Revista de Ciencias Tecnológicas (RECIT). Volumen 3 (1): 10-22

Revista de Ciencias Tecnológicas (RECIT). Universidad Autónoma de Baja California ISSN 2594-1925

Volumen 6 (4): e326. Octubre-Diciembre. 2023. https://doi.org/10.37636/recit.v6n4e326

ISSN 2594-1925

Research article

Adjust operating conditions of an in-made house

horizontal hydraulic press for a 90° cold bending process

Ajustar las condiciones de operación de una prensa hidráulica horizontal de

fabricación propia para un proceso de doblado en frío a 90°

Hugo Estrada Pimentel1, Hugo Arcos Gutiérrez2, José Antonio Betancourt Cantera3, Jan

Mayen2, John Edison García Herrera2*

1POSGRADO-CIATEQ A.C. Centro de Tecnología Avanzada, Circuito de la Industria Poniente Lote 11,

Manzana 3, No. 11, Col. Parque Industrial Ex hacienda Doña Rosa, Lerma, Estado de México. C.P. 52004.

2CONAHCYT-CIATEQ A.C. Centro de Tecnología Avanzada, Eje 126 No.225, Industrial San Luis, San Luis

Potosí 78395, México.

3CONAHCYT-COMIMSA, Corporación Mexicana de Investigación en Materiales, Ciencia y Tecnología No.

790, Col. Saltillo 400, 25290 Saltillo, Coahuila, México.

Corresponding author: John Edison García-Herrera, CONAHCYT-CIATEQ A.C. Centro de Tecnología

Avanzada, Eje 126 No.225, Industrial San Luis, San Luis Potosí 78395, México. E-mail:

john.garcia@ciateq.mx. ORCID: 0000-0001-5842-1658.

Received: September 6, 2023 Accepted: November 27, 2023 Published: December 1, 2023

Abstract. - During the cold-bending process, the tooling suffers considerable damage due to excess pressure.

This also causes the machines to break down, causing problems in the precision and quality of the metal parts

formed. The precision depends on the operating conditions of the press, the tooling employed, and the elastic

recovery effect of the material. This study determines the working conditions for a made-in-house horizontal

hydraulic press through an experimental design (DOE). This research carried out the V-forming to 90° (ISO

2768-1) of a hot-rolled carbon steel plate, considering pressure, piston permanence time, and recovery factor

(Kr). The experimental and statistical analysis ensures accurate forming while the work pressure decreases

by 17% and 33%, respectively, regarding the maximum. This reduction will delay the appearance of fatigue

damage and have the operating parameters well established; in turn, it will be possible to design tools

according to commercial standards.

Keywords: Cold forming; DOE ANOVA; Recovery factor (Kr); Factorial analysis 2k; Spring back (SB).

Resumen. - Durante el proceso de conformado en frío, las herramientas sufren daños considerables debido

al exceso de presión. Esto también causa que las máquinas se rompan, causando problemas en la precisión y

calidad de las piezas metálicas formadas. La precisión depende de las condiciones de funcionamiento de la

prensa, las herramientas empleadas y el efecto elástico de recuperación del material. Este estudio determina

las condiciones de trabajo de una prensa hidráulica horizontal fabricado en casa a través de un diseño

experimental (DOE). Esta investigación llevó a cabo el conformado en V a 90° (ISO 2768-1) de una placa de

acero al carbono laminada en caliente, teniendo en cuenta la presión, el tiempo de permanencia del pistón y

el factor de recuperación (Kr). El análisis experimental y estadístico asegura un conformado preciso, mientras

que la presión de trabajo disminuyó en un 17% y 33%, respectivamente, con respecto al máximo. Esta

reducción retrasará la aparición de daños por fatiga y tendrá los parámetros de funcionamiento bien

establecidos; con estos, a su vez, será posible diseñar herramientas de acuerdo con los estándares

comerciales.

Palabras clave: Conformado en frío; DOE ANOVA; Factor de recuperación (Kr); Análisis factorial 2k;

Recuperación elástica (SB).

