Table
of
Contents
10.2.2 V-profile Bend Dies
10.2.3
Universal Bending Dies
10.3
Dies of Complex Design
10.3.1
Closing Profile Dies
10.3.2
Special Bending Dies
10.3.3
Curling and Hinge Dies
10.3.4 Tube-forming Dies
10.3.5 Multiple-bend Dies
10.3.6
Combination Dies
10.3.7
Progressive Dies
Chapter 11 Deep Drawing Dies
11.1 Introduction
11.2 Draw Rings
11.2.1 Draw Rings with Corner Radius 11.2.2
Draw Rings with Conical Profile
11.3
Clearances and Tolerances
11.3.1
Calculation of the Dimensions of the Punch and Die
11.4 Blank Holders
11.4.1 Blank Holders
11.4.2 Blank Holder Pressure
11.4.3 Blank Holder Force
11.4.4 Draw Beads
11.5
Single-operation Dies
11.6
Multi-operation
Dies
11.7 Progressive Dies
11.8 11.9
Ironing Dies Drawing Dies for Pieces of Spherical and Parabolic Shape
Chapter 12 Various Forming Dies
12.1
Nosing Dies
12.2
Expanding and Bulging Dies
12.2.1 Expanding Dies
12.2.2
Bulging Dies
12.3 Flanging Dies
Chapter 13 Tool and Die Materials
13.1 Introduction
13.2 Carbon and Alloy Steels
13.2.1 Designations for Carbon and Alloy Steels
13.2.2 Effects of Various Alloy Elements
in Steels
13.2.3
Carbon Steels 137
138 139
139
139 141
142 144
144 145
147
147 147
147 149
151 151
154
154 155
155 156
158
160
160 162
164
167
167 170
170 171
172
175
175 175
176 176
176
Table of Contents
13.2.4 13.2.5
13.2.6 13.2.7
13.3 13.3.1
13.3.2 13.4
13.5 Alloy Steels
Machinability of Steels Mechanical Properties
of Steels Applications of Carbon and Alloy Steels
Tool and Die Steels Designation and Classification of Tool and Die Steels
Cold Work Tool and Die Steels Nonferrous Metals
Nonmetallic Materials
Appendix 1 Appendix 2
Appendix 3 Miscellaneous Information
Glossary Bibliography
Index Blank Diameter
of Drawn Shells Metric System Tolerances on Linear Dimensions
177 177
178 179
179 179
181 182
183
185 189
199 209
215 217
PREFACE
A very large variety of sheet-metal forming processes is used in modern sheet-metal press-working shop
practice. Many of these deformation processes, used in making aircraft, automobiles, and other products, use complex equipment that is derived from the latest discoveries in science and technology. With the ever-
increasing knowledge of science and technology, deformation processes promise to be even more
complex to satisfy the demand for more productivity, lower cost, and greater precision. However, for all their advantages, the more sophisticated deformation processes of today have not replaced the need for
basic sheet-metal forming processes and dies.
This book draws on the author’s 30-plus years of experience as an engineer and provides a com- plete guide to modern sheet-metal forming processes and die design
-
still the most commonly used manufacturing methodology for the mass production of complex, high-precision parts. Much more prac-
tical than theoretical, the book covers the and “whys” of product analysis, and the mechanisms
of blanking, punching, bending, deep drawing, stretching, material economy, strip design, movement of metal during stamping, and tooling design. Readers will find numerous illustrations, tables, and
charts to aid in die design and manufacturing processes; Formulas and calculations needed for vari- ous die operations and performance evaluation are included; and designations, characteristics, and
typ-
ical applications of various carbon and alloy steels for different die components are evaluated. The book concentrates on simple, practical engineering methods rather than complex numerical tech-
niques to provide the practicing engineer, student, technician, and die maker with usable approaches to sheet-metal forming processes and die design.
The first part of the book deals with the structures of metals and the fundamental aspects of the mechanical behavior of metals. Knowledge of structures is necessary to controlling and predicting the
behavior and performance of metals in sheet-metal forming processes. The second part of the book covers all aspects of forming sheet metal. It presents the fundamental
sheet-metal forming operations of shearing, blanking and punching, bending, stretching, and deep draw-
ing. Mechanics of various drawing processes indicate ways in which the deformation, loads, and process limits can be calculated for press forming and deep drawing operations. The book includes various draw-
ing processes nosing, expanding, dimpling, spinning and flexible die forming mostly used in the aircraft and aerospace industry.
Dies are very important to the overall mass production picture, so they are discussed in the last sec- tion of the book, which presents a complete picture of the knowledge and skills needs for the effective
design of dies for sheet-metal forming processes described. Special attention is given to:
Formulas and calculations needed for various die parts. Rules of thumb and innovative approaches to the subject.
Properties and typical applications of selected tool and die materials for various die parts.
...
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