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ME 416
TOOL DESIGN* CONTENTS
1- Introduction. ne a ae omer 1
The Place of Production (Tool) Engineering
Functional Responsibilities
Importance of Tool Engineering
2- Design Considerations For Press Forging.
Allowances
Parting Line Position, Web Design
Draft Angles, Comer, Radi
Flash Design, Gutter Design
Die Design, Forging Load
3- Mould Design...
Mould Design Procedure
Proposed Design
4- Injection Mould.
Classification
Functions
Procedure For Mould Design
Cavity Layouts
5- Metal Forming... ese 51
Plasticity of Metals
Cold and Hot Forming
Work Done
Design of Press Working Tools
Shearing
Bending
Drawing
Progressive-Compound-Die Design
Forces, Work Done, Components, Calculations in Shearing Bending,
Drawing
Criteria To Be Used in Selection of Sheet Metal Dies
Cut-off, Drop Through, Return, Compound, Progressive, Combination,
Subpress, Continental, Transfer, Shuttle, Inverted Dies
Mathematical Analysis of Die Components
Side Thrusts, Guide Pin, Heel, Punch, Die Steel, Pressure Plate,
Pad, Keeper, Base Plate Design, Check List for Die Design
29
35er eee ae eR Eager Ras oad earn EE Puen eee de ocean Se6- Extrusion. cee
Tooling, Tool Materials
Tool Design; Punch, Die
7- Jig & Fixture Design.
Locating Methods: (3-2-1), Radial, V-Locators
Clamping: Principles, Considerations, Factors, Forces
Mechanics of Clamping Devices: Screws, Cams
Clamping Elements and Applications
Check List and Design Studies
8- Die Materials and Die Manufacture.
Die Life, die Failure
Materials For Hot Forming
Conventional Die Manufacturing
CNC Machining
Non Traditional Techniques: Electrical Discharge
9- Appendix. .
Selected Standard Specifications
Supplementary Notes
Toggle, Strap
120
136
176
SlCHAPTER I
INTRODUCTION
1.1 The Place Of Tool (Production) Engineering In Total
Manufacturing Application
Manufacturing as a term may be here broadly defined as embracing
all planning, decisions, equipment and service provision, and all
operations which follow settled product-desing and marketing
decisions and which precede disposition of the finished goods.
Tool engineering is defined in Webster as "a branch of engineering
in industry whose function is to plan the processes of
manufacture, design and supply the tools, and integrate the
facilities required for producing given products with minimal
expenditure of time, labor and materials."
Finney adds that "Tool engineer embraces participation in the
refinement of product design and in the desig) of machinery,
machine tools, gages, dies, fixture, and special tools used in
manufacturing. It also consists of participation in the
development, fabrication, maintenance, safety, and economic
utilization of thase facilities to produce maximum quality at
minimum cost".
A tool engineer then handles the more specialized activities of
process engineering, machine designing, tool designing plant and
layout engineering, gage engineering, manufacturing cost
estimating, machine and tool building, and maintenance
engineering.
R.J. Smith in his studies has identified the following functional
titles for engineers employed by manufacturing companies
1)Research 2)Develapment 3)Design 4)Construction 5)Production
6)Operating & Maintenance 7) Industrial Application & Sales
9) Management.
As it is seen in the following graphical figure that engineeringis not a simple homogeneous activity by a spectrum of interlocking
activities requiring men of diverse talents, tracing and interest.
Engineering Sciences Exnginéering Arts Business % Managerial Arts
(Fdeas) Cthings) Cwloncy # People)
Industrial
Manogemear
Development
Fig. 1.1. Functional Titles For Engineering In Manufacturing
Companies.
1.2 Functional Responsibilities Within The Production Engineering
rea
The followins are the basic functions carried out in typical
Production Engineering.
i- Process Engineering :, Under the supervision of the chief
Process engineer exact determination is made of the processes,
methods, machinery, tools, equipment and services required for the
authorized production. Process sheets will be prepared and issued
to all departments and functions concerned, giving sequence of
operations, and designating the departments, machines, tooling and
services for each operation.
2- Tool Design : A preliminary layout of tooling is made as called
for by process sheets and is turned over the process and/or
mothods engineering for analysis. On final approval, design are
turned over to the toolrcom foreman for making the tools, dies,
machines, attachments, or accessories needed. Inspection of
completed tools, if not done in the toolroom, is the
responsibility of quality control.
