elective lesson 2-3 Flashcards
The industrial art of manufacturing stamping dies, plastics molds, and jigs and fixtures to be used in the mass production of solid objects.
TOOL AND DIE MAKING
The fabrication of pressworking dies constitutes the major part of the work done in tool and die shops. Most pressworking dies are utilized in the fabrication of sheet-metal parts that range in size.
TOOL AND DIE MAKING
pressworking die consists of two sections, called
punch and die, or male and female
Both sections are mounted firmly in an electrically or hydraulically driven press.
punch and die, or male and female.
is the most common method used by tool & to cut or shape the material mostly using a Press.
Die design
are a cost-effective way to create customized products ranging from paper clips to advanced automobile parts.
dies
are responsible for manufacturing complex equipment like cutting tools dies, molds, and other machinery and parts.
Tool and die makers
The development of modern tools and dies can be traced to the American inventor and manufacturer____________, who first implemented the concept of the planned manufacturing of interchangeable parts.
Eli Whitney
mass producing firearms for the War of _______.
1812
DIFFERENT TYPES OF TOOL AND DIE
Simple Die
Compound Die
Combination Die
Transfer Die
Progressive Die
Multiple Die
designed to perform only a single operation of each stroke of the press slide. Simple die can be further classified according to the functions such as cutting and forming.
Simple die or single operation die
are used in operations like trimming, notching, blanking and more. The forming die used in bending, and curling etc.
Cutting dies
die performs multiple operations like cut or punch can be done in one stroke. For example, it can perform cutting and forming operations simultaneously in one stroke. This very effective method for high-volume parts. ____________are used to stamp simple flat parts like washers.
COMPOUND DIE
In this type of dies, the cutting and bending operations are combined and carried out in a single operation. The cutting operation may include trimming, plercing, and blanking and is combined with noncutting operations like bending forming, etc.
combinations of different tool and die in one work station, parang per cycle
COMBINATION DIE
die uses a single press to operate multiple tools. In high volume production work, ________ comes with more advantages. It can freely transfer the work by adding more shape to the part until the metal workpiece achieves the final shape.
transferring to another operation in a same work station
TRANSFER DIE
widely used in producing various Industries parts, such as automotive and electronic, This type of die stamping consists of several individual workstations, each of which performs one or more different operations on the part.
Progressive die
has many unique benefits Including a high-speed production rate with low labor cost, the minimum amount of scrape, and this dies required only one setup to work.
progressive die
die is a punch press that produces two or more identical parts at a single stroke. A number of simple dies and punches are ganged together to produce two or more parts at each stroke of the press.
multiple or gang die
DIFFERENCE BETWEEN TOOL AND DIE
The easiest way to think of the difference between a tool and a die is simply that dies are a subset of tools-all dies are tools, but not all tools are dies, In metal stamping, a tool can be almost any mechanical device used to cut, form, support, or mold metals. By that definition, jigs and fixtures are tools, as are drills and cutting blades. Dies on the other hand are only those tools that functionally change the shape of the metal. Dies are typically the female components of a larger tool or press.
DIFFERENCE BETWEEN MALE AND FEMALE DIES
the male component is the protruding component, while the female is the depression or indentation.
the male portion will likely comprise multiple steel cutting or forming punches with the female portions matching the male pattern.
In the context of metal stamping, the male punch is driven into the die block to cut or form the workpiece or both
The requirement
for the production of standard workholding devices has paved the way for
two specific terms
named:
Jigs and Fixtures
is the device that guides the tool
jig
is a tool that securely
and firmly holds the job in position during
machining operations.
fixture
is a tool that guides the
machining tool.
Jigs
A common type of jig is the ______ jig, which guides
the drill for making holes at desired locations.
drill jig
Types of Jigs
Template Jig
Plate Jig
Channel Jig
Diameter Jig
Leaf Jig
Ring Jig
Box Jig
is the simplest of all the
models. The plate, having two holes, acts as a template fixed on the component to be machined. The drill is guided through these template holes, and the required
holes are drilled on the workpiece at the same relative positions as on the
template.
