What is a servo press?

A servo press uses servo motors for precise force and position control during forming operations.

How do I calculate servo press tonnage?

Use our free tonnage calculator at servopress.club/tonnage-calculator.html

Automotive Stamping with Servo Press: Real-World Case Study

admin

This case study examines the conversion of a Tier 1 automotive supplier's door inner panel line from conventional mechanical press to servo press.

## Background

The supplier was producing door inner panels from 0.8mm DP600 dual-phase steel on a 600-ton conventional mechanical press at 8 SPM. Key challenges: **4.2% scrap rate** due to springback variation, frequent die cracking, and inability to run thinner gauges.

## Servo Press Selection

A 600-ton servo press with link-drive mechanism was selected. Key criteria: high torque at BDC for DP600 forming, programmable dwell capability.

## Implementation

Die tryout took 3 weeks. Forming speed was reduced from 180 mm/s to 60 mm/s in the critical forming zone. A 0.2-second dwell was added at BDC. Approach speed was increased to 350 mm/s to maintain productivity.

## Results After 6 Months

| Metric | Before | After |
|--------|--------|-------|
| Scrap rate | 4.2% | 0.8% |
| Die life | 150k hits | 400k hits |
| Cycle rate | 8 SPM | 8 SPM |
| Material gauge | 0.8mm DP600 | 0.7mm DP780 |
| Energy vs hydraulic backup | baseline | -38% |

## ROI Calculation

- Annual savings: $317,000
- Press investment premium: $380,000
- **Simple payback: 14 months**

## Lessons Learned

The biggest challenge was retraining operators to think in terms of motion profiles rather than fixed press parameters. Invest in training.

sarah_mfg_eng

Similar experience at our plant. We converted a door inner panel line 2 years ago. Scrap went from 4.2% to 1.8%. The biggest factor wasn't the press itself —it was the force monitoring catching bad parts before they got to the next station. On the mechanical press we relied on visual inspection which missed about 30% of defects.

pete_retrofit

I did the retrofit on a similar line —500T mechanical to servo. The part that surprised everyone was the noise reduction. We went from mandatory hearing protection to normal conversation levels at the press. Operator satisfaction went through the roof. It's not in the ROI spreadsheet but it matters.