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Book Chapter
Forging Design Dimensions and Tolerances
Available to PurchaseSeries: ASM Handbook
Volume: 14A
Publisher: ASM International
Published: 01 January 2005
DOI: 10.31399/asm.hb.v14a.a0004035
EISBN: 978-1-62708-185-6
... for closed-die forgings, including finish allowances for machining, length and width tolerances, die-wear tolerance, match tolerances, die-closure or thickness tolerances, straightness and flatness tolerances, radii tolerances, flash-extension tolerances, and surface tolerances. It also contains a convenient...
Abstract
The design of forging operations; consisting of dies, fixturing, and parts; requires a consistent and unambiguous method for representing critical dimensions and tolerances. This article presents a dimensioning process, based on tooling points and datum planes, with the potential to simplify geometries while minimizing tolerance stack-ups. The method also facilitates inspection liaison between vendors and users because fixturing is easy to duplicate and tooling points are consistent from forging to finish-machined part. The article focuses on the most common dimensional tolerances for closed-die forgings, including finish allowances for machining, length and width tolerances, die-wear tolerance, match tolerances, die-closure or thickness tolerances, straightness and flatness tolerances, radii tolerances, flash-extension tolerances, and surface tolerances. It also contains a convenient summary in the form of a checklist.
Series: ASM Handbook
Volume: 1
Publisher: ASM International
Published: 01 January 1990
DOI: 10.31399/asm.hb.v01.a0001021
EISBN: 978-1-62708-161-0
...-to-finish factor or amount of stock that must be removed to satisfy the dimensional and detail requirements of the finished part. In addition to types and classifications, the article discusses critical design factors and ways to ensure that the resulting forgings measure up to metallurgical, mechanical...
Abstract
Forgings are classified in various ways, beginning with the general classifications open die and closed die. They are also classified according to how they are made; such as hammer upset forgings, ring-rolled forgings, and multiple-ram press forgings; and in terms of the close-to-finish factor or amount of stock that must be removed to satisfy the dimensional and detail requirements of the finished part. In addition to types and classifications, the article discusses critical design factors and ways to ensure that the resulting forgings measure up to metallurgical, mechanical property, and dimensional accuracy requirements. The responsibility for design verification is vested in material control, which depends on the proper application of drawings, specifications, manufacturing process controls, and quality assurance programs. The article addresses each of these areas as well as related topics; including stress-induced fatigue failure, tolerances, machining allowances; and the fundamentals of hammer and press forgings, hot upset forgings, and hot extrusion forgings.
Book Chapter
Cleaning, Pretreatment, and Maintenance of Surfaces
Available to PurchaseSeries: ASM Handbook
Volume: 2A
Publisher: ASM International
Published: 30 November 2018
DOI: 10.31399/asm.hb.v02a.a0006504
EISBN: 978-1-62708-207-5
... Abstract The necessary precursor to a proper and durable finish is the preparation of the active aluminum surface to receive the desired protective finish that will allow it to have a long and attractive service life. This article helps those who work with aluminum in the many varieties...
Abstract
The necessary precursor to a proper and durable finish is the preparation of the active aluminum surface to receive the desired protective finish that will allow it to have a long and attractive service life. This article helps those who work with aluminum in the many varieties of applications of such products. It describes the two main categories of cleaning that can be used with most any metal, namely, mechanical cleaning and chemical cleaning. The article provides a discussion on the laboratory evaluation of cleaners, field testing of cleaners, and cleaner types and procedures. It also describes the special cleaning procedures for aluminum alloys, such as steam cleaning and rotary wire-brush cleaning. The article reviews the use of temporary coatings and the use of maintenance coatings on aluminum. It provides information on the handling and storage procedures of aluminum alloys and the cleaning of specific applications of aluminum.
Book Chapter
Trimming Operations
Available to PurchaseSeries: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005118
EISBN: 978-1-62708-186-3
... Abstract Trimming is the removal of excess metal from a stamped part to allow the part to reach the finished stage or to prepare it for subsequent operations. This article presents an analysis of parts to be trimmed and describes the selection criteria for the different types of trimming dies...
