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punch assembly
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Book Chapter
Series: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005117
EISBN: 978-1-62708-186-3
...-and-extrude operations, slotting, countersinking, and cutting and lancing of tabs. The article provides information on the punch assembly, the die assembly, and the stripper and discusses the factors considered during piercing operations. It reviews the applications of the four types of blanks used in sheet...
Abstract
This article begins with a discussion on the fundamentals of cutting. It focuses on blanking and piercing operations in a press tool to form and shape the final part geometry. The types of piercing operations include conventional piercing, piercing with a pointed punch, piece-and-extrude operations, slotting, countersinking, and cutting and lancing of tabs. The article provides information on the punch assembly, the die assembly, and the stripper and discusses the factors considered during piercing operations. It reviews the applications of the four types of blanks used in sheet-forming operations, namely, rectangular blank, rough blank, partially developed blank, and fully developed blank. It concludes with a discussion on the process capabilities, applications, and limitations of fine-edge blanking and piercing.
Book Chapter
Series: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005114
EISBN: 978-1-62708-186-3
... shank A DIE ASSEMBLY is a complete punch-press tool that is used to produce large numbers of interchangeable stamped parts. It consists of mating pairs of punches and dies, their retention plates, a stripping device, and a subassembly called a die set. When the press is actuated, the mating...
Abstract
This article briefly describes the nomenclature, alignment and geometrical considerations, and functional and application requirements of a die set. The die set consists of the shank, guide posts, guide bushings, the punch, and die holders. The article illustrates plate flatness and parallelism in the die set. The testing for abrasion, seizure, and endurance in the die set are discussed briefly. The article concludes with information on die-set recommendations.
Series: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0009154
EISBN: 978-1-62708-186-3
... head, a pin, or bolt headed or clinched at both ends. The process in which this technique is implemented is called riveting ( Ref 1 ). Two main types of riveting processes are punch riveting and self-pierce riveting. Punch Riveting Figure 1 shows the riveting process in four steps. First...
Abstract
Mechanical joining by forming includes all processes where parts being joined are formed locally and sometimes fully. This article focuses on the types, advantages, disadvantages, and applications of the various mechanical joining methods, namely, riveting, crimping, clinching, and self-pierce riveting.
Book Chapter
Series: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005109
EISBN: 978-1-62708-186-3
.... Turret movement can also be controlled semiautomatically or automatically on numerical control or computer numerical control (CNC) punch presses. A closed-loop direct or alternating current drive connected to both the upper and lower turret assemblies provides the automatic turret with either...
Abstract
This article illustrates the characteristics of pierced holes and summarizes the hole wall quality. Specific guidance in selecting die clearances is provided by considering the types of edges produced with different clearances. The article discusses the effect of tool dulling and the use of small and large clearance. It informs that the force needed to pierce a given material depends on the shear strength of the work metal, the peripheral size of the hole or holes to be pierced, stock thickness, and depth of shear on the punch. The article discusses the presses and tools used in piercing. It illustrates the use of compound dies, progressive dies, and transfer dies; piercing of thick and thin stock and piercing holes at an angle to the surface; special piercing techniques; and shaving of low-carbon steels.
Book Chapter
Series: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005165
EISBN: 978-1-62708-186-3
... provides support and motion for the punch holder. Cutoff Unit The cutoff unit, placed between the press and the front forming slide, is used for cutting work metal into blanks before they are bent to shape. The ends can be cut off straight, or the cut can be curved. Various types of cutoff units...
Abstract
Multiple-slide forming is a process in which the workpiece is progressively formed in a combination of units that can be used in various ways for the automated fabrication of a large variety of simple and intricately shaped parts from coil stock or wire. This article discusses the components of multiple-slide rotary forming machines involved in the blanking and forming of strip stock. It describes a complicated application of the two-level forming, with an example.
Book Chapter
Series: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005178
EISBN: 978-1-62708-186-3
...Abstract Abstract This article discusses the most important factors required for cutoff methods. It explains the operations of machines used for the punching, shearing, notching, or coping of plates, bars, and structural sections. The article describes the effects of the blade angle and speed...