3- Cost Estimating : The cost estimator in closest cooperation
2with process engineer, must make preliminary production-cost
estimates for top executive guidance in making manufacturing
decisions. Cost estimator must estimate costs for tooling and
parts to assists the factory manager in making his decisions to
make or purchase; also to assists the sales department in
estimating prices.
4- Methods And Standarts Engineering _: The duties of these
functions embrace motion studies; study and set up of standart
times for each manufacturing operation; study of operation sheets
and plant-layout, for information of various functions;
determination of the ideal work place layout for each operation;
establishment of standart data for standart costs by the
accounting deparment; establishment and recording of machine tool
loads and machine-hour rates.
5- Tool Control : This funtion stocks, disburses, sales guards and
accounts for all tooling coming under his control. He schedules
and requisitions perishable tools, so as to maintain inventories
in keeping with production requirements.
6- Plant-Layout Engineering : This function is concerned with
Planning the location of departments, machines and other
productive equipment with reference to the sequence of
manufacturing operations and the process material handling
equipment.
7- Safety Engineering : This funtion is concerned with planning
the safety rules and regulations to be followed in the plant,
considering the types of machines used and the processes.
Determine the necessary guards and design and get them
constructed. Training the personel for safe operations, make
safety analysis of the operations and eleminate hazards.
@- Quality Control Engineer +: The responsibility and duty of
quality control engineering is very broad. Tool engineers design
the gages and plan their uses in processes. All standards and
measuring instrument must be calibrated according to predetermined
schedule for a certain quality level. The accuracies of machine
tools as well as instruments must be known. The errors inmeasurement should also be analysed. All these functions require
trained engineers.
1.3 The Importance of Praduc!
ion Engineering
Production engineering is a subject the importance of which is
being increasingly recognised. Not so very long ago it would have
been hard to say whether praductian engineering played a bad or
geod role to Mechanical Engineering. Certainly production
engineering was not always thougth to be quite respectable. There
can be little doubth that the result of this was not a very happy
one as far as industry was concerned.
Fortunately the old attitude to P.£. is changing. The importance
of national productivity is continually being urged upon us and
the production engineer has the greatest responsibility of making
sure that designs are good and economical and that manufacturing
Processes are speedy and efficient. [t seems that it is at last
being recognised that problems to be found in this area are worthy
of the attention of the best scientific engineering brains and
that effort put into solcing them is well worthwhile. It is to be
hoped that in the nearest future that P.E. based on sound
scientific principles, will be given the attention that it
deserves. our Turkish economic future well-being depends as much
upen paying proper attention to the application and improvement of
Production processes as it does upon any other area of research
and development in technology.
1.4 What Is Our Course + It is found that the development of in
understanding of production techniques is an excellent engineering
experience so it requires to dip into many of the engineering
science disciplines and apply them to specific, real processes.
Although our course emphasized methods for changing the size or
shape of metallic campanents many of the concepts can be directly
extented to include mast of the non-metallic materials.
The engineers must be able to make machine operating decisions
based on both cost and technical data. Thus, cost becomes such a
context that within which we must operate. It limits what we will
do to pieces of material just as effectively as does the materialstrength.
As engineers we are also limited by the production machines. A
machine which is perfectly able to produce a phsysically
satisfactory part may not be able to do so under the most
economical operating conditions. The machine may stoll, the
machine may break, the tolerances may not be satisfactory, the
machine may not have sufficient speed capabilities, and so forth.
We see that, our course is as much concerned with the limitations
composed on production processes as with the processes themselves.
We want to understand how material, money, machines, manpower
limit our productive capabilities.
Much of the material to be discussed in this course is subjected
to some simple experimental verifications. We can not accurately
predict even the results of a torsion test from the result of a
tensile test.
As production engineers we produce the basic data on which
predictions are based. We understand the assumptions in cooperated
into analysis. We observe the physical process and see to what
degree it outwardly resembles the analytical model. We perform the
actual process, take the pertinent data, and compare fact with
prediction we have to find out and explain errors and
discrepancies.CHAPTER 2
BASIC DESIGN CONSIDERATIONS FOR
PRESS FORGINGS
21 INTRODUCTION
"The following sequence is e common besic design process for press
forgings:
1) Mechining ellowance rust be added to surfeces thet will be
“mechined.
2) Perting line is located.
3) Webs are constructed for lerge holes.
4
8
8
7
Draft must be given to cylindrical portions of the pert.
Fillets end corner redii should be used to blend sharp corners.
Flesh end gutter geometry must be determined.
Volume of the forging including flesh is celculeted.
