| Preface IX 1. Basic Die Design and Die-Work Influence Factors 1 Introduction 1 Sheet-Metal Stamping in Comparison with Other Metal Fabricating Process 2 Balancing of Priorities 9 What Constitutes Suitability for Die Production? 12 Design Criteria for die-Manufacturable Products 14 Elimination of Secondary Operations through Better Part Design 17 Advantages of sheet-metal application 22 2. The Theory of Sheet Metal Behavior 30 Introduction 30 Sheet metal and its behavior in metal stamping process 30 External Influences on the Part and their Impact on Plastic Deformation 37 Shear of Metal in Cutting Operation 41 Bending and Forming of Sheet Metal Material 44 Movement of Metal in Bending and Forming, and Axis’ Shift 52 Variation of Stock Thickness in Bending and Forming Operations 56 3. Metal Stamping Dies and Their Function 62 Introduction 62 Description of a Die 65 Dies, According to Their Construction 68 Dies, According to Their Effect on the Structure of Material 71 New Methods in Metalworking 75 Fineblanking 86 4. Metal Stamping Dies, Their Construction, and Assembly 92 Introduction 92 Die Components, Their Fabrication, and Assembly 98 Mounting of Blocks 101 Machining of Blocks 103 Mounting Hardware 109 Jigs and Fixtures 112 5. Metalworking Machinery 118 Introduction 118 Metalworking machinery 118 Classification based on the design of the frame 122 Hydraulic press machine structure 127 Other press-room machinery 140 Electroerosive machining 149 6. Blanking and Piercing Operations 154 Introduction 154 Metal-cutting process 155 Forces involved in the metal-cutting process 160 Alignment of cutting tools 162 Cutting clearances 163 Punching and blanking pressure 165 Stripping pressure 165 Scrap and hole size recommendations 166 Practical advices and restrictions 167 7. Blank Calculation or Flat Layout 169 Introduction 169 The importance of flat layout or blank layout 170 Details of a flat layout 176 Flat layout and its additional uses 178 8. Bending and Forming Operations 181 Introduction 181 Stress, strain, elongation, compression 181 Bend radius 184 Radius of forming tools 185 Edge formability 188 Neutral axis in bending 189 Types of bending operations 189 Springback 193 Surface flatness after bending 194 Forming 195 Bending and forming pressure calculations 197 9. Drawn Parts 200 Introduction 200 Drawing of sheet metal 201 Technological aspects of drawing process 206 Drawing of cylindrical shells 211 Drawing of thick-walled cylinders 214 Drawing of irregular shapes 216 Redrawing operations 216 Blankholders and draw beads 218 Defects caused by drawing process 221 Friction and drawing lubricants 222 Drawing tonnage and other calculations 222 10. Practical Die Design 226 Introduction 226 Basic approach to die design 227 Progressive die design 235 Samples of die design work 240 11. Die Process Quality and Automation, Die Maintenance 243 Introduction 243 Die protection and the control of stamping process 244 Automation and in-die processes 251 Automated quality control 253 Die maintenance and die adjustments 254 Behavior simulating software 256 12. Springs, Their Design and Calculations 260 Introduction 260 Springs and their properties 261 Sourcing springs 264 Springs in die design 264 Helical compression springs 266 Calculation of compression springs 267 Special cross sections of the wire 269 Hot-wound springs 271 Helical extension springs 271 Flat springs 272 Gas and air springs and their applications 273 13. Spring Washers 277 Introduction 277 Cylindrically curved washers 278 Wave washers 279 Belleville spring washers 284 Lock washers 288 14. Materials and Surface Finish 295 Introduction 295 Metal materials and their properties 295 Mechanical propertiesof metal materials 299 Testing of mechanical properties 305 Materials used for tooling applications 306 Types of steel and alloys: properties and classifications 307 Comparison of materials worldwide 309 Heat treatment 310 Surface cleaning 312 Surface coating 312 15. Die Cost Estimating 315 Introduction 315 Trends in sheet-metal manufacturing 316 Basic approach to cost estimating 318 Die building estimates 319 Design and costs 319 Estimate format and terminology 320 Bibliography 326 Index 328 |
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