Abstract
This article discusses the most important factors required for cutoff methods. It explains the operations of machines used for the punching, shearing, notching, or coping of plates, bars, and structural sections. The article describes the effects of the blade angle and speed on the shear blade life. It reviews the design requirements and best practices for the production of blades. The article compares double-cut dies with single-cut dies used for shearing of structural and bar shapes. The shearing of specific forms, such as angle iron and flat stock, is also discussed. The article describes the advantages of hydraulic bar and structural shears. It concludes with information on the principle and construction of impact cutoff machines.
Series: ASM Handbook
Volume: 14A
Publisher: ASM International
Published: 01 January 2005
DOI: 10.31399/asm.hb.v14a.a0004005
EISBN: 978-1-62708-185-6
... the punch and die. The closing-in of the die bore when the die is assembled in shrink rings should be considered when designing this diameter. Fig. 6 Backward extrusion punch. A, nose angle; B, punch land; C, corner radius; D, relief angle Die Design The high forming pressure in cold...
Abstract
Cold extrusion is a push-through compressive forming process with the starting material (billet/slug) at room temperature. This article provides information on the different types of steels that can be cold extruded. Mechanical presses and hydraulic presses that are specifically designed for cold extrusion with high rigidity, accurate alignment, and long working strokes are described. The article details the factors that are critical in cold extrusion: punch design, die design, and tool design. It summarizes the role of lubricants during extrusion of steel, such as soap lubricant and polymer lubricants. The article describes several procedures for extruding specific steel parts such as tubular parts and stepped shafts. It lists problems such as tool breakage and galling or scoring of tools and explains cold extrusion of aluminum, copper, and nickel alloy parts. The article also discusses the impact extrusion of magnesium alloys.
Book: Powder Metallurgy
Series: ASM Handbook
Volume: 7
Publisher: ASM International
Published: 30 September 2015
DOI: 10.31399/asm.hb.v07.a0006034
EISBN: 978-1-62708-175-7
..., including punches, core rods, and punch clamp rings. core rods hydraulic press mechanical press powder metallurgy powder-fill ratio punch clamp rings punches rigid tooling compaction tooling POWDER METAL COMPACTING PRESSES, equipped with appropriate tooling, frequently are used...
Abstract
Powder metallurgy compacting presses usually are mechanically or hydraulically driven, but they can incorporate a combination of mechanically, hydraulically, and pneumatically driven systems. This article provides a comparison of mechanical and hydraulic presses based on the cost, production rate, and machine overload protection. The article lists the classification of powder metallurgy parts based on complexity of shapes as suggested by the Metal Powder Industries Federation, such as Class I parts, Class II parts, Class III parts, and Class IV parts. It describes rigid tooling compaction and details the powder-fill ratio considerations for these classes. The article elaborates on the types of tooling systems and presses used for these classes. Some important factors and components used in designing a tool are also described. Finally, the article considers tool materials, including punches, core rods, and punch clamp rings.
Book Chapter
Series: ASM Handbook
Volume: 14A
Publisher: ASM International
Published: 01 January 2005
DOI: 10.31399/asm.hb.v14a.a0004040
EISBN: 978-1-62708-185-6
... as receptacles, for mating members in assembly, serving as locations for fasteners or bearing surfaces, and contributing to a reduction in weight. Functions, as they relate to specific forging designs, are described in examples presented in this article. During the forging of a cavity, metal in the workpiece...
Abstract
Machining serves as a more specialized supplement to the forging process, particularly in the formation of cavities and holes. This article provides information on the enclosures, cavities, and holes in hammer and press forgings. It provides a checklist that serves as a guide to the procedure for reviewing the design of cavities and holes to be incorporated in forgings. The article also describes forging designs in which cavities and holes are related to rib and web designs, punchout, piercing, extruding, and combinations of these processes.
Book: Powder Metallurgy
Series: ASM Handbook
Volume: 7
Publisher: ASM International
Published: 30 September 2015
DOI: 10.31399/asm.hb.v07.a0006080
EISBN: 978-1-62708-175-7
... the tooling configuration in Fig. 7 . This part is axisymmetric, consisting of an outer rim (upper section) formed by the upper punch, and a hub (lower section) formed by the lower punch. A flange is formed between both punches, and an outer die and core rod complete the tool set. A preform containing...