Revista de Ciencias Tecnológicas (RECIT). Volumen 6 (4): e326.

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1. Introduction

Cold forming or forging is a highly efficient

process for shaping material profiles. A metal

plate is creatively deformed within a tooling

using a press at room temperature [1-3].

Predicting and controlling elastic recovery (SB,

spring back) during bending processes is one of

the principal challenges as it depends not only on

the bending process parameters but also on the

raw material's inherent characteristics and

processing [4-8].

Additionally, reducing scrap in die development

poses a complex challenge of full importance to

tooling designers. [9-14]. Failing to achieve this

objective can result in significant issues during

part assembly, thus generating additional

expenses for tooling adjustments. If recovery

cannot be accurately predicted, one must

repeatedly attempt to obtain the proper

conditions to compensate for the SB [15-18].

In the case of products manufactured using a cold

bending process, the standards for quality,

specifications, and tolerances tend to be quite

stringent. [19, 20], as they are cross-industry

[3,21-23]. The performance and dimensional

quality of these products can be influenced by

various factors, including but not limited to wear

and tear of tooling, environmental conditions,

production process, and service life [24-27].

When manufacturing, carefully considering the

hydraulic press's operating conditions is crucial.

Precision operations during the bending process

are indispensable factors to keep in mind,

particularly regarding the pressing form and

method [28-30]. Excessive load is often the cause

of premature damage to pre-forming tooling or

dies, despite their ability to withstand high levels

of stress and wear due to their design. Despite

being classified as perishable tooling, they are

engineered to resist fatigue and friction contact

[1, 31-34].

This research aims to establish a precedent for

operating an in-made house horizontal hydraulic

press and to acquire a deeper understanding of

achieving the best possible conditions for

effectively making bends, precisely 90° or V-

bends hot-rolled carbon steel plate. It is crucial to

optimize the press's performance, ensuring that it

operates with maximum efficiency while

avoiding exceeding the maximum pressure limit

of 3000 psi. Furthermore, we must consider the

necessary compensation for spring-back to

prevent deviations from the desired

specifications and maintain precise geometrical

tolerances. Maintaining a deviation of no more

than 1° from the nominal angle during the

bending process is crucial. This guarantees the

final component's quality and subsequent

procedures success. To prevent any deviations in

future processes and ensure the smooth operation

of the finished piece, it is essential to compensate

for spring-back adequately.

2. Materials and experimental details

The bending process was carried out at a 90°

angle of plate 6.963*2* ¾ inches (large, width,

and thick) hot-rolled carbon steel (by ASTM A-

36). The bending procedure was performed by

the method outlined in the reference [35] and

illustrated in Figure 1.

1. Material preparation: ensure the plate has

the correct dimensions and strength to withstand

the V-bending process.

2. Bending tool selection: select the

appropriate V-bending tool for the size and

thickness of the material to be bent. The bending

tool can be a bending die or a bending press.

3. Material positioning: place the plate on

the bending tool, ensuring that the bending line is

aligned with the V-shaped line of the die. As

shown in Figure 1 a).

4. Bending tool adjustment: It is necessary

to adjust the bending tool to achieve accurate

Revista de Ciencias Tecnológicas (RECIT). Volumen 6 (4): e326.

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bending and proper bending force. Setting the

tooling to apply the required bending force and

accomplish the correct bending angle is essential.

5. Bending: To bend the workpiece

accurately along the V-line shown in Figures 1 b)

and 1 c), the bending tool must be precisely

actuated to apply the required force.

6. Results verification: verify that the angle

and quality of the bend are adequate, as shown in

Figure 1 d).

Figure 1. The Manufacturing process of the arm for pendants by bending: a) Positioning, b) Bending, c) Piston retraction, d)

Manufactured part.

