Search Results for dies

This article discusses failure mechanisms in tool and die materials that are very important to nearly all manufacturing processes. It is primarily devoted to failures of tool steels used in cold working and hot working applications. The processes involved in the analysis of tool and die failures are also covered. In addition, the article focuses on a number of factors that are responsible for tool and die failures, including mechanical design, grade selection, steel quality, machining processes, heat treatment operation, and tool and die setup.

This article reviews the production variables that influence the selection of various stamping die materials: ferrous, nonferrous, and plastic die materials. It provides a discussion on the specific types of die materials for tool steels, cast irons, plastics, aluminum, bronze, zinc-aluminum, and steel-bonded carbides. The article describes factors to be considered during the selection of materials for press-forming dies.

This article discusses different factors for selecting progressive dies: costs, production volume, and press availability. It describes the purposes of strip development for a ring shaped part and presents the principles for the development of progressive dies. The article provides discussions on the general design features of progressive dies and the choice of proper auxiliary equipment such as coil feeders and scrap handling equipment. It concludes with information on different presses for progressive die work: open-back inclinable presses, four-column presses, and automatic underdrive presses.

This article introduces process factors that influence die wear and lubrication for metal forming operations such as bending, spinning, stretching, deep drawing, and ironing. It discusses the effects of part shape, sheet thickness, tolerance requirements, sheet metal, and lubrication on shallow forming dies. The article describes the wear of material for dies to draw round and square cup-shaped metal parts in a press. It also discusses the effect of process conditions on the shallow forming dies.

The selection of material for a drawing die is aimed at the production of the desired quality and quantity of parts with the least possible tooling cost per part. This article discusses the performance of a drawing die. It contains tables that list the lubricants used for deep drawing, and the typical materials for punches and blank holders. The article describes the typical causes of wear (galling) of deep-drawing tooling. It analyzes the selection of a harder and more wear-resistant material, the application of a surface coating such as chromium plating to the finished tools, and surface treatments such as carburizing or carbonitriding for low-alloy steels or nitriding or physical vapor deposition coating for tool steels.

For forming processes, optimization goals range from tuning the process parameters while keeping geometry unchanged to finding optimal geometry for intermediate dies in a multistage forming operation. This article commences with a description on the three salient steps of optimization procedures: defining the objective function, calculating the objective function, and searching an optimum design. It concludes with an example illustrating the optimization of conical-die extrusion.

This article describes two rapid tooling technologies, namely, direct rapid tooling and indirect rapid tooling, for forging-die applications. Commonly used direct rapid tooling technologies include selective laser sintering, three-dimensional printing, and laser-engineered net shape process. The indirect rapid tooling technologies include 3D Keltool process, hot isostatic pressing, rapid solidification process tooling, precision spray forming, and radially constricted consolidation process.

This article addresses dies and die materials used for hot forging in vertical presses, hammers, and horizontal forging machines (upsetters). It reviews the properties of die materials for hot forging, including good hardenability, resistance to wear, plastic deformation, thermal fatigue, and mechanical fatigue. The article describes heat treating practices commonly employed for chromium- and tungsten-base AISI hot-work tool steels. It discusses the fabrication of impression dies, and the advantages and disadvantages of cast dies. The article concludes with a discussion on the factors that affect die life and safety precautions to be considered during die construction.

This article describes the characteristics of tools and dies and the causes of their failures. It discusses the failure mechanisms in tool and die materials that are important to nearly all manufacturing processes, but is primarily devoted to failures of tool steels used in cold-working and hot-working applications. It reviews problems introduced during mechanical design, materials selection, machining, heat treating, finish grinding, and tool and die operation. The brittle fracture of rehardened high-speed steels is also considered. Finally, failures due to seams or laps, unconsolidated interiors, and carbide segregation and poor carbide morphology are reviewed with illustrations.

This article describes the six fundamental factors that decide a tool's performance. These are mechanical design, grade of tool steel, machining procedure, heat treatment, grinding, and handling. A deficiency in any one of the factors can lead to a tool and die failure. The article presents a seven-step procedure to be followed when looking for the reason for a failure. A review of the results of the seven-point investigation may lead directly to the source of failure or narrow the field of investigation to permit the use of special tests.

Forging machines use a wide variety of hammers, presses, and dies to produce products with the desired shape, size, and geometry. This article discusses the major types of hammers (gravity-drop, power-drop, high speed, and open-die forging), and presses (mechanical, hydraulic, screw-type, and multiple-ram). It further discusses the technologies used in the design of dies, terminology, and materials selection for dies for the most common hot-forging processes, particularly those using vertical presses, hammers, and horizontal forging machines. A brief section is included on computer-aided design in the forging industry. Additionally, the article reviews specific characteristics, process limitations, advantages, and disadvantages of the most common forging processes, namely hot upset forging, roll forging, radial forging, rotary forging, isothermal and hot-die forging, precision forging, and cold forging.