punch, the die, and the air cushion.
  4. Locate, identify and explain the purpose of the major components of a straight side press.
  5. Explain how the components of the press drive system work to provide movement to the ram.
  6. Explain how a press stroke, when triggered by the Operator, engages the clutch which cycles the crankshaft and the ram.
  7. Use the correct terminology for the top and bottom of the press stroke.
  8. Describe the ways that the piece parts and scrap may be removed from the dies after the press cycle.
  9. Explain what type of clutch the press is equipped with, and whether that press can be stopped part way through a stroke.

Lesson 2: Safe Operation [ Top ]

After completing this lesson the operator will be able to:

  1. Dress safely for manual press operation, including wearing all required hand, eye, ear and foot safety devices.
  2. Locate, identify and explain the purpose of all Operator controls on the press.
  3. Explain the settings on the Mode Select control, and when the settings are used.
  4. Identify and explain the purpose of Operator safety devices, including active devices such as pullbacks and guards, and passive devices such as barrier guards and restraints.
  5. Prepare a press for safe operation by cleaning the work area, inspecting the die area on the press for unsafe conditions, inspecting all safety devices, and starting any part or scrap conveyers.
  6. Start up the press and begin manual operation, using all safety devices correctly, on a press equipped with two-hand controls.
  7. Start up the press and begin manual operation, using all safety devices correctly, on a press equipped with a foot pedal control.

Lesson 3: Die Components and Operation [ Top ]

After completing this lesson the operator will be able to:

  1. Locate, identify and explain the purpose of major components of die assemblies.
  2. Explain names and terminology for types of dies and punches.
  3. Locate, identify and explain the purpose of die components which hold and control the piece part; for example strippers, kickers, pushers and air blowoffs.
  4. Explain the use and operation of die components which hold and control the piece part.
  5. Explain the three main types of press operations.
  6. Identify the major types of shearing operations on piece parts.
  7. Identify the major types of forming operations on piece parts.
  8. Identify drawn features on piece parts.
  9. Explain terminology used to describe drawing operations.

Lesson 4: Indicators of Incorrect Operation [ Top ]

After completing this lesson the operator will be able to:

  1. Identify the areas of a sheared edge on a piece part.
  2. Explain the stages of the metal shearing process, and identify the area of a sheared edge which is produced during each stage.
  3. Identify piece parts on which the burr is unacceptable.
  4. Describe the indicators which are found along with an oversized burr.
  5. Identify the die problems which are usually the causes of oversized burrs.
  6. Identify piece parts on which there is a double break.
  7. Describe the indicators which are usually found along with a double break, and explain the cause of double breaks on the piece parts.
  8. Identify piece parts on which there is cracking.
  9. Describe the indicators which are usually found along with cracking, explain the cause of cracks on the piece parts, and name the usual corrective actions for cracking.
  10. Identify piece parts with wrinkling, and explain the primary cause of wrinkling.
  11. Identify piece parts with galling, explain the possible causes of galling, and describe the procedure the Operator should take when galling appears.
  12. Identify piece parts with unacceptable burnishing on drawn features, and name the possible causes of burnishing.
  13. Name the piece part indicators of a broken or damaged punch or die.
  14. Name the piece part indicators of a worn or dull punch or die.
  15. Identify dull punches.
  16. Identify incomplete or missing features on piece parts.

Lesson 5: Measuring and Gauging Piece Parts [ Top ]

After completing this lesson the operator will be able to:

  1. Identify gauging and measuring devices used to check piece parts.
  2. Determine the proper gauges and gauge fixture by reading the gauge ticket.
  3. Correctly install piece parts on a gauge fixture with a bar-and-over-center clamp, and on a gauge fixture with a toggle clamp.
  4. Gauge workpiece holes using GO/NO-GO plug gauges; determine whether the features are over, under, or within the tolerance limits.
  5. Gauge workpiece features using GO/NO-GO gap gauges; determine whether the features are over, under, or within the tolerance limits.
  6. Gauge workpiece features using a gauge fixture with a bar gauge; determine whether the features are over, under, or within the tolerance limits.
  7. Gauge workpiece features using a gauge fixture with pin gauges; determine whether the features are over, under, or within the tolerance limits.
  8. Gauge workpiece features using a gauge fixture with a window gauge; determine whether the features are large enough and whether they are properly located.
  9. Determine whether a piece part feature is in tolerance using a receiver gauge.
  10. Properly zero an electronic indicator on a gauge fixture, using a gauge master, then gauge a piece part and determine whether it is in tolerance.
  11. Determine whether a dial indicator has a balanced dial or a continuous dial, and determine the size increment measured by the indicator.
  12. Use a dial indicator on a gauge fixture to measure a piece part feature, and determine whether the feature is in tolerance.
  13. Check the calibration of a micrometer mounted on a gauge fixture, then use the micrometer to measure a piece part feature.

