Chapter 1 Stamping Forming and Die Design 1
1.1 Introduction 1
1.2 Blanking and Punching Dies 4
1.2.1 Blanking 4
1.2.2 Blanking Deformation Process 5
1.2.3 Blanking Workpiece Quality 8
1.2.4 Blanking and Punching Dies 10
1.2.5 Blanking Tools 15
1.3 Bending Dies 18
1.3.1 Simple Bends 19
1.3.2 Bending Allowance 20
1.3.3 Bending Tool 21
Chapter 2 Plastics Molds 23
2.1 Introduction 23
2.2 The Properties of Plastics 24
2.2.1 Thermosets 25
2.2.2 Thermoplastics 25
2.2.3 Fillers 26
2.2.4 Properties of Plastics 26
2.3 Injection Molds 32
2.3.1 Injection Molding 32
2.3.2 Injection Molds 34
2.3.3 Mold Machine 39
2.4 Compression and Transfer Molds 43
2.4.1 Compression Molding 43
2.4.2 Transfer Molding 44
2.4.3 Compression Molds 46
2.4.4 Transfer Molds 48
Chapter 3 Casting Dies 51
3.1 Casting 51
3.2 Sand Casting 53
3.2.1 Sands 54
3.2.2 Types of Sand Molds 54
3.2.3 Patterns 55
3.2.4 Cores 57
3.2.5 Sand-Molding Machines 58
3.2.6 The Sand Casting Operation 60
3.3 Die Casting 63
3.3.1 The Die Casting Cycle 63
3.3.2 Die Casting Alloys 64
3.3.3 Die Casting Dies 65
3.3.4 Die Casting Machines 67
Chapter 4 Forging Die 71
4.1 Introduction 71
4.2 Open-Die Forging 72
4.3 Impression-Die and Closed-Die Forging 74
4.3.1 Precision Forging 77
4.3.2 Coining 77
4.4 Forging-Die Design 78
4.4.1 Preshaping 79
4.4.2 Die Design Features 79
4.5 Forging Machines 82
4.5.1 Presses 82
4.5.2 Hammers 84
4.5.3 Selection of Forging Machines 85
Chapter 5 Extrusion 86
5.1 Introduction 86
5.2 Design of Tools for Hot Extrusion 87
5.2.1 Mandrel 90
5.2.2 Dummy Blocks 90
5.2.3 Die Stack 90
5.3 Industrial Practice in Tool Design 92
5.3.1 Dummy Blocks 92
5.3.2 Dies 92
5.4 Cold Extrusion of Steel 95
5.4.1 Nomenclature and Tool Assembly Drawings 95
5.4.2 Punches 96
5.4.3 Dies 103
6.1.2 Basic Component of NC Machine Tools 108
6.1.1 Concept of NC and CNC 108
Chapter 6 Modern Mold Manufacturing 108
6.1 Fundamental of NC Technology 108
6.2 Classifications of NC Machines 111
6.2.1 Types of NC Motion Control System 111
6.2.2 Types of NC Servo-Drive Systems 114
6.3 Machining Centers 118
6.4 Automation of Manufacturing 120
6.4.1 Introduction 120
6.4.2 Flexible Manufacturing System 122
6.4.3 Computer Integrated Manufacturing System 123
7.1 The Computer in Die Design 125
Chapter 7 CAD/CAM/CAE 125
7.2 CAD/CAM 127
7.2.1 CAD 127
7.2.2 CAM 129
7.3 CAE 131
7.3.1 MPI Introduction 132
7.3.2 MPI Modules 133
7.3.3 CAE Example of MPI 138
Glossary 144
References 163