8) Scele allowance is considered end edded to volume of forging.
g
Billet geometry is selected.
10) Die block is designed to perform necessary forging operetions,
11) Forging load is estimeted.
12) Dimensional tolerances for die block end forging ere cbteined.
13) if required preform cavity (mould) is designed.2.2. MACHINING ALLOWANCE.
Mechining allowances are recommended for surfaces thet are going to be
mechined. The ellowance must be grest enough to ensure « defect-free
surface efter mechining. Therefore it must teke into ecccunt the depth of
decarburized leer, the depth of scale pockets, under filling of the
cavities and other surface defects that ere unevoideble in conventional
forging operstions. The values for machining allowances ere taken from
DIN Stendard 7523. end tebulsted in Teble 2.1,
Teble 2.1. Machining allowances [36)
Meximum sire
: Elongated forging:
(wid or Maximum length of forging
thickness)
an Rotationally symmetric forgings
thideee maximum diameter of forging
(ALLDIMENSIONS AREI (mm).
over] upto [ever |40 | 6s | 100 | 160 | 250 | 400 | e30 | 1000
vptoaolea |100 | 160 | 250 | 400 | ¢00 | 1000 |: 1600
40 15 15 2 2 25,8 4 5 6
so feos Jas 2 | 2 | 25] | os] 45] 55| 65
&3 100 2 2 25 8 3 85) 45 55] 65
100 | 160 - 25 3 3 85) 4 5 6 7
160 | 250 -|- [3 ss}a {5s |S] 7]e
wo} - |- |- | «a ]s]e}7]efes2.3. PARTING LINE POSITION
The die psrting line is the plene or plenes which divide the top end
bottom dies on forging as shown in Figure 2.1, Its location can influence,
the followings:
8) The esse end economy of die sinking.
b) The ease of die filling.
“ ¢) The formation of forging defects.
a
The ease of clipping.
©) The emount of draft required and hence forging weight,
{) The extent end detection of mismatch.
6) The ebility to nest forgings.
h) The need touse die locks.
ls) The forging tolerances,
Parting line is loceted at the widest section of forging for the removel
ofpiece from die.
' Parting line
Figure 2.1 Parting Line Applications
24, WEB DESIGN FOR CENTRAL HOLES AND CAVITIES
Insteed of forging parts having centre holes as solid bedies end then
adrill those holes causing weste of meteriel, it can be considered es a
better process to design those holes with webs.
Preforging of holes seves material and the residual web of a preforged
hole can be removed by the relstively chesp punching operetion, It is
stated thet the depth of cavity is limited to size of it is diameter,
The maximum depth may be 3/2 times the diameter when e full redius is
dllowed at the bottom 6s in Figure 2.2b
awd
de
Roe
hmaxvd
(a)
poe
h
J
we
tr
h
a hhnax=wd
(c) (a)
Figure 2.2, Dimensions of Cevities and Preforged Holes [1,37]
Holes of finished component ere preforged from both sides end a.web
'S itomaticelly formed et the parting line. The thickness of this web
Figure 2.2cq is determined by the maximum sllowsble depth of cevities
]or sccording to plan area of web for shellow holes by using curves, given
in Figure 2.3.
wt=7
wt = 0.8.wd+3
wt = O4.wdt 5
wt = 0.2.wd+ 10
wt = O4.wd + 6
wt = 0.2.wd+11
wt = 0.375 .wd + 5.75
where wt is web thickness in mm
wd is web diemeter in cm,
wds5
S
OIL BOX 4%
GAS BOX 3%
GAS CONTINIOUS 2.5%
ELECTRIC 15%
INDUCTION 1%
242.10. DIE DESIGN
The following formulee suggested by Bruchenow end Rebelski ,
hes been incorporeted to the program for celculation of the overall die
width.
x a
Dw= DDpit 03 ¥ (Dnit tas) + 10 (+1) (mm) (221)
it il
where
D,y The meximum cavity diemeter in each stege.
ty The totel cavity length in each stage.
n i Number of operations.
nis teken to be 1 since only finishing operation will be performed with
die, Then eqn (2.19) reduces to: :
Dw =D,y + 0.3 (D,i+ ty) + 20 (mm) (2.22)
The depth of die block must be selected by the user eccording to
wzileble die blocks and equipment, and number of re-sinking.
end die block height ere shown in Figure 2.11.