The process above was done at Martin Sprocket

& Gear Inc., a specialized company that

manufactures helical worm equipment for the

transporting and handling bulk materials. This

equipment is highly prevalent in various

industries, including food, mining, agriculture,

and pharmaceuticals, where they function as

mixers, dozers, elevators, or agitators based on

the worm principle. Figure 2 displays the purpose

of the sub-assemblies to prevent the helical

element from deflecting, thus reducing friction

between the component and the main housing.

Such a sub-assembly carries two pieces called

arms or pendants, obtained by cold bending.

Figure 2. Schematic representation of the function of support manufactured for a helical conveyor.

A 2k factorial experiment design was conducted

to determine the press operating conditions

necessary for obtaining a 90° bending (Fig. 1 c).

The variables in this DOE were the press pressure

and the time of the pressure permanence before

the piston recoil. Each variable had four levels

(k=4). In Figure 3, the variables are summarized

in the diagram.

Revista de Ciencias Tecnológicas (RECIT). Volumen 6 (4): e326.

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Figure 3. Schematic of the tests.

The pressure applied to a material is the principal

factor defining its deformability. Hence, the

pressure was considered one of the controlling

variables during the testing process; this

experimental analysis was done under four levels

in descending order from 3000 to 1500 psi with

500 psi steps. The second factor was the

permanence time before the piston retraction,

while the pressure was maintained to compensate

for the SB. Likewise, four levels were tested in a

permanence time, from 0 to 1.5 seconds with 0.5

seconds’ step. From the above, we have 24=16,

and two tests were made for each case of

experimentation, giving a total of 32 tests.

For each test, the angle after the bend was

measured with a Wixey digital goniometer,

model WR300 Type 2, as seen in Figure 4. The

measurements were utilized to compute the

deviation from the nominal angle, as the

objective is to achieve a bent workpiece with a

90° angle. The statistical analysis of the data was

performed by ANOVA using NCSS statistical

software (NCSS 2021, statistical software,

Kaysville, Utah, USA). This analysis considered

a confidence level of 95%, with a type of bilateral

interval.

Figure 4. Angle measurements in pieces subjected to the bending process.

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3. Results and Discussions

Table 1 shows the angles obtained after

subjecting each plate to bending. It is important

to remark that variables such as pressure and

permanence time before the piston retraction

were considered during the process.

Table 1. Value of angles measured for each experimental condition.

PRESSURE

(psi)

PERMANENCE TIME DURING THE PRESSURE

t1= 0 s

t2= 0.5 s

t3= 1 s

t4= 1.5 s

P1 = 3000

89.3

89.5

89.9

89.8

89.7

P2 = 2500

89.6

89.4

90.2

89.9

90.5

90.4

90.1

P3 = 2000

89.4

89.7

90.3

89.8

90.3

89.8

90.3

90.1

P4 = 1500

89.3

89.4

89.3

89.5

89.4

89.3

To quantify the recovery in the plate, the

recovery factor Kr was calculated by the

following ratio [36]:

Kr=βfβi

⁄ (1)

Where:

βi is the value of the bending angle with load

applied, which for the case study is 90°.

βf is the resulting angle after removing the load

(shown in Table 1).

The Kr values obtained are presented in Table 2;

in this case, Kr values close to 1 imply an absence

of elastic recovery, resulting in SB approaching

zero. In contrast, if SB values move away from

zero, there is an increase in the recovery effect.

Table 2. Recovery factor Kr.

PRESSURE

(psi)

PERMANENCE TIME OF THE PRESSURE

t1= 0 s

t2= 0.5 s

t3= 1 s

t4= 1.5 s

P1 = 3000

0.992

0.994

0.999

0.998

0.997

P2 = 2500

0.996

0.993

1.002

0.999

1.006

1.004

1.001

P3 = 2000

0.993

0.997

1.003

0.998

1.003

0.998

1.003

1.001

P4 = 1500

0.992

0.989

0.993

0.992

0.994

0.993

0.992

Figure 5 shows the values corresponding to the

factor Kr. According to the confidence level

established at 95%, the data show remarkable

adherence to the normal distribution line, thus

indicating an approximately normal distribution.