Book Chapter
Series: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005119
EISBN: 978-1-62708-186-3
... Composition and Condition on Blanking and Piercing” in this article). Presses A general-purpose punch press in good mechanical condition is acceptable for stamping laminations, but large-volume production of laminations by progressive-die methods requires the use of high-productivity presses (see...
Abstract
This article discusses the presses, auxiliary equipment, and dies used in the blanking and piercing of commonly used magnetically soft materials, namely, low-carbon electrical steels and oriented and nonoriented silicon electrical steels. It describes the effect of stock thickness and work metal composition and condition on blanking and piercing. The article provides an overview of the influence of burr height on stacking factors and presents a discussion on the lubrication and core plating of electrical steels that ease the process.
Book Chapter
Series: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005134
EISBN: 978-1-62708-186-3
.... Stretch bending imparts elongation throughout the bend and thus minimizes springback. Ram-and-Press Bending With this method, a workpiece is placed between two supports, and a rounded form die (ram or punch) is pressed against it ( Fig. 7 The two supports pivot as the ram moves forward...
Abstract
This article describes various bending methods: draw bending, compression bending, roll bending, stretch bending, and ram-and-press bending. It discusses the machines used for the bending of bars. These machines include devices and fixtures for manual bending, press brakes, conventional mechanical and hydraulic presses, horizontal bending machines, rotary benders, and bending presses. The article illustrates the tools used in bending and other bending process. It also tabulates the lubricants required for bending specific metals.
Series: ASM Handbook
Volume: 22B
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.hb.v22b.a0005527
EISBN: 978-1-62708-197-9
... a least three or five domains in which cost estimates apply (i.e., sheet metal assembly, injection-molded plastic parts, formed sheet metal parts, etc.). More complex products, such as an aircraft jet engine with 25,000 unique parts, might have 200 different manufacturing processes, each of which defines...
Abstract
This article focuses on the products defined by dimensions and tolerances, made from solid materials, and fabricated by some manufacturing process. It describes three methods of cost estimations: parametric methods, empirical methods, and the complexity theory. The article presents an example to illustrate the parametric cost estimation of aircraft. An example to illustrate the cost estimation of sheet metal and riveted parts is also provided.
Series: ASM Handbook
Volume: 20
Publisher: ASM International
Published: 01 January 1997
DOI: 10.31399/asm.hb.v20.a0002483
EISBN: 978-1-62708-194-8
... if they are only moderately complex, like a dishwasher with 200 unique parts, have a least three or five domains in which cost estimates apply (i.e., sheet metal assembly, injection-molded plastic parts, formed sheet metal parts, etc.). More complex products, such as an aircraft jet engine with 25,000 unique parts...
Abstract
This article focuses on products defined by dimensions and tolerances and fabricated by some manufacturing process. It describes the general concepts associated with cost estimation. These include domain limitation, database commonality, cost allocation, and elements of cost. The article discusses three methods of cost estimation, namely, parametric methods, empirical methods, and complexity theory, with examples. It concludes with recommendations for cost estimation.
Series: ASM Handbook
Volume: 2
Publisher: ASM International
Published: 01 January 1990
DOI: 10.31399/asm.hb.v02.a0001057
EISBN: 978-1-62708-162-7
... and more precise dimensional accuracy. Forgings are also available as rolled or mandrel-forged rings. Impacts Impacts are formed in a confining die from a lubricated slug, usually cold, by a single-stroke application of force through a metal punch causing the metal to flow around the punch...
Abstract
Aluminum, the second most plentiful metallic element, is an economic competitor in various applications owing to its appearance, light weight, fabricability, physical properties, mechanical properties, and corrosion resistance. This article discusses the primary and secondary production of aluminum and classification system for cast and wrought aluminum alloys. It talks about various manufactured forms of aluminum and its alloys, which are classified into standardized products such as sheet, plate, foil, rod, bar, wire, tube, pipe, and structural forms, and engineered products such as extruded shapes, forgings, impacts, castings, stampings, powder metallurgy parts, machined parts, and metal-matrix composites. The article also reviews important fabrication characteristics in the machining, forming, forging, and joining of aluminum alloys. It concludes with a description of the major industrial applications of aluminum, including building and construction, transportation, consumer durables, electrical, machinery and equipment, containers and packaging, and other applications.
