Cast Urethane Parts in Metal Forming
Metal forming facilities commonly find themselves in need of high-performance elastomers for use in their press systems. These facilities reach out to PSI Urethanes seeking cast urethane parts to replace and outperform less durable rubber components. Luckily, we have all the polyurethane expertise needed to improve production quality, reduce machine maintenance, and lower costs all with this incredibly versatile material. Polyurethane isn’t just an alternative material to rubber- in this case, it’s an upgrade.
Cast urethanes offer a wide host of benefits over other elastomers. In metal forming, urethane’s superior grip helps secure blank metal sheets from slipping during the pressing process. Urethanes also provide excellent scuff resistance- a crucial property to possess in a highly abrasive process that still requires high precision. Lastly, a unique quality that gives polyurethane a distinct advantage in metal forming is its ability to bond to a metal substrate. So long as the surface can be sanded or grit blasted to facilitate better adhesion, a polyurethane pad can be bonded to metal forming tubs and presses as a protective or sacrificial layer.
Urethane Pads in Metal Forming
A polyurethane pad or sheet is one of the most useful urethane tools in metal forming. These pads are used as overlays for all kinds of presses which force metal sheets into molded dies to give them their desired shape. Mechanical presses, hydraulic presses, servo presses- all of these can benefit from a protective polyurethane cover to extend their longevity.
For metal forming applications, urethanes in the 70A – 90A or 50D durometer range are typically preferred for their hardness, tear resistance, and shock absorption. They are soft enough to allow force to be evenly distributed across the surface of the metal as it is being shaped, but not so soft that they might become damaged under pressure.
While other materials easily deform and even fail under these high pressures, urethane has a high rebound which allows it to maintain its shape for far longer than other easily deformed elastomers. In the event that a polyurethane pad does sustain damage, the material has self-healing properties that allow it to withstand and recover from incredible wear. With all of this in mind, a polyurethane metal forming sheet is by far the best way to protect your metal press.
Invest in the longevity of your metal forming presses with polyurethane pads for unrivaled protection.
Contact PSI Urethanes today.
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Urethane Overlays for Fluid Cell Remold
Fluid cell presses are high precision cold metal forming systems, typically used to make parts for the aerospace industry. The fluid forming process allows for high throughput volume of intricately designed metal parts while still maintaining the highest possible quality.
Polyurethane components play a key role in a successful fluid cell system, especially polyurethane pads. A cylindrical steel housing holds a soft polyurethane pad in place. Hydraulic fluid fills the housing and makes the polyurethane expand similarly to a balloon. This allows the pad to evenly apply pressure from the hydraulic fluid across an entire sheet of metal. In doing so, the metal sheet is shaped exactly to the stationary tool underneath and the desired part is quickly formed.
Urethane is a crucial material in this application due to its ability to withstand these extremely high forming pressures as it inflates. Its high rebound also plays an integral role here since the pad must be able to return to its original shape to ensure consistent quality between presses.
As with other applications, polyurethane parts are also frequently used in place of rubber parts due to their longevity. Throw pads are also commonly used to reduce wear on a press’ internal elastomer components- all of which can be upgraded to polyurethane as well.
Custom Polyurethanes in Metal Forming
While PSI Urethanes has a wide selection of readily available polyurethane formulations, we know that some unique projects require specially formulated solutions. Custom formulation of urethanes is our specialty, so we always welcome the chance to provide an elastomer solution that delivers on performance.
Custom urethane formulations are great for metal forming processes that use particularly thick or thin sheet metal blanks. The thinner that a metal sheet is, the more likely it is to be damaged or even broken by a press if the durometer of the urethane pad is too hard. For your thinnest sheet metal forming presses, PSI can formulate a urethane that is the appropriate durometer while also maintaining desirable qualities like tear strength and rebound.
We can even incorporate multi layered urethane pads in your operations. A softer outer layer will allow for the press to more securely keep the sheet metal in place once they come into contact with each other, thanks to a higher coefficient of friction. If you choose to make each layer a contrasting color, the pad can also serve as its own wear indicator so you can keep an eye on when it’s time to be replaced.
Need a custom urethane formulation to enhance your metal forming press?
Contact PSI Urethanes today to learn more!
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About PSI Urethanes
Since 1966, through our own independent research and activity in the Polyurethane Manufacturers Association, PSI Urethanes has stayed on the leading edge of urethane technology – including developing advances in new materials, comprehensive designs, and processing technologies. Today we are among the most respected and trusted suppliers of custom polyurethane products.
We operate from our 45,000-square-foot manufacturing facility in Austin, Texas, which houses an extensive stock of polyurethane products. Our fully equipped manufacturing facility includes a versatile range of processing machinery, which allows us to work on unique, one-of-a-kind projects, as well as high volume components. Our in-house engineering, tooling, and custom mold shop, produces custom and stock production orders with exceptionally fast turn-around times. From conception to prototyping, to final production runs, our technical representatives and design engineers will work closely with your staff to meet your critical tolerances and specifications. You are guaranteed to receive experienced, professional, and personalized service from the first contact through your on-time delivery, with complete confidentiality and dedication to protecting your good name.