Abstract
Trimming is the removal of excess metal from a stamped part to allow the part to reach the finished stage or to prepare it for subsequent operations. This article presents an analysis of parts to be trimmed and describes the selection criteria for the different types of trimming dies such as conventional trimming dies and cam trimming dies. It provides information on rough and finish trimming and construction details of trimming dies. The article reviews the selection criteria of presses for a trimming operation. It provides a discussion on the scrap and material handling processes in trimming.
Book Chapter
Die Manufacture by Electrical Discharge Machining
Available to PurchaseSeries: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005158
EISBN: 978-1-62708-186-3
... (first cut) is made on a workpiece, leaving a finish allowance; the electrical condition for the finish allowance is switched to finish condition, decreasing the offset amount gradually so as to perform two or more surface-removal passes for finishing. As in general-purpose EDM, however, increased speed...
Abstract
The electrical discharge machining (EDM) process is used for machining dies because of its ability to machining difficult geometries or materials with poor machinability. This article provides a discussion on the fundamentals of electrical discharge erosion and the principles of EDM and orbital-movement EDM. It discusses various aspects of wire EDM in machining dies and provides an overview of the materials used in EDM electrodes. The article concludes with a discussion on electrochemical machining.
Book Chapter
Wire, Rod, and Tube Drawing
Available to PurchaseSeries: ASM Handbook
Volume: 14A
Publisher: ASM International
Published: 01 January 2005
DOI: 10.31399/asm.hb.v14a.a0004008
EISBN: 978-1-62708-185-6
... Abstract The drawing process, one of the oldest metal forming operations, allows excellent surface finishes and closely controlled dimensions to be obtained in long products that have constant cross sections. This article discusses the basic mechanics and preparation steps of drawing...
Abstract
The drawing process, one of the oldest metal forming operations, allows excellent surface finishes and closely controlled dimensions to be obtained in long products that have constant cross sections. This article discusses the basic mechanics and preparation steps of drawing. It presents an overview of the processes, equipment, dies and die materials, and lubrication associated with drawing of rod, wire, bar, and tube. The article also provides a discussion on the design considerations and manufacturing of commercial superconducting multifilamentary conductors.
Book Chapter
Introduction to Manufacturing of Polymer-Matrix Composites
Available to PurchaseBook: Composites
Series: ASM Handbook Archive
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003401
EISBN: 978-1-62708-195-5
... of producing a part with the required geometry, but it is also important to note that the technique selected influences surface finish, allowable reinforcement configurations, available resins and their properties as matrices, as well as a host of other properties, including cost. Table 1 illustrates some...
Abstract
This article explains the key features of the manufacturing techniques for polymer composites. It describes the selection of a technically and economically feasible manufacturing technique for a composite design. The article discusses widely accepted and emerging techniques to manufacture polymer composites such as open-mold techniques.
Series: ASM Handbook
Volume: 20
Publisher: ASM International
Published: 01 January 1997
DOI: 10.31399/asm.hb.v20.a0002494
EISBN: 978-1-62708-194-8
... throughout the part to help provide a uniform temperature distribution during heating Summary of design limitations for selected organic finishing processes Table 2 Summary of design limitations for selected organic finishing processes Process Design limitations Electrocoating Allow...
Abstract
This article presents general design principles for different types of surface-finishing processes, such as cleaning, organic coatings, and inorganic coatings applied by a variety of techniques. It discusses the factors that influence the selection of surface-finishing processes. These include fabrication processes, size, weight, functional requirements, and design features. The article discusses the design as an integral part of manufacturing. It contains tables that summarize the design limitations for selected surface-preparation, organic finishing, and inorganic finishing processes.
Book Chapter
Metalcasting Technology and the Purchasing Process
Available to PurchaseBook: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005188
EISBN: 978-1-62708-187-0
... component. Numerous factors influence the total cost of a finished cast component. These are considered in two groups: factors directly affecting the cost of a cast component and indirect cost factors for a finished casting. Dimensional tolerances and allowances are also discussed, since they have...
Abstract
This article describes the four basic steps of the purchasing process of cast components. These steps include defining requirements and developing a purchasing plan; requesting and evaluating bids from potential sources; selecting a source and negotiating contract terms; and carrying out the contract and pursuing continuous improvement. It provides guidance on purchasing cast components and explains specific issues and approaches that have proven to be useful in purchasing castings. The article presents a list of the most significant considerations when attempting to determine the overall cost and design requirements of a metal casting.
