Die Design Fundamentals

by Vukota Boljanovic, J R Paquin, Robert E Crowley

• ISBN13: 9780831131197
• ISBN10: 0831131195
• Edition: 3rd
• Format: Hardcover
• Copyright: 2005-12-28
• Publisher: INDUSTRIAL PRESS

Summary

Retaining its unique and much praised organization, this leading text has been revised to reflect the most recent developments in design tools. It provides balanced coverage of relevant fundamentals and real-world practices so that students, apprentices and on-the-job professionals can understand the important and often complex interrelationships between die design and the economic factors involved in manufacturing sheet-metal forming products. Following introductory material and a discussion of 20 types of dies in Chapter 2, the design process of a representative die is separated into seventeen distinct chapters. Each chapter is one step which is illustrated in two ways; first, as a portion of an engineering drawing, that is, as the component is actually drawn on the design. Second, the die design is shown pictorially in order to improve the user's visualization. In successive sections each step is detailed as it is applied to the design of the various types of dies listed in Chapter 2. Includes English and Metric systems. Covers new methods of producing blanks, such as waterjet cutting and laser cutting. Contains a glossary of terms for the first time. Illustrates each step in pictorial view and as a portion of an engineering drawing. Offers a completely revised chapter on presses and quick die-changing systems and includes the addition of "Quick Die Change Systems.

Table of Contents

Preface	vii
Introduction to Die Design	1	(20)
Basic Meanings	1	(4)
Die Components	5	(5)
Processing a Die	10	(6)
Die Operations	16	(5)
Classifications and Types of Dies	21	(18)
Die Classifications	21	(1)
Types of Dies	22	(17)
The Material Strips	39	(12)
Introduction	39	(1)
Steel	39	(2)
Mechanics of Shear	41	(4)
Determining Strip	45	(4)
Methods for Producing Strips	49	(2)
The Blank	51	(10)
Definition and Types of Blanks	51	(1)
Producing Blanks	51	(7)
Blanking Force	58	(3)
Fourteen Steps to Design a Die	61	(14)
Introduction	61	(1)
The Scrap Strip (Step 1)	62	(1)
The Die Block (Step 2)	62	(1)
The Blanking Punch (Step 3)	62	(2)
Piercing Punches (Step 4)	64	(1)
The Punch Plate (Step 5)	65	(1)
Pilots (Step 6)	65	(1)
Gages (Step 7)	66	(1)
The Finger Stop (Step 8)	67	(1)
The Automatic Stop (Step 9)	68	(1)
The Stripper (Step 10)	69	(1)
Fasteners (Step 11)	70	(1)
The Die Set (Step 12)	71	(1)
Dimensions and Notes (Step 13)	72	(1)
Bill of Material (Step 14)	72	(3)
How to Lay Out a Scrap Strip	75	(16)
Introduction	75	(1)
Strip Material Economy	75	(1)
Scrap Strips	76	(9)
Scrap Strip Allowances	85	(2)
Strip Area per Blank Calculations	87	(4)
How to Design Die Blocks	91	(12)
Introduction	91	(1)
Applying the Die Block	91	(2)
Recommendations for Designer	93	(3)
Types of Die Block	96	(7)
How to Design Blanking Punches	103	(8)
Introduction	103	(1)
Applying Blanking Punches	103	(5)
Blanking Punches with Bevel-Cut Edges	108	(1)
Shedders	109	(2)
How to Design Piercing Punches	111	(10)
Introduction	111	(1)
Methods of Designing Punches	111	(2)
Methods of Holding Punches	113	(1)
Methods of Supporting Punches	114	(2)
Stepping Punches	116	(1)
Keeping the Punch from Turning	117	(1)
Shedders	118	(3)
How to Design Punch Plates	121	(8)
Introduction	121	(1)
Methods of Designing and Applying Punch Plates	121	(5)
Commercial Punch Plates	126	(3)
How to Design Pilots	129	(12)
Introduction	129	(1)
Direct Piloting	129	(5)
Indirect Piloting	134	(4)
Spring-Backed Pilots	138	(3)
How to Design Gages	141	(8)
Introduction	141	(1)
Back Gage and Front Spacer	141	(1)
Strip Support	142	(3)
Strip Pushers	145	(1)
Strip Equalizers	145	(1)
Positioning a Particular Blank	145	(4)
How to Design Finger Stops	149	(8)
Introduction	149	(1)
Operation of Finger Stops	149	(1)
Conventional Finger Stop	150	(2)
Spring Finger Stop	152	(5)
How to Design Automatic Stops	157	(10)
Introduction	157	(1)
Types of Stops	157	(3)
Actuating Automatic Stops	160	(1)
Standardized Components of Stops	161	(4)
Simple Pin Instead of Automatic Stop	165	(2)
How to Design Strippers	167	(16)
Introduction	167	(1)
Solid Strippers	167	(1)
Elastic Strippers	168	(5)
Stripping Force	173	(1)
Methods of Applying Knockouts	174	(7)
Center of Stripping Force	181	(2)
How to Apply Fasteners	183	(18)
Introduction	183	(1)
Types of Fasteners and Methods of Fastening	184	(3)
Screws	187	(8)
Bolts	195	(1)
Dowels	196	(5)
How to Select a Die Set	201	(20)
Introduction	201	(1)
Principles of Selecting the Die Set	201	(2)
Die Set Components	203	(6)
Establishing the Die Set Center	209	(2)
Drawing the Die Set	211	(3)
Machining the Die Set	214	(2)
Type of the Die Sets	216	(5)
Dimensions and Notes	221	(24)
Introduction	221	(1)
Trigonometry as a Tool for Solving Problems	221	(2)
Dimensions	223	(4)
Die Clearances	227	(3)
Blank Development	230	(10)
Notes	240	(5)
The Bill of Material	245	(12)
Introduction	245	(1)
Die Drawing	245	(3)
Types of Components	248	(5)
Tool Steels	253	(4)
Presses and Quick Die-Change Systems	257	(12)
Introduction	257	(1)
Mechanical Presses	257	(4)
Hydraulic Presses	261	(2)
Lubrication System	263	(1)
Press Selection	264	(1)
Quick Die-Change Systems	265	(4)
Glossary	269	(8)
Index	277