Lesson 6: Setup Controls and Tools [ Top ]

After completing this lesson the operator will be able to:

  1. Locate the Specification Plate on a press, and determine from the plate information needed for setup of the press.
  2. Explain information required for setup, including press shut height, die shut height, stroke length, and pressure of the ram.
  3. Explain when the use of a Safety Block is necessary.
  4. Locate, identify and explain the purpose of all setup controls on the press.
  5. Select the correct mode on the press controls, start the main motor, and inch the press through a complete cycle.
  6. Locate, identify and explain the purpose of all air gauges and regulators used during setup.
  7. Disconnect and/or remove any safety devices which restrict access to the die area, such as "pullbacks".
  8. Safely lower the ram to bottom dead center.
  9. Move the adjustment rod on the knockout mechanism to the top of its adjustment range.
  10. Release the air cushion air pressure, remove any die assembly air lines, loosen and remove all holding clamps and devices, then inch the ram up to break the punch shoe loose from the ram.
  11. Unclamp the bottom half of the die assembly, then slide out the die assembly and make it accessible for removal by forklift.
  12. Identify different types of die clamping devices.
  13. Select the proper clamping devices for a particular die shoe, including T-bolts, fulcrum blocks, bridges, washers and nuts. These devices will be adequate size and strength for holding down the die assembly.
  14. Install and tighten the die shoe clamping devices.

Lesson 7: Installing the Die Assembly [ Top ]

After completing this lesson the operator will be able to:

  1. Select and measure the proper pressure pins for setup of a die assembly with an air cushion.
  2. Prepare the bolster plate by cleaning and deburring it, installing the pressure pins in the proper bolster holes and placing bolster plugs in all other bolster holes.
  3. Select a collar of the correct ID and OD, and install the collar on a die with a shank.
  4. Properly align a die assembly with the hole in the ram and with the pressure pins. When there is no shank or pressure pins, the Operator will position the die by centering it on the bolster plate.
  5. Perform the measurements and calculations needed to determine the correct rough shut height.
  6. Rough adjust the press shut height, using either a ram adjusting screw or electric slide adjustment controls.
  7. Safely lower the ram to bottom dead center for clamping the punch, using the proper procedure for that type of press clutch and die.
  8. Select the proper clamping devices for attaching the punch to the ram face, then install and tighten the clamping devices.
  9. Select the proper fulcrums, T-bolts and bridges for clamping the die, the clamp the die to the bolster plate.
  10. Check the clearance between the punch shoe and the die stop block using a feeler gauge or visual inspection, and adjust if necessary by readjusting the shut height.
  11. Check the stability and clearance of an installed dieset by inching the ram through a few strokes.
  12. Adjust the knockout bar until the kickout pins extend the proper distance from the punch assembly.
  13. Determine the required air pressure for a die assembly by comparing the top-half weight to the weight-to-air chart on the press.
  14. Adjust the air counterbalance on a press when the top-half weight is unknown or the weight-to-air chart is missing.

Lesson 8: Trial Stamping the First Piece Part [ Top ]

After completing this lesson the operator will be able to:

  1. Locate the air pressure regulator and gauge for the air cushion, and make an initial adjustment of the air cushion pressure.
  2. Safely produce a piece part by inching the press, using safety tongs to install the blank and remove the piece part.
  3. Inspect and gauge the first piece part, and identify any flaws or defects.
  4. Take the proper corrective action for excessive bottoming marks.
  5. Take the proper corrective action for cracks or tears.
  6. Take the proper corrective action for bent features which are not bent to full angle and formed features which are not fully formed.
  7. Check a die setup by running piece parts at full speed, then inspecting and gauging the piece parts.
  8. Correctly install or position all parts and scrap handling equipment, including conveyors, bins and chutes.
  9. Install kicker air lines onto a die and adjust the air pressure for proper piece part removal.
  10. Locate, identify and explain the purpose of the kick cam and the retract cam on a kicker attachment. Also explain the proper operation of the kicker during the press stroke.
  11. Adjust the kicker cams for correct timing.
  12. Attach and adjust all other required devices onto the die, including any piece part or slug removal air lines.
  13. Locate, identify and explain the purpose of major components of "Posson's" pullbacks and "Safeguard" pullbacks, including components used for adjustment of the pullbacks.
  14. Identify all "pinch points" on a dieset.
  15. ("Posson's" Pullbacks) Connect the pullback connecting rod and adjust the Multiplier.
  16. ("Posson's" Pullbacks and "Safeguard" Pullbacks) Adjust the pullback length until the Operator is able to load piece parts at top dead center, and until the Operator's fingers are at least three inches from all pinch points at bottom dead center. On "Safeguard" pullbacks, this procedure also includes adjusting the cable travel (dwell).
  17. ("Posson's" Pullbacks) Check the tension of the tension spring and readjust the cable adjusting plate to provide adequate spring tension.
  18. ("Posson's" Pullbacks) Adjust the pullback length using the cable adjusting handle on the Multiplier.
  19. ("Posson's" Pullbacks and "Safeguard" Pullbacks) Inspect the entire pullback mechanism: identify binding or sloppy movement in moving parts; frayed, kinked or damaged cables; loose, worn or damaged cable connectors; and signs of fraying, wear or damage to the cuffs.
  20. Prepare the machine for full production; tell the Operator all required information including blank lubrication procedure and intervals, blank placement in the die, and gauging and measuring procedures and intervals; inspect the production of the first piece parts and perform any required adjustments required for Operator convenience and safety.