Settings are evenly distributed above and below

zero. Since the value p exceeds the limit of 0.05,

as can be seen in Table 3, it can be concluded

with statistical certainty that the data exhibit a

normal distribution. Therefore, the results are

statistically significant for further analysis.

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Figure 5. Normal test with p-value > 0.05.

Table 3. Normality test results.

Normality Test

Prob. Level

Decision

Shapiro-Wilk W

0.1325

Can´t reject normality

Anderson-Darling

0.0958

D'Agostino Skewness

0.6559

D'Agostino Kurtosis

0.1084

D'Agostino Omnibus

0.2495

The results of the variance analysis (ANOVA), a

statistical technique employed to detect

significant discrepancies between the averages of

two or more groups, are shown in Table 4. This

study examined two primary factors: pressure

and time, as previously mentioned.

Table 4. Statistical values (Analysis of Variance).

The analysis reveals that the pressure has a

significantly high F-ratio value of 31.69. In

ANOVA, the F ratio compares the systematic

Variance resulting from the tested factors against

the random Variance, which stems from

unexplained variations. A higher F-value

indicates a higher probability that group

differences are systematic rather than random.

Figure 6 displays a chart depicting the effect of

the control factors (pressure and time) on the

response variable (Kr value) through a

presentation of the main effects. This graphical

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representation visualizes how each factor

impacts the system's response.

Achieving a Kr value of 1 during the bending

process is crucial because it signifies that the

part's appropriate and final bending angles are a

perfect match. A Kr value of 1 indicates that the

component has been bent precisely to the desired

angle, thereby minimizing any discrepancies that

may compromise the quality of the end product.

In Figure 6 a), it can be observed that Kr reaches

minimum deviation with a value of 0.9995,

which is close to the ideal value of 1 when the

pressure is at 2000 psi. This result suggests that

pressure has a significant impact on bending

accuracy.

Figure 6 b) represents the value of Kr as a

function of the permanence time of the load

(pressure). Notably, a permanence time of 1

second before piston retraction also produces a

minimum deviation of Kr, reaching a value of

0.99963. This observation indicates that time is

another crucial factor that can optimize bending

accuracy.

Figure 6. Plots of the main effects: a) recovery factor as a function of pressure and b) recovery factor as a function of time.

The data in these graphs indicate that the most

precise bending can be achieved by combining

2000 psi pressure and 1 second time. It's

important to comment that these values might

fluctuate due to other factors, like the material

type and machine specifications. Therefore, it is

always recommended to perform additional

experiments and fine adjustments to optimize the

bending process in each case.

Considering the variance analysis presented in

Table 4, which indicates that pressure is the most

significant factor, Figure 7 a) displays the

interactive effect of the control variables by

illustrating the Kr behavior based on the pressure

function. In the graph, there are three conditions

for which Kr is very close to 1, for a pressure of

2000 psi with a time of 0.5 and 1 s, and at 2500

psi at 0.5 s. These three conditions are confirmed

as observed in the surface response graph shown

in Figure 7 b).

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Figure 7. Interaction’s plot: a) Kr as a function of pressure, and b) surface plot.

Figure 8 shows a comparative box plot of two

process variables to ascertain the most favorable

combinations to produce optimally formed parts.

Upon examining Figure 8 a), it can be inferred

that the conditions most conducive for attaining

an optimal Kr value of 1 lie between 2000 and

2500 psi. The data underscores this inference by

showing a median Kr value of less than 1 at 2000

psi and a value exceeding 1 at 2500 psi.

Consequently, these two pressure points

represent the highest probability of achieving the

ideal Kr value. Notably, the 2000 psi condition

exhibits a normal distribution slightly more

centralized than that at 2500 psi.

On the other hand, Figure 8 b) provides a

chronological plot of Kr values. Notable

observations at the timestamps of 0.5, 1, and 1.5

seconds reveal a certain reproducibility level

where Kr is proximate to 1. A wider distribution

around the 1 s mark contrasts with the 0.5 s mark.