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005308
EISBN: 978-1-62708-187-0
..., it is not dimensionally identical to the casting. A number of allowances must be made on the pattern to ensure that the finished casting is dimensionally correct, to ensure that the pattern can be effectively removed from the mold, and to allow for cores to be firmly anchored. Shrinkage Allowance Shrinkage...
Abstract
This article discusses the types of patterns used for a specific application such as loose patterns, match plate patterns, cope and drag patterns, and special patterns. It describes the principles of the patternmaking techniques used to make expendable molds and for metal casting processes such as die casting and permanent mold casting. The article reviews the pattern features and mold production considerations used in the pattern design, namely, parting line considerations, addition of gates and risers, core prints, and locating points. It examines the pattern allowances for ensuring a dimensionally correct final pattern. A variety of materials and advanced composite materials used in the manufacture of patterns are discussed. The article evaluates the factors influencing the selection of type of patterns for specific castings.
Book Chapter
Roller Burnishing
Available to PurchaseBook: Machining
Series: ASM Handbook
Volume: 16
Publisher: ASM International
Published: 01 January 1989
DOI: 10.31399/asm.hb.v16.a0002138
EISBN: 978-1-62708-188-7
... Abstract Roller burnishing is a method of working a metal surface to improve its finish and dimensional accuracy and can provide some degree of work hardening. This article discusses the workpiece requirements used for roller burnishing. It illustrates the types of roller burnishing tools...
Abstract
Roller burnishing is a method of working a metal surface to improve its finish and dimensional accuracy and can provide some degree of work hardening. This article discusses the workpiece requirements used for roller burnishing. It illustrates the types of roller burnishing tools, such as internal tool, external tool, and tools for the roller burnishing of tapered holes and circular flat surfaces. The article contains a table that lists typical inside and outside diameter speed and feed rates for roller burnishing tools. It exemplifies typical lubrication techniques and the conditions used in the roller burnishing of magnesium alloy castings. The article reviews fillet rolling that is used to improve fatigue resistance of the materials. It concludes with a discussion on the process considerations for three basic types of bearingizing tools for the finishing of bores: bottoming, semi-bottoming, and through-hole.
Image
Application of tolerances and allowances to forgings. The dimensions are no...
Available to PurchasePublished: 01 January 1990
Fig. 21 Application of tolerances and allowances to forgings. The dimensions are not to scale. a, finish machined; b, machine allowance; c draft allowance; d, die wear tolerance; e, shrink or, length tolerance; f, mismatch allowance
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Image
Application of tolerances and allowances to forgings. The dimensions are no...
Available to PurchasePublished: 01 January 2005
Fig. 25 Application of tolerances and allowances to forgings. The dimensions are not to scale. a, finish machined; b, machine allowance; c, draft allowance; d, die wear tolerance; e, shrink or length tolerance; f, mismatch allowance
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Book Chapter
Summary of Aluminum Temper Designations
Available to PurchaseSeries: ASM Handbook
Volume: 2A
Publisher: ASM International
Published: 30 November 2018
DOI: 10.31399/asm.hb.v02a.a0006531
EISBN: 978-1-62708-207-5
... except that minor straightening is allowed after stretching, to comply with standard tolerances T652 Solution heat treated, stress relieved by compressing to produce a permanent set of 1–5%, and artificially aged T654 Solution heat treated, stress relieved by restriking cold in the finish die...
Abstract
This article presents a summary of aluminum temper designations, and applicable aluminum alloys and product forms for temper designations used in the United States (ANSI H35.1), Europe (EN 515), and internationally (ISO 2107).
Book Chapter
Replicast Molding
Available to PurchaseBook: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005256
EISBN: 978-1-62708-187-0
... flat flange faces, and blind and through holes as small as 9.6 mm ( 3 8 in.) in diameter can be attained. For those surfaces requiring finish machining, an allowance of 1.6 to 3.2 mm ( 1 16 to 1 8 in.) is usually sufficient. Acknowledgment Revised from R.E. Grote...
Abstract
The Replicast process is developed to overcome the formation of lustrous carbon defects and carbon pickup observed in conventional evaporative pattern casting processes. This article provides a discussion on the pattern production, process capabilities, advantages, and limitations of Replicast process.
