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Anil Chaudhary, Suhas Vaze
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Kuldeep Agarwal, Rajiv Shivpuri
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Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006818
EISBN: 978-1-62708-329-4
... 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. cold working dies failure...
Abstract
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.
Book Chapter
Selection of Materials for Press-Forming Dies
Available to PurchaseSeries: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005140
EISBN: 978-1-62708-186-3
...-aluminum, and steel-bonded carbides. The article describes factors to be considered during the selection of materials for press-forming dies. aluminum bronze cast irons ferrous die materials material selection nonferrous die materials plastic die materials plastics press-forming dies...
Abstract
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.
Book Chapter
Progressive Dies
Available to PurchaseSeries: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005160
EISBN: 978-1-62708-186-3
... Abstract 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...
Abstract
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.
Book Chapter
Wear and Lubrication of Sheet-Metal Forming Dies
Available to PurchaseSeries: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005179
EISBN: 978-1-62708-186-3
... 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. bending deep drawing deep-drawing dies ironing lubrication metal forming shallow...
Abstract
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.
Book Chapter
Selection of Materials for Deep-Drawing Dies
Available to PurchaseSeries: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005148
EISBN: 978-1-62708-186-3
.... The types of dies and other tooling used for conventional deep drawing are illustrated in Fig. 1 . Fig. 1 Schematic showing tools used for the first draw (top) and the first redraw (bottom) in deep drawing It is sometimes necessary for redrawn shells to have a wrinkle-free sidewall of uniform...
Abstract
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.
Book Chapter
Design Optimization for Dies and Preforms
Available to PurchaseSeries: ASM Handbook
Volume: 14A
Publisher: ASM International
Published: 01 January 2005
DOI: 10.31399/asm.hb.v14a.a0004022
EISBN: 978-1-62708-185-6
... Abstract 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...
Abstract
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.
Book Chapter
Rapid Tooling for Forging Dies
Available to PurchaseSeries: ASM Handbook
Volume: 14A
Publisher: ASM International
Published: 01 January 2005
DOI: 10.31399/asm.hb.v14a.a0004024
EISBN: 978-1-62708-185-6
... 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. 3D Keltool process direct rapid tooling forging dies hot isostatic pressing indirect...
Abstract
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.
Series: ASM Handbook
Volume: 14A
Publisher: ASM International
Published: 01 January 2005
DOI: 10.31399/asm.hb.v14a.a0003975
EISBN: 978-1-62708-185-6
... Abstract 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...
Abstract
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.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0001814
EISBN: 978-1-62708-180-1
... Abstract 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...
Abstract
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.
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0009222
EISBN: 978-1-62708-180-1
... 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. dies failure grinding handling heat...
Abstract
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.
Book Chapter
Forging Machinery, Dies, and Processes
Available to PurchaseSeries: ASM Desk Editions
Publisher: ASM International
Published: 01 December 1998
DOI: 10.31399/asm.hb.mhde2.a0003183
EISBN: 978-1-62708-199-3
... Abstract 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...
Abstract
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.
Image
Locked and counterlocked dies. (a) Locked dies with no means to counteract ...
Available to PurchasePublished: 01 January 2005
Fig. 13 Locked and counterlocked dies. (a) Locked dies with no means to counteract side thrust. (b) Counterlocked dies. (c) Dies requiring no counterlock because the forging has been rotated to minimize side thrust
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Image
Temperatures in dies with air-water cooling of the dies between blows. Init...
Available to PurchasePublished: 01 January 2005
Fig. 24 Temperatures in dies with air-water cooling of the dies between blows. Initial die temperature: 100 °C (210 °F). Initial stock temperatures: (1) 1150 °C (2100 °F), (2) 1050 °C (1920 °F), (3) 950 °C (1740 °F). Upper curves are the temperatures achieved during forging; lower curves
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Image
Locked and counterlocked dies. Locked dies (a) with no means of counteracti...
Available to PurchasePublished: 01 December 1998
Fig. 12 Locked and counterlocked dies. Locked dies (a) with no means of counteracting side thrust, (b) with counterlock, and (c) requiring no counterlock because the forging has been rotated to minimize side thrust.
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Orientation of a forging in the die to avoid counterlocked dies and to elim...
Available to PurchasePublished: 01 January 1990
Fig. 12 Orientation of a forging in the die to avoid counterlocked dies and to eliminate draft. Workpiece forged with (a) and without (b) lock in die
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Image
Effect on distribution of flow caused by use of dies of different conicity....
Available to PurchasePublished: 30 September 2015
Fig. 10 Effect on distribution of flow caused by use of dies of different conicity. Small-scale experiments with cylindrical tin samples. Source: Ref 6
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Image
Stress-number of cycles fatigue plot for a gravity die-cast automotive dies...
Available to PurchasePublished: 01 December 2008
Fig. 7 Stress-number of cycles fatigue plot for a gravity die-cast automotive diesel engine block. The alloy is AlSi7MgCu0.5. Fatigue life was determined using rotating beam equipment. At a given stress level, a three- to ten-fold increase in fatigue life is seen when HIP is used. The fatigue l...
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Relative service lives of three steel dies and one carbide die. Die life wa...
Available to PurchasePublished: 01 January 2006
Fig. 19 Relative service lives of three steel dies and one carbide die. Die life was obtained under the same operating conditions; that is, the blanking of 3.25% Si electrical steel sheet 0.36 mm (0.014 in.) thick. Dies were reground when they had worn sufficiently to produce a burr 0.13 mm
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