How to Make Dies for Hydraulic Presses

Hydraulic presses are machines that utilize hydraulic fluid to generate and transfer force, using compressed cylinders of hydraulic presses to generate immense levels of pressure.

Metalwork can now be completed quickly and on an industrial scale; coining, stamping and forming metal into shapes are among the many processes this allows.

Basics

Hydraulic presses are essential tools in manufacturing industries for applications involving metal forming, stamping and bending. These presses utilize hydraulic fluid to generate force from one small piston to a larger one that can then be adjusted according to production needs. Hydraulic presses are popular choices among metal fabricators due to their ability to produce high levels of pressure while being easily customizable for different materials.

Hydraulic presses not only generate massive amounts of force, but they are also silent - this is an invaluable benefit for companies as noise pollution can lead to worker discomfort and health concerns. Furthermore, hydraulic presses allow precise control over how much pressure is applied to workpieces - this precision can especially useful for companies required by government monitoring agencies to ensure employee safety.

Hydraulic presses operate using relatively straightforward mechanical principles: A hydraulic cylinder is installed inside of a large stationary frame to hold workpieces; then filled with hydraulic fluid using either an hydraulic lever or pump to apply pressure from an eccentric system that converts screw or piston movements to crank movements - which are then compressed against a baseplate or die to exert force that deforms them into their desired shapes.

Hydraulic presses can also be utilized in many other processes, including forging, clinching, molding and blanking. Their primary advantage lies in their ability to provide full pressing force across their entire stroke of application; enabling an operator to quickly change size or shape without waiting for the machine to finish the task.

When crafting dies for a hydraulic press, there are two general shapes you should choose from when designing them: non-conforming (also called silhouette dies) and conforming (sometimes known as converging or conforming dies). A silhouette die features one shape pressed into metal surface; conforming dies have mating positive and negative shapes arranged on their surfaces. When choosing either shape for your die, ensure the line of design you're drawing extends at least 1" around all four sides.

Materials

Hydraulic presses require intense pressure to shape metal. You can build one at home fairly easily if you don't mind having your neighbors mistakenly think you are creating works of metal art from old car parts. The key component for making such presses is their dies. Lexan, a high-density polycarbonate material, can be used to craft permanent reusable dies that can last. A less expensive and softer option would be urethane; to create one for reuse you'll need a model of what form you wish to produce first. Make the plate, part A, larger than its final form by at least 3/8-inches all around and drill a hole through it with either a saw or drill to create part B of your shape. Scribe a line around your shape, then carefully cut along it using a saw, making sure to maintain straight, perpendicular lines. The resultant plate, part B, will become your matrix. Punches for hydraulic presses can be created from reversible conforming dies. After placing it over both punch and piece of annealed metal, tape it to plate A using flexane as an intermediary layer. Reposition Plate A so that the punch can contact the matrix while sandwiching annealed metal between A and B plates, so as to keep its edges free from pressuring into corners of mold that could ruin final piece. This step ensures a successful casting experience!

Once the die is ready to use, spray both it and the metal with silicone lubricant for easier metal entry and exit from the die. A piece of hardwood should also be placed atop it so as to protect surfaces being shaped from marring caused by steel edges.

Conforming dies can be used to create small hollow forms and other sculptural forms with casual flowing qualities, providing an alternative to repoussage's sharp curves. They're also great for quickly creating complex forms without the surface detail that would come from carving.

Design

Hydraulic presses are heavy-duty machines designed to generate high pressure by pumping hydraulic fluid through two cylinders. A piston in one cylinder pushes this hydraulic fluid towards a larger one where its pressure deforms metal into desired shapes; this process can be used for making pellets for soil, water, or air testing, jewelry creation or components for bracelet links, bales and charms.

To create a conforming die, first create a model of the form you wish to produce out of plexiglass, wax, wood or plaster. Your model should be at least 3/8 inch larger all around than its final form so as to leave enough flange space and avoid crushing and tearing when forming metal; additionally it will give room for detailing or texturing by way of chasing techniques.

Once the model has been constructed, it should be sanded to smooth away rough edges before it can be sawed with a spiral saw blade to follow its form. When sawed off to size, save any part that was cut away as this will become your die and coat it in silicone or another release agent to maintain an optimal working environment for production.

Die modifications should have a flange that is 1/4 inch wider than its original model. A sheet of masonite or plexiglass makes an ideal bottom of the die, since they are durable materials that won't be marred by punches. Position the die so the punch sits centered in plate B with doublestick tape applied along its flange on both sides.

Install a pad of flexane on the lower platen and place the metal you wish to press onto it, followed by your die. Pump the arm of your hydraulic jack until the platen reaches your die, pressing down hard on flexane as necessary - once released, this will push metal into your die and create the desired form.

Assembly

Hydraulic presses are mechanical devices that utilize static pressure to shape, deform and configure materials like metals, rubber and plastics. Hydraulic presses come in different sizes and configurations ranging from tabletop models to massive floor presses that can apply hundreds of tons of force. Depending on the material being processed by these hydraulic presses they can also perform functions such as drawing, punching, embossing stamping and trimming operations.

To operate a hydraulic press, hydraulic fluid must be supplied at high pressure from a hydraulic pump. This pump connects to several cylinders; one large cylinder carries the ram that drives anvil and die, with smaller ones housing plungers forced down by larger cylinders to apply pressure onto anvil and drive ram. Hydraulic pressure created in system is balanced using control valves which regulate amount of fluid supplied to each cylinder as well as acting as safety overflow valves.

While most people may recognize a scrap baling hydraulic press for crushing cars and equipment, smaller hydraulic presses are also widely utilized in manufacturing settings - especially manufacturing that involves bearings, bolts, rivets, washers or struts production. A hydraulic press has become an invaluable tool in these environments as a vital way of shaping metal parts to size or design specifications as well as producing components like bearings bolts rivets washers or struts.

One of the key advantages of hydraulic presses is their ability to provide consistent pressure all throughout a stroke, helping ensure parts remain intact and improving overall quality. Furthermore, you can customize the pressure and stroke speed settings as necessary - further increasing efficiency and quality with each press.

Hydraulic presses aren't just great manufacturing equipment - they're also fantastic hobby and craft projects! Smaller versions of hydraulic presses are often used for jewelry scale projects such as pancake dies or impression dies; making pendants, earrings or rings with ease!