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13th International Conference on Tribology, ROTRIB’16 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 174 (2017) 012006 doi:10.1088/1757-899X/174/1/012006

Dynamic analysis of six-bar mechanical press for deep

drawing

S Mitsi, I Tsiafis and K D Bouzakis

Laboratory for Machine Tools and Manufacturing Engineering, Mechanical
Engineering Department, Aristotle University, University Campus, 54124
Thessaloniki, Greece

E-mail: [email protected]

Abstract. This paper analyzes the dynamical behavior of a six-bar linkage used in mechanical
presses for metal forming such as deep drawing. In the under study mechanism, a four-bar
linkage is connected to a slider through an articulated binary link. The motion of the six-bar
linkage is studied by kinematic analysis developing an analytical method. Furthermore, using
an iterative method and d’ Alembert’s principle, the joint forces and drive moment are
evaluated considering joint frictions. The simulation results obtained with a MATLAB
program are validated by comparing the theoretical values of the input moment with the ones
obtained from the conservation of energy law.

1. Introduction
The mechanical press is widely employed for metal-forming processes. Many different types of
linkage drives have been proposed to satisfy the load – stroke characteristics for the specific metal-
forming process. The metal forming operations like shearing requires very short stroke of the ram and
deep drawing requires a slow and long stroke of the punch. Yan and Chen [1, 2] proposed the novel
approach of varying the input speed such that the ram’s motion was suitable for both deep-drawing
and precision-cutting processes. Hsieh and Tsai [3] developed a novel press system with six links for
precision deep drawing so that can generate complicated and flexible output motion. Soong [4]
proposed a new design method for single DOF mechanical press with variable speeds and length-
adjustable driving links. Yossifon and Shivpuri [5] investigated the design, analysis and construction
of a double knuckle press for precision forming driven by a servo motor. The dynamic analysis of the
double-toggle press, performed in [6], included the evaluation of bearing forces and the required input
torque without considering joint friction. Tso and Liang [7] proposed a nine-bar linkage for
mechanical presses in order to obtain slow forming speed and a long period of dwell time in the
bottom of the ram stroke. The dynamic analysis and simulation of a hybrid-driven two-degrees-of-
freedom seven-bar press using Lagrangian’s formulation have been developed by Li and Zhang [8].
The force analysis of a six-linkage used in mechanical presses for metal forming such as coining and
blanking, considering joint frictions is presented in [9].
In the present paper the dynamic analysis of a six-bar linkage for mechanical press used for the
deep drawing, is investigated. First, the kinematic analysis, dealing with the displacement, velocity
and acceleration of the mechanism links, is performed. Then, the force analysis, taking into account
the external force and joint frictions, is presented.

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13th International Conference on Tribology, ROTRIB’16 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 174 (2017) 012006 doi:10.1088/1757-899X/174/1/012006

2. Kinematic analysis of six-bar linkage

The investigated mechanical press contains a six-bar linkage (figure 1). An electrical motor provides
the input torque to the crank through a gears transmission. The six-bar linkage is composed of the
A0ABB0 four-bar linkage connected to the slider through the articulated binary link CD. Structural,
this mechanism includes the frame 0, the input link 1 and the second-class Assur group RRR (links 2
and 3) connected to the second-class Assur group RRP (links 4 and 5) through the revolute joint C,
where R denotes a revolute pair and P a prismatic pair. The joints A0 and B0 are fixed and the input
link 1 rotates with a constant known angular velocity ω10. Also the link lengths l0=A0B0, l1=A0A,
l2=AB, lAC=AC, l3=B0B, l4=CD and the distance a are given.

Figure 1. Kinematic model of six-bar mechanical press.

The equations for kinematic analysis are written and solved considering a Cartesian coordinate
system, with origin the joint A0. The mechanism has two independent closed contours A0ABB0A0 and
A0ACDEA0. Every link length and slider displacement (from a convenient reference point E) are
represented by suitable planar vectors. The vector equation corresponding to each above independent
closed loop is:
For closed contour A0ABB0A0:
l1  l2  l3  l0  0 (1)
and for closed contour A0ACDEA0:
l1  l 2  l 4  s D  a  0
(2)
The vector equations (1) and (2) are projected on the Cartesian reference system. It is obtained:
l1cos10  l2 cos20  l3 cos30  0 (3)
l1 sin10  l2 sin20  l3 sin30  l0  0 (4)
l1cos10  l AC cos20  l4 cos 40  a  0 (5)
l1 sin10  lAC sin20  l4 sin40  sD  0 (6)
Equations (3) and (4) constitute a set of two nonlinear equations in two unknowns, namely φ20 and
φ30. To determine the angle φ20, the equations (3) and (4) are rearranged as:
l3 cos30  l1cos10  l2 cos20 (7)

