Die Design Fundamentals

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