Die cavity dimensions should include an ellowance for the expansion
of the stock on hesting and 1.5% hes been suggested for this es
contraction allowance
25HIOISH
woo1g 31d
HLGIA
yoo 31d
figere 2.11. Die Block Width And Height
2.1). FORGING LOAD
Forging loscl end pressure estimation in closed end impression die
Inying eperations is difficult due to the cherecteristics of forgings. Most
Seung operstions ere of nonstesdy-stete type in terms of metal flow,
Hoes
* end temperstures. In addition to this forgings include a lege
tonler of different geometrical shepes which needs perticuler enslysis.
Tor this reason meny researche ; ‘have been trying to
: limste forging load by using empricel, stetistical or enelyticel enelysis,
+, Ws stated in that none of the works give exect results for ell
-. Oisses of forgings end depend on certain sssumptions. In this study sn
“pried method called “Modified Drebing Method" which is steted to
re results with + 10% error’ will be used, for load and energy
tlevletions,
In
Order to calculate forging loed according to Modified Drebing Method
losing detsis necessary,
26L
2)
3) Projected eres of forging excluding flash A (mm?)
4) Volume of flesh in flesh lend VF 1 (mm®)
5)
6)
7
‘Volume of forging excluding flesh V (mm)
Length of forging excluding flesh 1 (mm)
Length of forging including flesh land It (mm)
Plen area of flesh land Afl (mm?)
Yield strength ¥ (kg/mm2),
‘The forging load is determined es follows:
‘The load on the flash land Lfl (kgf) is given by
afl
Lf-=yan (cn)"* (2.23)
‘The load on the forging Lig (kgf) is given by
Lig sya" pe (2.24)
The totel forging load is then given by.
L= (Ly +A) (2.28)
For different meteriels end different forging temperstures some yield
strength values are presented in Teble 2.7.
Other methods ere elso evaileble in the program end celculeted losd
can be compered or chenged by the results of one of the selected
methods, if desired. Analysis of forging losd eccording to different
researchers is given in Appendix 1.
27Teble 2.7. Yield Strength for Steel (kg/mm_2)
Yield strength [kg/mm2],
Steel Quelity Forging temperature ‘C
En BS 970 1100-1150 12001280
No No
3 080A 27 10.08 faa 8.62) tuuen7 5G am6.3)
8 080 M 40 945 756 693 5867
16 605M 36 1071 945 756 6,93
608M 38 1008 882 756 693
18 530M 40 945 819 693 6.90
20 1008 882 756 6.230
21 11971071 9458.82
22 1197 1071 «945 B82
23 «853M 31 11871071 945 8.82
24 817M 40 1134 1008 «8.19 (7.56
25 = 826M 31 1134-1008 «8827.56
26 = 828M 40 1197 10.08. 8.82. 8.19
30 835M 30 1197-1071" 9.45 B82
31 543.99, 945 8.19 693... 6.30
34 665M 17 10.71 9.45) @.19 ©
35. 665M 23 O71 9.45 =< 8.19 ++
36 «855M 13 1134 1008... 882. | 7.56
37 1197 1071. 945° 8.82
38 1119 7g 10.7 Oem a)
339° 835M 15 1197 1071945882
40 722M 24 11341071 9458.19
41 905M 41 1008 882 756 693
42 O70A72 945 819 693 6,30
43° 0B0A47 945 819 693 620
44 o60A96 945 818 693 6390
45 280053 1134 9450 8.19. 7.56
46 Mgt 945 897.56
47 735 A50 9.45 8.19 6.93 630
48 527A 60 11.34 10.08 819 7.56
1300
5.67
4.41
5.67
5.67
5.67
5.67
7.56
7.56
7.56
6.30
6.93
6.93
” 7.56
5.04
6.30
6.30
6.93
7.56
7.56
7.56
7.56
6.30
5.04
5.04
5.04
6.30
6.30
5.04
6.93
28CHAPTER 3
MOULD DESIGN
3.1. INTRODUCTION
‘The life of the finishing die can be greatly extended by moulding the
part before finishing, The moulding die hes seversl functions. Firstly it
converts the billet more closely to the finel required shspe, secondly it
reduces weer on the finishing die cavity and finelly it fecilitstes filling of
deep cavities providing metel at necessary points in the die,
The necessity of moulding impression for the finisher cavity
depends on forging geometry, production volume end expected die life
per setup.
In ASM forging end cesting hendbook’ °.'it'is steted thet on the
averege; for'a die life exceeding~-10000 ‘pieces before resinking, a ~
moulding impression is required. However this number cen increase or
decrease ercording to complexity of forging.
