Global Expansion of Human Activity
and The Wave of Motorization

Enhancing the productivity of international automobile manufacturers
In the attractive international automobile manufacturing market, fineblanking(FB) provides a state-of-the-art technology far superior to any other techniquesin terms of accuracy, quality and economy.

FINEBLANKED AUTOMOTIVE PARTS

Introduction by Teizo Maeda,
Professor Emeritus of the University of Tokyo

Seventy years have passed since fineblanking was developed by Fritz Schiessin Switzerland. Starting in the late '60s, Japan imported many fineblankingpresses from Switzerland. However, users were not completely satisfiedwith the productivity and services of these machines, and suggested thatthe fineblank presses be manufactured by Mori Iron which, quite similarto Schiess, had a history of seventy years, an impressive R&D background,and much experience in the design and manufacture of hydraulic presses.

Recommendation by Hirokazu Odamoto,
Director, Japan Metal Stamping Association

Backed up by the cooperation of the Japanese users of the imported conventionalfineblank (FB) presses, the first FB press was manufactured, with improvementsmade to the efficiency, operability and maintainability of the conventionalmachines. These improvements to the FB press drew wide-spread acclaim.This first version was then followed by the development of a new FB, whichwas equipped with a CNC, creating a new standard for the industry, and greatlycontributing to the development of the automotive industry.

The photo illustrates a 8000 kN FB press equipped with a CNC, currentlyin service at the world's top-level FB production line in the clutch manufacturingindustry.

Principles of FB

The FB machine is based on the principle of hydrostatic pressure that plasticdeformation of metal is increased by application of high pressure. Thisprinciple is based on the studies of Dr. Bridgeman, a U.S. scientist whowon the 1964 Nobel prize in physics. The principle is now widely knownin many fields.

Conventional process Punch Workpiece Die	FB Process Punch Workpiece Die V-ring Ejector

Surface produced by conventional method (Top)
Smooth surface produced by FB method (Bottom)

FB Features:

• Provides a clean-cut surface without the need for secondary machiningsuch as shaving or milling.
• Ensures stable production with high quality and precision.
• Permits three-dimensional composite processing including coining, semi-shearing,bending, and drawing.
• Assures better flatness than conventional press techniques.
• The FB requires special presses featuring high accuracy and rigidity aswell as precision tools.
• The FB press uses three independently adjustable pressures (Triple ActionMode) for blanking operation.

Selection from an extensive assortment of products

• A wide selection of presses is available. You can choose the productbest suited to your particular work requirements, which depend on the shape,quality and thickness of your workpieces.
• Two basic structural types of FB tools are available: a moving punch typeand a fixed punch type. The fixed punch tool is mainly used for multi-punchingand progressive punching, while the moving punch tool is employed mainlyto produce large components.
• There are ten types of hydraulic presses ranging from 1600 kN to 12,000kN. Two mechanical presses of 1,000 and 1,600 kN are also available.

• The press is designed in a welded mono-block structure and is carefullytempered.
• Special steel is used for the cylinder, ram, and bolster.
• The ram slide consists of a preloaded long and broad 8-sided guidewayto help the unit withstand eccentric loads in composite forging operations.
• A mechanical stopper ensures stopping at the top dead center, and repeatabilityis held to a tolerance of below 0.01mm.
• Model FB-250 and later machines are provided with center supports thatprovide a longer service life, lighter weight, and reduced tool cost.
• The ram is raised hydraulically from below, and is lowered under its deadweight without excessive force being applied.
• Timing of the shearing pressure, V-ring, counter pressure, and additionalpressure can be adjusted separately.

Standard Accessories FB press

Specification

>>Check of specification

1. Tool protection device
   When the FB shearing process is completed, the products and slugs are pushedback to the top surface of the tool and are ejected. This is followed bythe next process. The tool protection device prevents possible tool breakageby stopping the ram motion immediately when it has detected a remainingproduct or slug. (Patented)
   
   
2. Shut-height adjustment
   
   • Production can be resumed according to the work data stored in the sequencerCPU merely by entering the volume of regrinding for the punching operation. There is no need to interrupt production. (Patented)
     
     
3. Material feed unit
   
   • Feeding units are required to feed in and feed out both coil and sheetmaterials. This unit employs an independently controllable roller drivenby an AC servo motor, and releases the material when a progressive toolis used.
   • The pass-line and width of the material can be adjusted according to theparts to be produced.
   • When workpiece is inserted automatically, the position to stop the tipof the workpiece and the remaining work volume up to the end of the workpiececan be preset or stored in the memory. This data makes automatic controlpossible.
   • On the standard machine, the workpiece is fed from left to right, facingthe machine. This direction can be reversed according to your requirements.
   • To save machine space, an NC leveler is used. This will eliminate theneed to install material feed units on the in-feed and out-feed positions. Instead, a pinch roller to eject the remaining material is used on theout-feed side.