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13th International Conference on Tribology, ROTRIB’16 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 174 (2017) 012006 doi:10.1088/1757-899X/174/1/012006

l3 sin30  l1 sin10  l2 sin20  l0 (8)

Squaring the equations (7) and (8) and adding them, the following equation is obtained:
A cos20   sin20  C (9)
where:
A  -2l1l2 cos 10
  2  l0  l1 sin10  l2

C  l2 2  l32  l12 cos 2 10  l0  l1 sin10 

2
(10)
Equation (9) has the solutions [9]:
20  atan (C /(  A2  B2  C 2  )  atan  A/ B 
1/ 2
(11)
The double sign “±” in equation (11) corresponds to the two different assembly modes of RRR
Assur group.
The angle φ30 is obtained using a similar procedure eliminating the angle φ20 from equations (3) and
(4).
For each value of the angle φ20, using equation (5), the angle φ40 is determined [9]:
40  atan ( 1  D2 
1/ 2
/ D) (12)
with D   a  l1cos10  l AC cos 20 / l4 . The double sign “±” in equation (12) corresponds to the
two different assembly modes of RRP Assur group.
Finally, once φ20 and φ40 are known, from equation (6) the slider displacement sD is obtained:
sD  l1 sin10  lAC sin20  l4 sin40 (13)
It has been mentioned that from the four configurations of the six-bar linkage, the one that
corresponds to the working specifications of the mechanical press is chosen.
The results of displacement analysis are used for velocity analysis. Differentiating equations (3)
and (4) with respect to time and after rearranging terms it is obtained a set of two linear equations in
the unknown angular velocities ω20 and ω30. By solving this system the unknown velocities are
determined as [9]:
20   10 l1 sin  10  30  /  l2 sin  30  20   (14)
30   10 l1 sin  20  10  /  l3 sin  30  20   (15)
where i0  d i0/ dt  i  1, 2, 3 .
Differentiating equation (5) with respect to time, a linear equation in unknown angular velocity ω40
is obtained and the solution is:
40   l110 sin10 – lAC 20 sin20 /  l4 sin40  (16)
The slider velocity vD is determined by solving the linear equation obtained by differentiating
equation (6) with respect to time:
vD  l110 cos10 – l AC 20 cos20  l4 40 cos40 (17)
Acceleration analysis is performed by differentiating the equations derived in velocity analysis with
respect to time. From the obtained equations are determined the angular accelerations ε 20, ε30, ε40 and
the slider acceleration aD:
 20   1cos30  B1 sin30 /  l2 sin 30  20   (18)
 30    A1cos20  B1 sin20 /  l3 sin 30  20   (19)
 40   axC  l440 2 cos40 /  l4 sin40  (20)

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13th International Conference on Tribology, ROTRIB’16 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 174 (2017) 012006 doi:10.1088/1757-899X/174/1/012006

aD  ayC  l4 40 cos40  l440 2 sin40 (21)

where:
1  l110 2 cos10  l220 2 cos20  l330 2 cos30
1  l110 2 sin10  l220 2 sin20  l330 2 sin30
axC  l110 2 cos10  l AC  20 sin20  l AC 20 2 cos20
a yC  l110 2 sin10  l AC  20 cos20  l AC 20 2 sin20
The results of kinematic analysis are furthermore used to calculate the accelerations of the link
mass centers needed to perform the kinetostatic analysis of the mechanism.

