Application examples

The picture above shows a longitudinal floor beam from a light goods vehicle 

BEAM FORMING TO TWO DIFFERENT DEPTHS.
Problem: Forming of beams with multiple depths.
Solution: KALLER Controllable gas springs.

 

 

THE PROCEDURE:
The upper part of the tool descends and activates the blank holder, which provides the blank holding force during the forming operation.
Around the halfway stage, the forming of the shallower sections of the beam begins, using the force provided by underlying KALLER Controllable gas springs. When these springs become fully compressed they are subsequently locked in position.This way, the beam is not deformed when the upper part of the tool is lifted away by the press.
When the upper part of the tool reaches its top position, the KALLER Controllable gas springs are reactivated thus helping to lift out the part from the die.


FRONT FENDER FORMING IN A SINGLE OPERATION.
Problem: Sheet forming in a single operation as opposed to two.
Solution: KALLER Controllable gas springs.


The picture above shows a front fender being formed with the help from KALLER
Controllable gas springs.

THE PROCEDURE:
The upper part of the tool descends and activates the blank holder, which holds the blank in position during the forming operation.
When the KALLER Controllable gas springs are fully compressed they are subsequently locked in position. For this application, a system using "positive lock down" is required. Here the piston rod is drawn inward when the locking function is activated.This ensures the front fender is not deformed in any way when the upper part of the tool is lifted away by the press.

When the upper part of the tool reaches its top position, the KALLER Controllable gas springs are reactivated thus helping to eject the part from the die.