Yet, most results cluster around a Kr value of 1,

rendering 1 s a suitable choice. The 1.5 s

condition, however, does not seem to represent

the desired outcomes and would lead to an

increased cycle time in the process.

Figure 8. Box plot for a) Kr as a function of pressure and b) Kr as a function of time.

The results show that the two reliable

combinations are 2000 psi/1 s and 2500 psi/0.5 s. By selecting these sets of parameters as optimal

and accounting for any deviations from the

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desired 90º angle, we can guarantee the ability to

achieve bending with a ±0º 20' tolerance,

categorized as type C according to ISO 2768's

(International Organization for Standardization

(1989), ISO 2768-1: General Tolerances:

Tolerances for Linear and Angular Dimensions

Without Individual Tolerance Indications). It

should be noted that such tolerance is lower than

required in the plane (±1º) for the part

manufacturing. Furthermore, applying 2000 and

2500 psi pressures would lead to a remarkable

16.66% and 33.33% reduction in the press

operating pressure, respectively. It is worth

highlighting that, for the bending process, the

adjustment of the press is not the only parameter

that influences the final angle obtained; other

variables affect the final result, such as the

punch's radius, the material, the thickness, and

the mechanical behavior during the deformation

process, among others [4, 9, 10, 12]. However,

the objective of this work focused on obtaining

the appropriate dam operating conditions, and the

expected result of this improvement is an

increase in the durability of components

subjected to friction, reducing their wear and

minimizing the probability of fatigue failure in

mechanical elements [26]. It is also expected that

the temperature levels in the hydraulic unit are

below the critical level to avoid overheating and

the adverse effects it generates.

4. Conclusions

The findings of this study illustrate the viability

of producing a 90º bend in a hot-rolled carbon

steel plate (ASTM A-36) with dimensions of 2

inches in width, 3/4 inches in thickness, and

6.963 inches in length, utilizing an in-house

fabricated press.

Effective bending can be achieved by either

applying a pressure of 2000 psi with a dwell time

of 1 s before retracting the piston or utilizing a

pressure of 2500 psi with a waiting period of 0.5

s. These operational conditions comply with the

tolerance specified for type C in ISO 2768-1.

The applied pressures represent a decrease of

17% and 33%, respectively, about the maximum

pressure employed. These reductions are

anticipated to enhance the lifespan of tools,

pistons, and dies due to decreased wear and

fatigue. Moreover, the established operating

parameters facilitate the creation of a tool design

that aligns with commercially available matrices.

Another practical implication of these

operational parameters is the expectation that

temperature levels in the hydraulic unit will not

reach critical thresholds, thereby mitigating risks

associated with overheating. The importance of

thoroughly validating these final considerations

cannot be overstated. However, it's worth

highlighting that these analyses, while of

potential interest, were deemed tangential to the

study's primary objective and were not included

within its scope.

5. Acknowledgements

The authors would like to thank Martin Sprocket

& Gear Inc. for allowing the use of their facilities

to perform this work. The authors also

acknowledge the CONAHCYT (Consejo

Nacional de Humanidades, Ciencias y

Tecnologías-México) for the support through the

Investigadores Por México program, projects

850 and 674.

6.- Authorship acknowledgement

Hugo Estrada: Conceptualization; methodology;

validation; writing; revision; project

administration; software; investigation; display;

draft writing; reviewing and editing. Hugo

Arcos: Conceptualization; methodology;

validation; writing; revision; simulation;

software; reviewing. José A. Betancourt:

Supervision; methodology; validation; writing;

revision; draft writing: writing reviewing and

editing. Jan Mayen: Supervision; methodology;

validation; writing; revision; formal analysis.

John E. García: Conceptualization; supervision;

Revista de Ciencias Tecnológicas (RECIT). Volumen 6 (4): e326. 
 
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methodology;  validation;  writing;  revision; 
project  management;  formal  analysis,  draft 
writing: writing reviewing and editing. 
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