Book Chapter
Coatings for Commercial Structures and Building Deficiencies that Affect Performance
Available to PurchaseSeries: ASM Handbook
Volume: 5B
Publisher: ASM International
Published: 30 September 2015
DOI: 10.31399/asm.hb.v05b.a0006050
EISBN: 978-1-62708-172-6
...) that are painted, integrally colored, or covered by veneer (typically brick or stone), exterior insulating finishing systems (EIFS), or unpainted glass curtain walls. Figure 1 is a cutaway of a typical big-box retail store. Fig. 1 Cutaway of a typical big-box retail store. Supporting columns and roof...
Abstract
This article identifies the coatings applied to many substrates for both beautification and protection, and the inherent conflicts that exist between the coatings and the buildings they are designed to protect; emphasis is placed on masonry walls. It provides information on the purposes of the coatings in the commercial buildings. The article briefly describes some of the most common types of substrates found in buildings and the coatings commonly associated with each substrate. The selection of the coating system depends on the substrate and service expectations. The article addresses the primary causes of masonry coating problems and also provides a detailed discussion on the wall design considerations, moisture considerations, and coating system challenges in the masonry buildings.
Book Chapter
Aluminum Alloy Temper Designations and Definitions
Available to PurchaseSeries: ASM Handbook
Volume: 2B
Publisher: ASM International
Published: 15 June 2019
DOI: 10.31399/asm.hb.v02b.a0006622
EISBN: 978-1-62708-210-5
..., and naturally aged to a substantially stable condition 2011, 2014, alclad 2014, alclad 2024 Sheet: rolled or cold-finished rod, bar, or wire; drawn tube and extruded tube, wire, rod, bar, and profiles (2024 only) T31 Solution heat created, cold worked ~1%, and naturally aged to a substantially stable...
Abstract
This article lists temper designations and their definitions for aluminum alloys along with their product forms used in the United States (ANSI H35.1), Europe (EN 515), and internationally (ISO 2107).
Image
Conventional aluminum alloy forgings for gimbal ring: ring-rolled (a) and f...
Available to PurchasePublished: 01 January 2005
Fig. 14 Conventional aluminum alloy forgings for gimbal ring: ring-rolled (a) and finished by closed-die forging (b). See Example 8 . Dimensions in figure given in inches Item Conventional closed-die forging (revised) Material and temper Aluminum alloy 2014-T6 (a) Forging
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Series: ASM Handbook
Volume: 2A
Publisher: ASM International
Published: 30 November 2018
DOI: 10.31399/asm.hb.v02a.a0006519
EISBN: 978-1-62708-207-5
... Abstract Investment casting, in which molten metal is poured into hot molds, allows for the production of aluminum parts with extremely thin sections, knife edges and sharp detail. This article describes the various steps in the investment casting process, including patternmaking...
Abstract
Investment casting, in which molten metal is poured into hot molds, allows for the production of aluminum parts with extremely thin sections, knife edges and sharp detail. This article describes the various steps in the investment casting process, including patternmaking and dimensioning, the design and manufacture of shell molds, melting and casting methods, and postcasting operations such as knockout, core removal, and cleaning. It also addresses a wide range of design considerations, discusses casting defects, and provides several design examples.
Book Chapter
Closed-Die Forging in Hammers and Presses
Available to PurchaseSeries: ASM Handbook
Volume: 14A
Publisher: ASM International
Published: 01 January 2005
DOI: 10.31399/asm.hb.v14a.a0003979
EISBN: 978-1-62708-185-6
... are produced in relatively inexpensive dies, but their weight and dimensions are somewhat greater than those of corresponding conventional closed-die forgings. A blocker-type forging approximates the general shape of the final part, with relatively generous finish allowance and radii. Such forgings...
Abstract
This article provides an overview of the capabilities of closed-die forging. One of the most important aspects of closed-die forging is proper design of preforming operations and of blocker dies to achieve adequate metal distribution. The article describes the effects of friction and lubrication in forging. It discusses the types of closed-die forgings, namely, blocker-type, conventional, and close-tolerance. The article illustrates the classification of forging shapes and explains how to predict the forging pressure and the control of die temperature during closed-die forging. It explains the use of heating equipment for closed-die forging and tabulates the maximum safe forging temperatures for carbon and alloy steels. The article concludes with a discussion on a trimming method used for closed-die forgings.
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