There isn’t a project Automated Industrial Machine, Inc. couldn’t handle. When it comes to forming applications, the right press can make a significant difference in both production efficiency and product quality. We design and build presses around the specific requirements of each and every application. This year we took on a project to design and fabricate a custom countersink-forming press and tooling.
This project needed a system capable of forming countersinks in stainless steel sheet metal while maintaining the strength and integrity of the fastener interface. The machine needed to be able to form countersinks for a wide range of fastener sizes, ranging from 3/16” to ¾”. It also had to be robust enough to form those countersinks in stainless steel up to 12-gauge thick.
To meet these requirements, AIM-Joraco designed and fabricated
a customized 16-ton Hydro-Aire Series hydro-pneumatic press.
The design process focused on creating a reliable forming system
that could withstand the 16 tons of force generated by the press ram.
Engineers used stress simulations and iterative design to determine the appropriate press frame dimensions and evaluated different methods of transferring motion and load throughout the system. The design also incorporates standardized fasteners and geometry to minimize tooling changeouts. Simple adjustable stops let the user set the fastener head to the desired position without needing a different tool for every size.
Testing helped establish the practical limits of forming countersinks in different sheet metal thicknesses. Engineers tested various material thicknesses and pilot hole sizes to determine maximum countersink depths and develop best practices for the forming process.
The testing identified a rotating cam as the most reliable way to move and support the lower forming tool under load. Hard stops with different heights control the countersink's depth and diameter, giving users the flexibility to achieve a flush or slightly below-flush fastener head by adjusting the stop height. A dedicated pneumatic switch positioned near the Synchro-Sig two-hand controller provides an intuitive way to operate the cam.
The Hydro-Aire press design also allows the material to be formed through multiple cycles. This means deeper countersinks can be achieved through cumulative deformation—with countersinks deeper than ½ inch possible by cycling the press twice. The result is a versatile forming process that provides consistent countersinks while reducing the need for complex tooling changes.
By combining robust press construction, application-specific tooling, and ergonomic controls, our presses are engineered to deliver consistent forming results while reducing the need for manual, handheld processes.
For an in-depth guide on this project, look here: Forming Sheet Metal Countersinks
If you want to see the press in action, click here: Forming Sheet Metal Countersinks
Joraco Press Company has been an innovator in the pneumatic press industry since 1947. The trademarked TOGGLE-AIRE® Series has been the core product of Joraco Press for over 60 years having been installed in thousands of manufacturing facilities all over the world. The past 20 years have seen Joraco Press expand its benchtop pneumatic press products to cover more applications and more force ranges than ever before. Joraco Press Company is a division of Automated Industrial Machine, Inc located in Smithfield, RI. Our products are designed, fabricated, and assembled at the AIM headquarters and as always, the same people who build our presses are always available to help troubleshoot your press.