3. Forces analysis
The kinetostatic force analysis takes into account the inertia forces and moments imposed on the links
and the joint friction forces considering known the ram force Fext. The ram external force is opposed to
the motion of the link 5. The friction losses are due to the sliding friction at the contact area between
the ram 5 and the frame and the friction moment in revolute joints. In the calculation of friction forces
and moments, the joint reaction forces, the characteristic property of the joint materials in contact and
the relative velocities are considered.
The determination of the joint reaction forces and the input moment is performed using an iterative
procedure [9]. After kinematic analysis, the joint reaction forces and the input moment are calculated
without friction. At the solution step m+1 of the iterative procedure, friction forces and moments are
assumed to be external loads that have been defined during the determination of the joint reaction
forces at the previous iteration step m. The iterative procedure converges when the difference between
two successive values of the obtained joint reaction forces is smaller than a prescribed criterion ε that
indicates the desired accuracy of the calculation. The solution converges rapidly due to the low values
of the friction forces and moments.
Due to decupled structure of the mechanism, the equations for the force
analysis are written and solved separately for each Assur group (dyad) and
input link 1 considering D’ Alembert principle. In each link k, the inertia
force Fink (k=1,n, n=links number) is assumed to act at the mass center Ck and
an inertia moment Mink is added.
The dynamic analysis starts with the RRP (4, 5) dyad because the external
force Fext is known. Figure 2 shows the forces and the moments that act on
the RRP (4, 5) dyad. The unknown joint reaction forces are F45= - F54, F05
and F24. The joint reaction F05 is perpendicular to the sliding direction of the
ram 5. To calculate the reactions forces, a force equation for links 4 and 5
and a moment equation on link 4 are written.
The vector sum of all the forces that act on the links 4 and 5 is zero:
( 4, 5 )  ΣF  F24  G4  G5  Fin4  Fin5  Fext  F05  0 (22)
and the vector sum of all the moments on link 4 about D is zero:
4   M D  rDC  F24  rDC 4  ( G4  Fin4 )  Min4  0 (23)
where G4 and G5 are gravitational forces of links 4 and 5 respectively. The
vectorial equations (22) and (23) give three scalar equations on x, y and z,
that form a linear system of three equations with three scalar unknowns F 24x,
F24y and F05x. For solving this system of equations the MATLAB program is
used. The joint reaction force F45 is calculated from the force equation for
link 5:
Figure 2. RRP (4, 5) 5 –  F  F45  Fin5  G5  Fext  F05  0 (24)
dyad forces. The application point of the reaction force F05, calculated from a moment
equation about D for link 5, is at D.

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13th International Conference on Tribology, ROTRIB’16 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 174 (2017) 012006 doi:10.1088/1757-899X/174/1/012006

Figure 3 shows the forces and the moments that act on the RRR (2, 3) dyad. The unknown joint
reaction forces are F03, F32 and F12. The joint force F42 = - F24 was calculated from the previous RRP
(4, 5) dyad.

Figure 3. D’ Alembert principle for RRR (2, 3) dyad.

The vector sum of all the forces that act on links 2 and 3 is zero:
( 2, 3 )  ΣF  F12  F42  G2  G3  Fin2  Fin3  F03  0 (25)
The vector sum of all the moments on link 2 about B is zero:
2   M B  rBA  F12  rBC 2  ( G2  Fin2 ) + rBC  F42  Min2  0 (26)
and the vector sum of all the moments on link 3 about B is zero:
3   M B  rBB0  F03  rBC 3  ( G3  Fin3 )  Min3  0 (27)
The vectorial equation (25) gives two scalar equations on x and y and equations (26) and (27) give
one scalar equation on z, that form a linear system of four equations with four scalar unknowns F03x,
F03y, F12x and F12y. For solving this system of equations the MATLAB program is used.
The joint reaction force F32 is calculated from the force equation for link 2:
2 –  F  F12  Fin2  G2  F42  F32  0 (28)
The force analysis without friction ends with the input link 1. Figure 4 shows the forces and
moments that act on the input link. The unknowns are the joint reaction force F01 and the input
moment (motor moment) Mmot. The joint force F21 = - F12 was calculated from the previous dyad
RRR.

Figure 4. D’ Alembert principle for input link 1.

The joint reaction force F01 is calculated from the force equation for link 1:

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13th International Conference on Tribology, ROTRIB’16 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 174 (2017) 012006 doi:10.1088/1757-899X/174/1/012006

1 –  F  F01  Fin1  G1  F21  0 (29)

and the input moment Mmot is determined from the equation of moments with respect A0:
1   M A0  Mmot  rA0 A  F21  rA0C 1  ( G1  Fin1 )  Min1  0 (30)
The joint reaction forces without friction are used furthermore in the first step of the iterative procedure to
analyze the forces considering the joint frictions. At the solution step m+1 of the iterative procedure,
friction forces and moments are calculated with the aid of reaction forces Fijm determined at the step m.
The friction moment Mfijm+1 at the revolute joint ij, opposed to relative angular velocity ωji, is:
M mfij 1  sign (  ji )  rij Fijm  i, j  0,  , 5  (31)
and the friction force Ff05m+1at the prismatic joint D is:
Ffm05 1  sign  v50   F05m (32)
where μ is friction coefficient and rij is joint shaft radius.
These friction moments and friction force, considered to be external loads, are introduced in the
corresponding equations of the method above described to calculate the joint reaction forces and input
moment at step m+1.

