Servo presses have recently come into prominence for sheet metal forming operations due to their flexibility, controllability, and simplicity. Minimum energy consumption and maximum tool life are their significant characteristics, leading to considerable reductions in manufacturing costs. This article presents technological review on design and applications of servo presses. The characteristics of servo presses are described and compared to conventional and hydraulic presses. Mechanisms used in servo presses and their motion concepts are evaluated with design features. The industrial background of mechanisms is reported with typical examples from leading press manufacturers. A new classification of the servo presses is presented according to mechanisms and drivers. Besides, ranking of press types according to power control and mechanisms is determined. Servo presses with slider-crank mechanism design are preferred due to their distinctive characteristics.

The widespread and increasing consumption of fossil-based fuels as an energy source causes a rapid decrease of these natural sources, as well as an increase of pollution in the atmosphere. Fuel oil, one of the products of fossil fuels, is today the commonly used energy source for transportation. The importance of contributing to the fuel economy and of increasing environmental consciousness have necessitated certain measures in the automotive sector, as well as in other industrial sectors. Therefore, the technological developments recently carried out in the automotive sector aim to reduce the consumption of fossil fuels, for example by recovering waste energy in vehicles. In this direction, efforts have been centered upon the development of energy harvesting systems that provide energy recovery from dynamic parts of the vehicles, such as suspensions. Moreover, the regenerative braking systems that recover some amount of kinetic energy of the vehicles slowing down have been developed and have been in use long since. In this study, research studies on providing the recovery of the vehicles’ waste energy are reviewed with their comparisons.

Due to precision, flexibility, simplicity in construction, easy control, higher speed and lower energy consumptions, servo presses have recently become popular in metal forming applications. Servo press technology combines the advantages of hydraulic and conventional mechanical presses without their drawbacks. This study presents design, construction and demonstration of a servo crank press system for metal forming operations. The research involves structural design and analysis with dynamic considerations of the servo press. A design and manufacturing guide is offered. The press used in this work has a load capacity of 500kN and stroke capacity of 200mm. Structural CAD model is constructed, and Finite Element Analysis (FEA) of press parts are performed within safety limits. Experimental studies are performed on this machine. Satisfaction at the output is seen

Planar mechanisms are essential for many applications. The metal forming process is a vital application for industrial sectors such as automotive and space. Manufacturing precision and generating dwell motion are also important issues. These properties cannot be realized on conventional mechanical presses. Therefore, a novel single degree of freedom (1DOF) eight-bar planar mechanism was developed in this study. The main advantages of the new mechanism are slider balance and dwell motion without a servo motor. Thanks to these advantages, manufacturing difficulty and cost can be reduced. In this study, the new mechanism was modeled kinematically and verified. An optimization methodology was also presented for determining the mechanism dimensions. In order to achieve the desired dwell motion, dimensions of the mechanism for three cases (stroke capacities with 60 mm, 600 mm (crank length ≤ 300 mm), and 600 mm (crank length ≤ 250 mm)) were optimized by using the Genetic Algorithm (GA). The optimized dimensions were also compared kinematically, and the comparison results were shown. The best-optimized dimensions were determined based on the position, velocity, and acceleration simulations of the new mechanism.