It is steted in a work by Chamuard and reviewed by Choi and Dean
thet for complex shapes a moulding impression is normelly required and
forgings with rib height to rib width ratio exceeding 2.5 are classified as
complex forgings. In Teble 3.1 shepe complexity factors for different
‘sections sre shown,
7)Teble 3.1. Shape Complexity Fectors ,
Complexity Factor] Degree of
(n/v) Complexity
Simple Forging h/b
negligible
tsi bod
Semi-simple
Forging h/bet ay
Semi-complex | a onsyco, Ori {1b
Forging ene? 8 Bo
Complex Forging
maa
2.5¢h/be4 25 eo
Very Complex
Forging
a.senypes.o| > Gl
ita
30In most of the practice necessity of moulding impression is
dependent on meny process veriebles, There is no sufficient design
criteria availeble to decide for moulding impression sstomstically.
Therefore it is logical to leave this decision to the user in a computer
program. In the following sections different works on mould design are
discussed end a design procedure is determined to use in the progrem.
3.2, MOULD DESIGN PROCEDURE, “
The general accepted outlines of mould design can be found in
different publications, ; . and summerized es
follows:
1) At the perting line which is elong the widest section of the forging, the
mould cavity is kept 0.4 mm to].6 mm nerrower then the finisher cavity
so thet the preformed part can easily fit into the finisher cavity. This is
also necessary to avoid shesring of the moyjded shape by the walls of the
finisher cavity.
2) Mould cavity is designed deeper then the finisher cavity in order to
compansste the reduction on the lateral dimension described shove end
therefore to provide volume constency, It is elso stated thet , _. the
dimensions of thé moulded shepe should be lerger then those of the
finished part in the forging direction so thet the metal flow is mostly of
the upsetting type rather then the extrusion type. During the finishing
stage the msteriel then will be sequeezed Isterally toward the die cavity
without sdditional shear et the die-meterisl interfuce. This minimizes
friction and forging low, therefore reduces the wear slong the die
surface,
33) The volume of the mould cavity must be as lerge as the volume of the
material in finisher cavity including flash ellowance.
4) The mould should have longer redii end fillets then finisher cavity to
esse metel flow in the finel operetion, °
5) Draft angles of the moulded shepe must conform to the ‘angles in the
finished shape.
6) Itissteted that -, in order to provide mete] flow toward the ribs, an
opening teper from center of webs toward the ribs should be provided
Figure 3.1.
7) High ribs should be lowered in the moulding stege to provide metel
flow in the finishing shape,
8) Web thickness in the mould cavity must be lerger then the web
thickness in the finishing cavity. :
t
Figure 3.1. Opening teper (AB) from center of web toward rib.
323.4 THE PROPOSED DESIGN PROCESS:
‘With the help of discussion ebout the sufficiencies and insufficiencies
of previous works on mould design. It can be suggested thet a computer
program should conform the following items:
1) A computer program must perform the general outlines of mould
design processes eccepted by all reseerchers [2-3, 12-14, 17-19, 25, 28,
37] these ere:
8) Mould must be nerrower then finisher csvity at the parting line,
b) Volume constency must be setisfied thet volume of mould cavity
must be equel to or grester then the volume of finisher cavity including
flesh ellowence.
c) Thin end tell ribs must be evoided.
a) Webs must be thicker in mould cavity.
e) Radii on mould cavity must be comiperatively lerger then the ones in
finisher cavity.
f) The top of thin ribs should be circuler to esse filling of them.
2) Since preform design is a highly experience dependent process,
interective algorithms must be incorporsted in a program to interect with
the user end make any desired modificetions as follows:
8) Type of eny entity must be changed. eg, line to circular arc or vice
versa.
b) Any corner redii end fillet redii cen be eltered.
c) Any edge cen be roteted.
33d) Any edge con be shifted
; e) Redif can be inserted onto eny location.
f) Redif can be deleted from eny locetion,
] ¢) Redii of circular entities must be altered.
3) Program must axtometicelly detect snd blend eny sharp corner thet is
en undesired festure in a mould design,
4) The user must intersctively check the volume of moulded shape end
the ratio of the volume of moulded shepe to volume of finished shape end
flash allowance.
5) Structure of such @ program must be such thet it must execute well
] defined procedures satometicelly, then must supply useble tools to user
to interactively modify the shspe designed ky program.yrotseqs ‘124204 'j9h Busssooud a “ueoy esmionus Bussz00ud Joy paxdope 999
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