Unit One The Die and Mold Materials and Heat Treatment 1
1.1 Abstract 1
1.2 Die and Mold Materials 1
1.2.1 Carbon Steels 1
1.2.2 Alloy Steels 2
1.2.3 Die and Mold Steels 3
1.2.4 Selection of Typical Mold Steels 4
1.3 Heat Treatment of Die and Mold Materials 5
1.3.1 The Purposes of Heat Treatment 5
1.3.2 Types of Heat Treatment 5
New Words and Expressions 7
Glossary of Terms 9
Notes 11
Questions 11
Unit Two Die Design 13
2.1 Abstract 13
2.2 Sheet Metal Forming 13
2.2.1 Deformation Modes in Sheet Forming 13
2.2.2 Characteristics of Sheet-Metal Forming Processes 15
2.3 Piercing Die 16
2.3.1 Piercing Die Processes 16
2.3.2 Piercing Die Design 16
2.4 Blanking Die Design 18
2.4.1 Shearing Action in Die Cutting Operations 18
2.4.2 Center of Pressure 19
2.4.3 Clearances 19
2.4.4 Blanking Die Design 20
2.4.5 Definition of Various Shearing Operations 21
2.5 Bending Die Design 22
2.6 Drawing Die Design 25
2.6.1 Drawing Die 25
2.6.2 Drawing Die Design 27
2.7 Compound Die Design 29
New Words and Expressions 31
Glossary of Terms 35
Notes 38
Questions 40
Unit Three The Plastic Mold Design 41
3.1 Abstract 41
3.2 Plastics 41
3.2.1 Classification of Plastics 42
3.2.2 Properties of Plastics 42
3.2.3 Filler of Plastics 43
3.3 Plastic Material Molding 43
3.3.1 Compression Molding 44
3.3.2 Transfer Molding 45
3.3.3 Injection Molding 45
3.4 Thermoplastic Mold Design 47
3.5 Thermosetting Mold Design 48
New Words and Expressions 49
Glossary of Terms 53
Notes 55
Questions 58
Unit Four The Parts for Dies and Molds 59
4.1 Abstract 59
4.2 Die Parts 59
4.2.1 Stock Stops 59
4.2.2 Pilots 61
4.2.3 Strippers 63
4.2.4 Knockout Bars 64
4.2.5 Standard Die Base 64
4.3 Plastic Injection Mold Parts 65
4.3.1 Plastic Injection Mold Parts 65
4.3.2 Design Guides for the Part to Be Molded 67
4.4 Pressure Die-Casting Die Parts 68
4.4.1 The Assembly of Pressure Die-Casting Dies 68
4.4.2 The Die Insert 68
4.5 Trouble-shooting Guide for Thermoplastic Part Defects 71
4.5.1 Sink Marks 71
4.5.2 Burnt Streaks/Brown Marks/Silver Streaks 72
4.5.3 Weld Line/Meld Lines 72
4.5.4 Jetting 73
4.5.5 Air Streaks/Air Hooks 74
4.6 Trouble-shooting Guide for Thermosetting Part Defects 75
4.6.1 Blisters 75
4.6.2 Cracks 77
4.6.3 White Marks 79
4.6.4 Porosity 79
4.6.5 Orange Rind 81
New Words and Expressions 82
Glossary of Terms 85
Notes 87
Questions 88
Unit Five The Forming and Molding Equipment 90
5.1 Abstract 90
5.2 The Forming Equipment 90
5.2.1 Press Types 91
5.2.2 Main Components of a Press 94
5.3 The Molding Equipment 94
5.3.1 The Injection-molding Machine 94
5.3.2 Components of Injection-molding Machine 97
5.3.3 Types of Injection-molding 100
5.3.4 The Injection-molding Products&i 1
5.3.5 The Economics of Injection-molding Products 102
5.4 The Specification of Equipment 103
5.4.1 The Specifications of Press 103
5.4.2 The Specifications of Injection-molding Machine 105
New Words and Expressions 107
Glossary of Terms 111
Notes 116
Questions 117
Unit Six CNC Manufacturing and Programming 119
6.1 Abstract 119
6.2 Applications of CNC Machines 119
6.2.1 Definition of NC/CNC Machines 119
6.2.2 Classification of CNC Machines 120
6.2.3 The Applications of NC/CNC 120
6.2.4 Types of CNC Equipment 121
6.2.5 Control System for Controlling Tool Feed 122
6.2.6 Type of System Control for Tool Movements 123
6.3 CNC Machining Centers 124
6.4 The Advantages and Disadvantages of CNC Machines 125
6.4.1 The Advantages of CNC Machines 125
6.4.2 The Disadvantages of CNC Machines 125
6.5 The Operation Panel of CNC Machines 125
6.6 Coordinate System of CNC Machines 131
6.7 The Components of CNC Machines 135
6.7.1 The Construction of CNC Machines 135
6.7.2 The Components of CNC Machines 136
6.8 NC Programming 138
6.8.1 Basic Requirement of NC Machine Control 138
6.8.2 Setup Procedure 140
6.8.3 Debugging the Program 141
6.8.4 Manual Part Programming 142
6.8.5 Computer-aided Part Programming 145
6.9 Main Specification of CNC Machining Centers 146
6.10 Electrochemical Machines 149
6.11 Electro-discharge Machines 150
New Words and Expressions 152
Glossary of Terms 156
Notes 161
Questions 164
Unit Seven CAD/CAM/CAE/CAPP 166
7.1 Abstract 166
7.2 Historical Development of CAD/CAM 166
7.3 CAD/CAM 167
7.4 The Applications of CAD/CAM 171
7.4.1 The Application in Computer-aided Die Design 171
7.4.2 The Application of CAD/CAM in Injection Mold 173
7.4.3 Animation and CAD/CAM 173
7.4.4 Computer Integrated Manufacturing 173
7.4.5 CIM in Making Mold 174
7.4.6 Process Planning and CIM 175
7.4.7 Computer-Aided Process Planning(CAPP) 175
7.4.8 Manufacturing Resources Planning(MRPⅡ)and CIM 176
7.4.9 Computer-aided Manufacturing 178
7.4.10 Computer-aided NC Part Programming 178
7.5 CAD/CAM Hardware 179
7.6 CAD/CAM Software 182
7.7 CAD System ExampIes 183
7.7.1 Pro/Engineering 184
7.7.2 AutoCAD 185
7.8 CAD/CAM Selection Criteria 186
7.9 CAE 187
7.9.1 CAE for Polymer Processing 188
7.9.2 The Applications of CAE 190
New Words and Expressions 193
Glossary of Terms 197
Notes 199
Questions 201
Unit Eight Advanced Manufacturing Technology 202
8.1 Abstract 202
8.2 Rapid Prototyping and Manufacturing 202
8.2.1 The Application Areas of RP and M 203
8.2.2 Characteristics of Rapid Prototyping Technologies 204
8.2.3 Subtractive Processes 206
8.2.4 Additive Processes 206
8.2.5 Virtual Prototyping 208
8.3 Manufacturing Technology for Special-purposes 208
8.3.1 Ultrasonic Machining Installations 208
8.3.2 Laser Cutting Machines 209
8.3.3 Electron-beam Cutting Installations 209
8.3.4 Traveling-wire EDM 209
8.4 Group Technology 210
8.5 Flexible Manufacturing Systems 211
8.6 Robotics Technology 212
New Words and Expressions 213
Glossary of Terms 216
Notes 217
Questions 219
Appendix A Glossary of Terms and Abbreviations 220
Appendix B Vocabulary 246
参考文献 272