1. Product and Slug Ejection
   
   • The standard air blower is recommended to improve efficiency .
     (Use of an optional ejector ensures automatic separation between the partsand slug, and allows the front and back sides of parts to be differentiated. Furthermore, it prevents the parts from being dented and your plant frombeing contaminated by splashes of a lubricant. It also protects your workenvironment against noise.
     
     
2. Lubricating unit
   
   • For FB, you can select the type of lubricant best suited to your particularwork requirements.
     
   • The spray unit provides easy control of the volume of oil applied to theupper and lower sides of the workpiece. It also ensures the minimum oilmist generation.
     
   • Oil remaining on the bolster can be recovered through a channel.
     
   • The press will be automatically stopped at the instance of sensing thelower oil limit.
     
     
3. Hydraulic unit
   
   • This is a freestanding unit independent of the press body, and is completelyunaffected by vibration or heat.
   • Domestically manufactured hydraulic equipment and pumps are adopted tominimize running costs and to provide better servicing.
   • A quiet plunger-type axial piston pump is used for the main pump.
   • Use of this axial piston pump ensures a longer service life than an inscribedgear pump.
   • The standard hydraulic oil temperature control system is based on water-cooling.
   • (An optional air-cooling device is available; it is provided to preventcooling water from freezing in cold regions.)
   • Use of an electrostatic oil cleaner eliminates foreign substances whichmay enter oil, thereby preventing operation failure and oil deterioration.
     
     
     
4. Safety door
   
   • Continuous operation is possible only while the door is closed. Furthersafety is ensured by an optical safety device.
     
     
5. Scrap cutter
   
   • The hydraulic scrap cutter allows free adjustment of the length of thescrape to be cut. It has a shearing angle to permit cutting at a lower pressure.

Special Accessories

1. Additional hydraulic circuits
   
   • Additional independently controllable hydraulic circuits are providedto reduce the number of processes as in composite forging operations andto enhance product accuracy.
     
     
2. Material feed monitor
   
   • This unit stops the press if the roller feeder is overloaded.
   • When a progressive tool is used, this device prevents the tool from beingdamaged by workpiece interference or incorrect feeding.
     
     
3. Pre-roller
   
   • A collapsible rail fitted on the front of the press permits easy settingand removal of tools.
     
     
4. Hydraulic tool clamper
   
   • This hydraulic clamper ensures accurate, rapid, easy, and safe mountingand dismounting of tools.
     
     
5. Hydraulic tool lift roller
   
   • Installation of this hydraulic tool lift roller in the bolster permitseasy handling of heavy tools.
     
     
6. Tool change wagon
   
   • Allows tool changes to be made quickly and safely.
   • Available in fixed or adjustable versions. It allows the tool to be pushedin and pulled out both manually and automatically.
     
     
7. Oil mist collector
   
   • Contributes to a cleaner working environment in the factory because itprevents contamination of oil splashes, which occurs with use air-blowingparts and slugs.
     
     
8. Moving bolster
   
   • Permits easy external setup of the tool and the insert ring to be usedin the next step while the press is operating.
     
     
9. Optical safety device
   
   • Protects the operator during a tool adjustment. It stops the press whenactuated.

Features of CNC

• This is a Manual Data Input (MDI) control unit. Before the work is started,you can enter the optimum running conditions in conformity to the shapeof components to be made, and the quality and thickness of the workpiece.
• The input data are displayed on a color CRT (screen). After being confirmed,they are stored in the CPU memory, which is capable of storing a maximumof 100 different patterns.(more memory available on request)
• When the tool is changed, the running data is called up by the serialnumber of the tool.
• The system provides reproduction of accurate running data to ensure stableproduction of high-quality products even when operated by an unskilled operator. Furthermore, it minimizes tool change time. The system is particularlyeffective in the production of multiple product types in small quantity.
• The CNC unit incorporates functions to check the hydraulic unit and controlequipment. In the event of a failure, the details of the failure and nameof the equipment are displayed on the control panel and the CRT to allowyou to make an instant correction.
• Even while the press is operating, running data of the tool for the nextjob can be called up, checked, and modified.

This page shows the FDE model that uses a CNC system. We also manufacturean LCD touch panel model (called the "FD model") as a popularversion, which provides electronic control of only the slide position.

Mori Iron offers FB periphery equipment including coil-lines, levelers,sheet feeders, product/slug ejectors, deburring equipment, tools and workpieces.Also our FB program provides you with total support and services throughour experiences and know-how.

The FB presses are manufactured by Mori Iron in a clean work environment,surrounded by greenery and under a warm climate. Our FB presses are widelyregarded as being superior to any other comparable types on the market,in terms of safety and efficiency. Sales of Mori FB presses have grown over the years to the point where they now eclipse that of Switzerland,and our international business and service network has been consolidatedand expanded. Our worldwide network of contacts with component researchersand companies involved in FB technology is helping us to develop softwareand tool technologies and to design new FB presses that incorporate uniquespecifications.

NC Leveler Feed
Directly coupled with Press

:About Fine Blanking Press
:Introduction of Fineblanking in Japan.