Apply Now
Advanced Tool Design
Abbreviations.....................................xiii
Preface.............................................xvii
1.General.Tool.Design..........................1
Design Ob jectives .............................. 1
Tool Designer Responsibilities ............. 2
The Design Process ............................ 2
Economics of Design ......................... 3
Economical Lot Sizes .......................... 6
Breakeven Charts .............................. 7
Tool Drawings ................................... 7
Typical Tooling Layout Process ............ 8
Safety ............................................... 8
Material Handling in the
Workplace .................................... 10
Tool Designer’s Guide to Machine
Tools ............................................... 12
References ...................................... 13
Review Questions ............................ 13
2.Materials.Used.for.Tooling...............15
Physical Properties ........................... 15
Mechanical P roperties ...................... 16
Ferrous Tool Materials ...................... 20
Nonferrous Tool Materials ................ 26
Nonmetallic Tool Materials ............... 27
Heat-treating ................................... 31
Instructional Support Materials ......... 34
Review Questions ............................ 34
3.Cutting.Tool.Design.........................37
Form and Dimension ....................... 37
Basics of Metal Cutting .................... 38
Chip Formation ............................... 38
Cutting Forces ................................. 45
Power R equirements ......................... 48
Tool Wear ....................................... 50
Tool Life .......................................... 57
Guidelines for Cutting Tool Design ... 62
Single-point Tools ............................ 64
Multiple-point Tools ......................... 70
Linear-travel Tools ........................... 74
Axial-feed Rotary Tools ..................... 78
References ...................................... 91
Instructional Support Material ........... 92
Review Questions ............................ 93
4.Workholding.Concepts....................95
Basic Workholders ........................... 95
Workholder Purpose and Function .... 96
General Considerations ................... 96
Locating and Supporting Principles ... 97
Chip and Burr Problems ................. 116
Clamping Principles ....................... 119
Chucks ......................................... 130
Vises ............................................. 137
Nonmechanical Clamping ............. 142
Power Clamping ............................ 143
Jig and Fixture Construction
Principles .................................... 145
Instructional Support Material ......... 150
Review Questions .......................... 150
5.Jig.Design.....................................153
General Considerations ................. 153
Machine Considerations ................ 153
Process Considerations .................. 154
Drill Jigs ........................................ 154
Drill Jig Bushings and Liners ........... 166
Jig Design Example ....................... 174
Reference ...................................... 181
Instructional Support Material ......... 181
Review Questions .......................... 181
6.Fixture.Design...............................183
General C onsiderations ................. 183
Types of Fixtures ............................ 186
Fixture C lassifications ..................... 187
Standard Fixture Mounting ............. 190
Design Fundamentals .................... 192
Fixture Design Example .................. 194
Instructional Support Material ......... 198
Review Questions .......................... 199
7.Power.Presses...............................201
Gap-frame Presses ........................ 201
Straight-side Presses ...................... 201
Mechanical Versus Hydraulic
Presses ........................................ 204
Upgrading Existing Presses ............. 206
Die Cushions................................. 207
Hydraulic Forming Machines and
Dies ............................................ 207
Tubular H ydroforming .................... 208
The High-Speed Straight-side
Press ........................................... 210
Transfer Press and Die
Operations ................................. 212
CNC Laser and Turret Punching
Machines .................................... 214
Forging ......................................... 216
References .................................... 217
Instructional Support Materials ....... 217
Review Questions .......................... 218
8.Die.Design.and.Operation............219
Systems of Length, Area, and
Force Measurement ..................... 219
Simple Die Punching ...................... 219
Die-cutting Operations .................. 219
Ball-lock Punches .......................... 228
Bending ........................................ 228
Forming ........................................ 234
Embossing .................................... 237
Beading and Curling ..................... 237
Twisters and Benders ...................... 238
Hole Flanging or Extruding ............ 239
Compound Dies ........................... 241
Stamping Analysis ......................... 242
Deep Drawing of Cups .................. 245
Progressive Dies ............................ 253
Extrusion ....................................... 265
References .................................... 270
Instructional Support Materials ....... 270
Review Questions .......................... 271
9.Inspection.and.Gage.Design..........273
Tolerance ...................................... 273
Conversion Charts ......................... 274
Gaging Principles .......................... 274
Gage Wear Allowance ................... 277
Gage Materials ............................. 278
Gaging Policy ................................ 278
Gage Measurement ....................... 278
Gage Types ................................... 279
Amplification and Magnification
of Error ....................................... 285
Automatic Gaging Systems ............. 293
Coordinate Measuring Machines .... 293
Measuring with Light Rays .............. 297
Gaging Methods ........................... 300
Design Rules for Positionally
Toleranced Parts .......................... 311
References .................................... 317
Instructional Support Material ......... 320
Review Questions .......................... 320
10. Tool.Design.for.Joining..
Processes...................................323
Physical and Mechanical Joining .... 323
Tooling for Physical Joining
Processes .................................... 323
Resistance Welding ........................ 326
Soldering and Brazing ................... 332
Tooling for Thermal Cutting............ 338
Tooling for Mechanical Joining
Processes .................................... 339
Rivets ............................................ 342
Stapling ........................................ 346
Wire Stitching ................................ 347
Metal Stitching ............................... 347
Staking ......................................... 348
Tooling for Adhesive Bonding ......... 349
References .................................... 350
Instructional Support Materials ....... 351
Review Questions .......................... 351
11. Modular.and.Automated.Tool..
Handling....................................353
Design .......................................... 353
Modular Tooling Systems................ 354
Quick-change Tooling .................... 360
Automatic Identification ................. 362
References .................................... 365
Review Questions .......................... 365
12. Computer.Applications.in.
Tool.Design................................367
Computer-aided Design ................. 367
Collaborative En gineering .............. 369
Rapid Prototyping and
Manufacturing ............................... 369
Simulation ..................................... 373
Tolerance Analysis ........................ 373
Design Document Management ..... 374
References .................................... 374
Instructional Support Materials ....... 374
Review Questions .......................... 375
13. Geometric.Dimensioning..
and.Tolerancing.........................377
Symbols and Definitions ................. 377
Three-plane C oncept ..................... 391
Fundamental Rules ........................ 393
References .................................... 396
Bibliography.................................. 396
Review Questions .......................... 396
Bibliography.....................................399
Chapter 1: Tool Design .................. 399
Chapter 2: Materials Used for
Tooling........................................ 399
Chapter 3: Cutting Tool Design ...... 399
Chapter 4: Workholding
Concepts .................................... 400
Chapter 5: Jig Design .................... 400
Chapter 6: Fixture Design .............. 400
Chapter 7: Power Presses ............... 400
Chapter 8: Die Design and
Operation ................................... 401
Chapter 9: Inspection and Gage
Design ........................................ 401
Chapter 10: Tool Design for
Joining Processes ......................... 402
Chapter 11: Modular and
Automated Tool Handling ............ 402
Chapter 12: Computer
Applications in Tool Design .......... 402
Chapter 13: Geometric
Dimensioning and Tolerancing ..... 402
Appendix.A:.Geometric..
Characteristic.Overview.of..
. ASME.Y14.5-2009......................403
Appendix.B:.Geometric..
. Tolerancing.Reference.Charts..
. per.ASME.Y14.5M-1994.............405
Appendix.C:Sources.of.Tool..
. Design.Components...................419
Appendix.D:.Web.Resources.............421
Appendix.E:.Geometric..
. Characteristic.Symbols.per..
. ASME.Y14.5M-1994...................423
Index...............................................427