Template Jig
improves the template jig by
incorporating drill bushes on the
template. is employed to
drill holes on large parts, maintaining
accurate spacing with each other.
Plate Jig
s a simple type of jig having
a channel-like cross-section. The
component is fitted within the channel
and is located and clamped by rotating
the knurled knob. The tool is guided
through the drill bush
Channel Jig
is used to drill radial holes
on a cylindrical or spherical workpiece
Diameter Jig
has a ______ that may be swung
open or closed on the work for loading or loading purposes.
Leaf Jig
is employed to drill holes on
circular flanged parts. The work is
securely clamped on the drill body, and
the holes are drilled by guiding the tool
through drill bushes.
Ring Jig
is of box-like construction within
which the work is rigidly held so that it can be drilled or machined from different angles at a single setting depending on which face of the jig is turned toward the
tool.
Box Jig
Types of Fixtures
Turning Fixtures
Milling Fixtures
Broaching Fixtures
Indexing Fixtures
Grinding Fixtures
Boring Fixtures
Duplex Fixtures
Welding Fixtures
Tapping Fixtures
Assembly Fixtures
These fixtures are generally mounted on the nose of the machine spindle or a faceplate, and the workpieces hold them The fixture may have to be provided with a counterweight or balance the unbalance fixture whenever necessary.
Turning Fixtures
fixtures are typically mounted on the nose of the machine spindle or a faceplate, and the workpieces hold them. The table is shifted and set in the proper position about the cutter. The workpieces are located in the base of the fixture and clamped before starting the operation
Milling Fixtures
are used on
different broaching machines to
locate, hold and support the
workpieces during the operations,
such as keyway broaching operations, such as keyway broaching, hole broaching, etc.
Broaching Fixtures
Several components need machining on different surfaces such that their
machined surface surfaces or forms are evenly spaced. Such elements must be indexed equally as many as the number of surfaces to be machined. The holding devices (jigs or fixtures) used are made
to carry a suitable indexing mechanism. A fixture having such a device is known
as an ______________.
Indexing Fixtures
These fixtures may be the standard workholding devices, such as chucks,
mandrels, chuck with shaped jaws,
magnetic chucks, etc. For external
surface grinding, cylindrical grinding
utilizes plain or tapered mandrels. The
workpiece is located and held on the
mandrel with the help of the bore so that the external surface may be machined truly concentric to the bore.
For internal grinding, the chuck is the most standard
fixture. For holding irregularly shaped
components, the fixture is designed the same as turning or boring fixtures.
Grinding Fixtures
This fixture incorporates almost all the
prevailing principles of jig and fixture
design; their construction need not be as sturdy as that of the milling fixtures
because they never have to bear as
heavy cutting loads as involved in milling fixtures because they never have to endure as heavy cutting loads as
involved in milling operations.
Boring Fixtures
It is the name given to the fixture which
holds two similar components
simultaneously and facilitates
simultaneously machining of these
components at two separate stations.
Duplex Fixtures
are carefully designed to
hold and support the various components
welded in proper locations and prevent
distortions in welded structures.
Welding Fixtures
are specially designed to position and firmly secure
identical workpieces to cut internal
threads in drilled holes. Odd-shaped and unbalanced components will always need such fixtures, especially when the tapping operation is to be carried out repeatedly on a mass scale on such
parts.
Tapping Fixtures
The function of these fixtures is to hold
different components together in their
proper relative position when assembling
them.
Assembly Fixtures
The primary purpose of a jig or a
fixture is to
create a secure mounting
point for a workpiece, allowing for
support during operation and
increase accuracy, precision,
reliability, and interchangeability in
the finished parts.
Jigs are commonly used in
drilling,
boring, reaming and tapping
fixtures are used for
milling,
slotting, shaping, turning and
planning.
Jigs are usually more
expensive than fixtures.
True
Jig designs
are often more complex than simpler
fixture designs.
True
The primary benefits of jigs and
fixtures are:
Accuracy
Simplicity
Ease of Use
Repeatability
Safety
