HANDBOOK OF DIE DESIGN

Transcription

1 HANDBOOK OF DIE DESIGN Ivana Suchy Consultant, Design Engineer Fair Lawn, New Jersey Second Edition McGRAW-HILL New York Chicago San Francisco Lisbon London Madrid Mexico City Milan New Delhi San Juan Seoul Singapore Sydney Toronto

2 CONTENTS Preface xi Acknowledgments xiii Chapter 1. Basic Die Design and Die-Work Influencing Factors 1-1. Sheet-Metal Stamping in Comparison with Other Metal Fabricating Processes / What Constitutes Suitability for Die Production? I Design Criteria for Die-Manufacturable Products / Elimination of Secondary Operations through Better Part Design / Advantages of Sheet-Metal Application / 56 Chapter 2. The Theory of Sheet Metal Behavior Sheet Metal and Its Behavior in Metal Stamping Process / Plasticity Theories / External Influences on the Part and Their Impact on Plastic Deformation / Shear of Metal in Cutting Operation / Bending and Forming of Sheet Metal Material / Movement of Metal in Bending and Forming, and Axis' Shift / Variation of Stock Thickness in Bending and Forming Operations / 93 Chapter 3. Metal Stamping Dies and Their Function Description of a Die / Dies, According to Their Construction / Dies, According to Their Effect on the Structure of Material / New Methods in Metalworking / Fineblanking / 145 Chapter 4. Metal Stamping Dies, Their Construction, and Assembly 149 * 4-1. Tolerancing Systems / Die Components, Their Fabrication, and Assembly / Mounting of Blocks / Machining of Blocks / Mounting Hardware / Jigs and Fixtures / 206

3 viii CONTENTS Chapter 5. Metalworking Machinery Metalworking Machinery / Parts of the Press / Press Operating Parameters / Presses, According to Their Operation / Other Press-Room Machinery / Press Mounting, Performance, and Productivity / Electroerosive Machining / 243 Chapter 6. Blanking and Piercing Operations Metal-Cutting Process / Forces Involved in the Metal-Cutting Process / Alignment of Cutting Tools / Design of Cutting Tools / Cutting Clearances / Punching and Blanking Pressure / Stripping Pressure / Scrap and Hole Size Recommendations / Practical Advices and Restrictions / 284 Chapter 7. Blank Calculation or Flat Layout The Importance of Flat Layout or Blank Layout / Details of a Flat Layout / Flat Layout and Its Additional Uses / 320 Chapter 8. Bending and Forming Operations Stress, Strain, Elongation, Compression / Bend Radius / Radius of Forming Tools / Edge Formability / Neutral Axis in Bending / Types of Bending Operations / Springback / Surface Flatness After Bending / Forming / Bending and Forming Pressure Calculations / 363 Chapter 9. Drawn Parts Drawing of Sheet Metal / Metal Movement in Drawing Operation / Technological Aspects of Drawing Process / Drawing of Cylindrical Shells / Drawing of Thick-Walled Cylinders / Drawing of Square or Rectangular Shapes / Drawing of Irregular Shapes / Redrawing Operations / 425

4 CONTENTS IX 9-9. Types of Drawing Dies and Their Construction / Blankholders and Draw Beads / Defects Caused by Drawing Process / Friction and Drawing Lubricants / Drawing Tonnage and Other Calculations / 448 Chapter 10. Practical Die Design Basic Approach to Die Design / Progressive Die Design / Samples of Die Design Work / 472 Chapter 11. Die Process Quality and Automation, Die Maintenance Die Protection and the Control of Stamping Process / Automation and In-Die Processes / Automated Quality Control / Die Maintenance and Die Adjustments / Behavior Simulating Software / 523 Chapter 12. Springs, Their Design and Calculations Springs and Their Properties / Springs in Die Design / Helical Compression Springs / Calculation of Compression Springs / Special Cross Sections of the Wire / Hot-Wound Springs / Helical Extension Springs / Flat Springs / Gas and Air Springs and Their Applications / 561 Chapter 13. Spring Washers Cylindrically Curved Washers / Wave Washers / Belleville Spring Washers / Lock Washers / 597 Chapter 14. Materials and Surface Finish Metal Materials and Their Properties / Mechanical Properties of Metal Materials / Testing of Mechanical Properties / Materials Used for Tooling Applications / Types of Steel and Alloys: Properties and Classifications / Comparison of Materials Worldwide / Heat Treatment / Surface Cleaning / Surface Coating / 670

5 X CONTENTS Chapter 15. Die Cost Estimating Trends in Sheet-Metal Manufacturing / Basic Approach to Cost Estimating / Die Building Estimates / Design and Development Costs / Estimate Format and Terminology / 706 Appendix 713 Bibliography 717 Index 721