4. Numerical application
The above equations have been implemented in a computer program using MATLAB software to
generate the simulation presented throughout the paper. The main dimensions of the six-bar linkage
(figure 1) used for kinematic analysis are inserted in table 1. These dimensions have been chosen in
order to assure an approximately constant and small velocity and, accordingly, a quick return suitable
for deep drawing. The driver link 1 rotates with a constant angular velocity of ω10=-4 rad/s. All five
moving links are rectangular prism with depths d1=5 mm, d2=d3=8 mm, d4=10 mm, d5=20 mm and
heights h1=2 mm, h2=h3=4 mm and h4=5 mm, h5=16 mm. The density of the material is ρsteel= 8000
kg/m3. The joint shaft radii are: rA0=rD= 20 mm, rA=rB= rB0= rC= 30 mm and the friction coefficient is
μ=0.1. The center of mass of links 1 and 5 is located in the joint A0 and joint D respectively.

Table 1. Main dimensions of six-bar press.

Dimensions l0 l1 l2 l3 lAC l4 l5 a
(mm) 128 64 112 112 160 290 80 110

The ram external force is opposed to the motion of the link 5: F ext = - sign(vD)Fe, where Fe=106 N
throughout the working stroke.
The results for the kinematic simulation are shown in figures 5 and 6. Figure 5 shows the ram
displacement (a), velocity (b) and acceleration (c) of the forming mechanical press. It is observed, that
in the working zone, the ram velocity is approximately constant and has small values (figure 5b). The
links positions for a complete rotation of the driver link 1 (the step of the angle is 10 0) are given in
figure 6.

Figure 5. Displacement (a), velocity (b) and acceleration (c) of ram.

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13th International Conference on Tribology, ROTRIB’16 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 174 (2017) 012006 doi:10.1088/1757-899X/174/1/012006

Some results for the dynamic simulation are shown in figures 7 and 8. Figure 7 illustrates the x, y
components of the joint reaction forces F01 (a) and F03 (b) respectively versus crank angle with and
without friction. In figure 8a is given the input torque versus crank angle with and without friction.
In order to validate the simulation results obtained with the MATLAB program, the values of the
input torque without friction (method 1 in figure 8b) are compared with the ones obtained from the
conservation of energy law (method 2 in figure 8b). It is remarked a very good agreement of the
results.

Figure 6. The link positions of six-bar press along the entire ram stroke.

Figure 7. Joint reaction forces F01 (a) and F03 (b).

5. Conclusions
In the current study, the kinematic and kinetostatic analysis of a six-bar linkage of a mechanical press
for deep drawing has been investigated developing a MATLAB program. An analytical method has
been used for the determination of the displacement, velocity and acceleration of the links and the
simulation of mechanism motion. The force analysis considering the joint friction is performed with

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13th International Conference on Tribology, ROTRIB’16 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 174 (2017) 012006 doi:10.1088/1757-899X/174/1/012006

an iterative procedure, applying the D’Alembert principle. It is observed that due to the low values of
the friction forces and moments, the solution converges after one iteration step. The developed
program can be useful for the optimization of the press design considering different constraints.

Figure 8. Input moment versus crank angle.

References
[1] Yan H S and Chen W R 2000 A variable input speed approach for improving the output motion
characteristics of Watt-type presses Int J Mach Tools Manuf 40 675
[2] Yan H S and Chen W R 2002 Optimized kinematics properties for Stevenson-type presses with
variable input speed approach Trans ASME J Mech Des 124 350
[3] Hsieh W H and Tsai C H 2011 On a novel press system with six links for precision deep
drawing Mech Mach Theory 46 239
[4] Soong R Ch 2010 A new design for single DOF mechanical presses with variable speeds and
length-adjustable driving links Mech Mach Theory 45 496
[5] Yossifon S and Shivpuri R 1993 Analysis and comparison of selected rotary linkage drives for
mechanical presses Int J Mach Tools Manuf 33 175
[6] Yossifon S and Shivpuri R 1993 Design considerations for the electric servo-motor driven 30
ton double knichle press for precision forming Int J Mach Tools Manuf 33 209
[7] Tso P L and Liang K C 2002 A nine-bar linkage for mechanical forming presses Int J Mach
Tools Manuf 42 139
[8] Li H and Zhang Y 2010 Seven-bar mechanical press with hybrid-driven mechanism for deep
drawing Part 2 Dynamic modelling and simulation J Mech Sci Technol 24 2161
[9] Mitsi S, Tsiafis I and Bouzakis K D 2015 Force analysis of six-bar linkage for mechanical
presses considering joint frictions J Balk. Tribol. Assoc. 21 281