Cushion Cylinders for Die Cushion Systems | Specifications & Selection

Product Specifications

Technical details and manufacturing context for Cushion Cylinders

Definition

Cushion cylinders are specialized hydraulic or pneumatic cylinders that form a critical component of die cushion systems in stamping presses. They provide controlled pressure and cushioning action during the forming process, absorbing impact forces and ensuring smooth operation of the press while protecting dies and workpieces from damage. These cylinders are typically constructed with steel bodies and chrome-plated steel piston rods, with sealing materials such as rubber or polyurethane to ensure reliable operation. Available bore diameters range from 32 to 200 mm (per ISO 6432), with stroke lengths from 25 to 500 mm, and custom strokes up to 2000 mm possible. Operating pressure is typically 1.0 to 1.6 MPa, with a cushioning force adjustable from 500 to 5000 N via a needle valve. The cushioning stroke, which determines deceleration distance, ranges from 10 to 50 mm. Operating temperature is -20 to 80 °C (per ISO 8573-1), and piston speed ranges from 0.1 to 1.5 m/s. Leakage rate is ≤0.05 L/min at nominal pressure (per ISO 10099). The cushioning adjustment range is 0 to 100%, allowing fine-tuning of impact force. Mounting types include flange, foot, and trunnion (per ISO 15552). Weight depends on bore and stroke, ranging from 1.5 to 25 kg. IP ratings of IP54 to IP65 are available for dusty environments. These parameters are reference ranges; always verify model-specific values with the manufacturer or supplier. Cushion cylinders are used in stamping presses to control the blank holder force, prevent wrinkling, and improve part quality. They also reduce shock and noise, extending die life. Proper selection requires consideration of press tonnage, stroke length, required cushion force, and operating speed. Regular maintenance includes checking seals, rod surface, and pressure settings. Failure signs include excessive leakage, erratic cushioning, or unusual noise, indicating seal wear or internal damage. Always consult the manufacturer's documentation for installation, operation, and maintenance guidelines.

Working Principle

Cushion cylinders operate by using hydraulic fluid or compressed air to create controlled resistance during the press stroke. When the press ram descends, the cylinders absorb impact energy through controlled compression of the fluid or gas, providing cushioning at the bottom of the stroke and controlled pressure release during the return stroke. The cushioning force is adjustable via a needle valve, allowing fine-tuning of the deceleration rate. The cushioning stroke determines the distance over which deceleration occurs, and the adjustment range (0-100%) enables precise control of impact force. This principle ensures smooth press operation and protects dies and workpieces from damage.

Common Materials

Steel, Chrome-plated steel, Sealing materials (rubber/polyurethane)

Technical Parameters

Parameter	Typical range	Notes & selection driver
Bore Diameter	32–200 mm	Common range; larger sizes available on requestISO 6432
Stroke Length	25–500 mm	Custom strokes up to 2000 mm possible
Operating Pressure	1.0–1.6 MPa
Cushioning Force	500–5000 N	Adjustable via needle valve
Cushioning Stroke	10–50 mm	Determines deceleration distance
Operating Temperature	-20–80 °C	For higher temps use special sealsISO 8573-1
Piston Speed	0.1–1.5 m/s	Higher speeds require external shock absorbers
Leakage Rate	≤0.05 L/min	At nominal pressureISO 10099
Cushioning Adjustment Range	0–100 %	Fine-tune impact force
Mounting Type	ISO 15552	Available: flange, foot, trunnionISO 15552
Weight	1.5–25 kg	Depends on bore and stroke
IP Rating	IP54–IP65	Higher protection for dusty environmentsIEC 60529

Ranges are indicative industry figures for RFQ preparation, not a supplier commitment. Confirm every value and standard with the legal manufacturer before ordering.

Components / BOM

Cylinder Barrel
Main housing that contains the piston and hydraulic fluid

Material: Steel
Piston Part
Moves within the barrel to create pressure differential

Material: Steel with sealing rings
Piston Rod Part
Transmits force from the piston to the external load

Material: Chrome-plated steel
Seals Part
Prevent fluid leakage between moving parts

Material: Rubber or polyurethane
End Caps Part
Seal the ends of the cylinder barrel

Material: Steel
Needle Valve
Meters the fluid escaping the cushion, which is what sets how fast the ram decelerates.

Applied To / Applications

This component is essential for the following industrial systems and equipment:

Die Cushion System

View system integration details

Manufacturers of Cushion Cylinders

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Frequently Asked Questions

What is the typical bore diameter range for cushion cylinders?

The common bore diameter range is 32 to 200 mm, per ISO 6432. Larger sizes may be available on request, but you should confirm with the manufacturer for your specific application.

How is the cushioning force adjusted?

The cushioning force is adjustable via a needle valve, with a range of 500 to 5000 N. This allows fine-tuning of the impact force to suit the forming process.

What operating temperature range is typical?

The typical operating temperature range is -20 to 80 °C, per ISO 8573-1. For higher temperatures, special seals may be required; consult the manufacturer.

What maintenance is required for cushion cylinders?

Regular maintenance includes checking seals, rod surface, and pressure settings. Look for signs of leakage, erratic cushioning, or unusual noise, which may indicate seal wear or internal damage. Always follow the manufacturer's guidelines.

Data Basis

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Preliminary Technical Classification

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pressure:	Up to 210 bar hydraulic, 10 bar pneumatic (typical)
other spec:	Flow rate: 0-100 L/min hydraulic, 0-5000 NL/min pneumatic; Stroke length: 50-500 mm; Cushioning adjustment: 0-100%
temperature:	-20°C to +80°C (standard), -40°C to +120°C (special seals)

Cushion Cylinders

Product Specifications

Applied To / Applications

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Application Fit & Sizing Matrix

Reliability & Engineering Risk Analysis

Compliance & Manufacturing Standards