Fundamentals of Tool Design, Fifth Edition

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Society of Manufacturing Engineers, Dec 8, 2003 - Technology & Engineering - 404 pages
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The book contains material from leading industry experts on topics such as rapid prototyping; design of pressworking tools; bending, forming and drawing; forging dies; inspection and gaging; CAD applications; and more. It outlines all the factors that impact the success of your tools, showing you how and why your tools will work in relation to the manufacturing processes you're designing them for. Each chapter details the 'nuts & bolts' you need to know that impact tool designs - such as material science, tool layout, cost analysis, calculating economical lot sizes, safety, and more. Topics also include: tool materials, cutting tool design, workholding principles, jig design, fixture design, design of pressworking tools, joining processes, inspection and gaging, modular tooling and automated tool handling, CIM/CAD/CAM technology, 3-D solid modeling, and more.
 

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Contents

TUBULAR HYDROFORMING
201
TRANSFER PRESS AND DIE OPERATIONS
202
TURRET PUNCHING MACHINES FORGING
206
REVIEW QUESTIONS
209
Metal Cutting Forming and Drawing SYSTEMS OF LENGTH AREA AND FORCE MEASUREMENT SIMPLE DIE PUNCHING
211
BALLLOCK PUNCHES
220
BENDING
222
FORMING
227

Tool Materials PHYSICAL PROPERTIES
13
MECHANICAL PROPERTIES
14
FERROUS TOOL MATERIALS
16
NONFERROUS TOOL MATERIALS
24
NONMETALLIC TOOL MATERIALS
26
HEATTREATING
29
REVIEW QUESTIONS
32
Cutting Tool Design
33
CHIP FORMATION
34
CUTTING FORCES
41
POWER REQUIREMENTS
45
TOOL WEAR
46
TOOL LIFE
54
GUIDELINES FOR CUTTING TOOL DESIGN
59
SINGLEPOINT TOOLS
62
MULTIPLEPOINT TOOLS
67
LINEARTRAVEL TOOLS
72
AXIALFEED ROTARY TOOLS
73
REFERENCES
86
REVIEW QUESTIONS
87
Workholding Principles BASIC WORKHOLDERS
89
WORKHOLDER PURPOSE AND FUNCTION
90
LOCATING PRINCIPLES
91
FOOLPROOFING
96
CLAMPING PRINCIPLES
111
CHUCKS
125
VISES
133
NONMECHANICAL CLAMPING
137
POWER CLAMPING
139
BASIC CONSTRUCTION PRINCIPLES
140
REVIEW QUESTIONS
145
Jig Design GENERAL CONSIDERATIONS MACHINE CONSIDERATIONS
147
PROCESS CONSIDERATIONS
148
DRILL JIGS
149
DRILL JIG BUSHINGS
161
DRILL BUSHING INSTALLATION
163
JIG DESIGN EXAMPLE
165
REVIEW QUESTIONS
172
Fixture Design GENERAL CONSIDERATIONS
175
TYPES OF FIXTURES
178
FIXTURE CLASSIFICATIONS
180
RELATIONSHIP BETWEEN FIXTURE AND CUTTING TOOL
183
TOOL POSITIONING
184
DESIGN FUNDAMENTALS
186
FIXTURE DESIGN EXAMPLE
187
REVIEW QUESTIONS
190
Power Presses GAPFRAME PRESSES
193
STRAIGHTSIDE PRESSES
194
MECHANICAL VERSUS HYDRAULIC PRESSES
195
DIE CUSHIONS
198
HYDRAULIC FORMING MACHINES AND DIES
200
EMBOSSING
230
TWISTERS AND BENDERS
231
HOLE FLANGING OR EXTRUDING
232
STAMPING ANALYSIS
235
DEEP DRAWING OF CUPS
239
PROGRESSIVE DIES
247
EXTRUSION
260
BIBLIOGRAPHY
265
REVIEW QUESTIONS
266
Tool Design for Inspection and Gaging
267
GAGING PRINCIPLES
268
GAGE MATERIALS GAGING POLICY
272
GAGE MEASUREMENT
273
GAGE TYPES
274
COORDINATE MEASURING MACHINES
288
MEASURING WITH LIGHT RAYS
291
GAGING METHODS
296
BASIC DESIGN RULES FOR POSITIONALLY TOLERANCED PARTS
305
BIBLIOGRAPHY
307
REVIEW QUESTIONS
316
Tool Design for Joining Processes TOOLING FOR PHYSICAL JOINING PROCESSES
319
RESISTANCE WELDING
322
LASER WELDING FIXTURES
327
TOOLING FOR SOLDERING AND BRAZING
328
TOOLING FOR INDUCTION BRAZING
330
TOOLING FOR MECHANICAL JOINING PROCESSES
335
RIVETS
339
WIRE STITCHING
343
METAL STITCHING
344
STAKING
345
TOOLING FOR ADHESIVE BONDING
346
REVIEW QUESTIONS
348
Modular and Automated Tool Handling DESIGN
351
ADVANTAGES OF MODULAR TOOLING
354
MODULAR TOOLING SYSTEM DESIGN
355
QUICKCHANGE TOOLING
359
AUTOMATIC IDENTIFICATION
361
REVIEW QUESTIONS
362
The Computer in Tool Design COLLABORATIVE ENGINEERING
363
RAPID PROTOTYPING AND MANUFACTURING
364
TOLERANCE ANALYSIS DESIGN DOCUMENT MANAGEMENT
369
BIBLIOGRAPHY REVIEW QUESTIONS
370
Geometric Dimensioning and Tolerancing SYMBOLS AND DEFINITIONS
371
THREEPLANE CONCEPT
384
GENERAL RULES
385
BIBLIOGRAPHY
387
REVIEW QUESTIONS
388
Bibliography
389
Index
393
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About the author (2003)

DAVID A. SMITH is currently an Associate Professor in the Department of Sociology, University of California, Irvine.

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