Series: ASM Handbook
Volume: 22B
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.hb.v22b.a0005531
EISBN: 978-1-62708-197-9
... and Sinter Powder Compaction Powder compaction is the most widely used powder shapemaking process. The process involves compression of a powder mass confined in a die cavity and acted upon by upper and lower punches, as shown in Fig. 3 . First, powder flows into the die cavity from a feed shoe...
Abstract
Power metallurgy (PM) is a process of shaping metal powders into near-net or net shape parts combined with densification or consolidation processes for the development of final material and design properties. This article introduces the general considerations, models, and applications in the modeling of PM processes. It describes the PM process in terms of powder compaction and sintering. The article schematically illustrates powder injection molding for the production of plastic parts and describes PM process models such as discrete-element model (DEM), linear continuum model, and nonlinear continuum model. It concludes with information on the application of press and sinter modeling to practical problems in PM.
Series: ASM Handbook
Volume: 14A
Publisher: ASM International
Published: 01 January 2005
DOI: 10.31399/asm.hb.v14a.9781627081856
EISBN: 978-1-62708-185-6
Series: ASM Handbook
Volume: 14B
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v14b.a0005141
EISBN: 978-1-62708-186-3
.... The Olsen cup test measures the maximum penetration of a 22 mm (0.875 in.) diameter hemispherical punch into a clamped flat blank (see the section “Stretching Tests” in the article “Formability Testing of Sheet Metals” in this Volume). The punch depth at failure is the Olsen cup value. The test has been...
Abstract
This article discusses the general formability considerations of aluminum alloys. To conduct a complete analysis of a formed part, the required mechanical properties, as determined by several standard tests, must be considered. The article describes tension testing and other tests designed to simulate various production forming processes, including cup tests and bend tests, which help in determining these properties. It provides information on the equipment and tools, which are used in the forming of aluminum alloys. The article presents a list of lubricants that are most widely used in the forming. It also analyzes the various forming processes of aluminum alloys. The processes include blanking and piercing, bending, press-brake forming, contour roll forming, deep drawing, spinning, stretch forming, rubber-pad forming, warm forming, superplastic forming, explosive forming, electrohydraulic forming, electromagnetic forming, hydraulic forming, shot peening, and drop hammer forming.
Series: ASM Handbook
Volume: 22B
Publisher: ASM International
Published: 01 November 2010
DOI: 10.31399/asm.hb.v22b.a0005539
EISBN: 978-1-62708-197-9
... are presented in the order they would be used in a typical manufacturing process sequence: primary materials processing, hot forging and cold forming, and product assembly. The article discusses four FEM modules: the deformation model, the heat-transfer model, the microstructural model, and the carbon diffusion...
Abstract
This article provides a summary of the overall development of the finite element method (FEM) and its contribution to the materials forming industry. It focuses on the overall philosophy and evolution of the FEM for solving bulk forming issues. A number of applications of FEM are presented in the order they would be used in a typical manufacturing process sequence: primary materials processing, hot forging and cold forming, and product assembly. The article discusses four FEM modules: the deformation model, the heat-transfer model, the microstructural model, and the carbon diffusion model. The article also covers material fracture and die stress analysis and reviews optimization of the design of forming processes.
Series: ASM Handbook
Volume: 14A
Publisher: ASM International
Published: 01 January 2005
DOI: 10.31399/asm.hb.v14a.a0004021
EISBN: 978-1-62708-185-6
... forming process) process sequence: primary materials processing, hot forging and cold forming, and product assembly. The article discusses the material fracture and dies stress analysis and presents the optimization techniques used in 2-D and 3-D preform die design. bulk forming cold forming...
Abstract
This article provides a summary of the overall development of the finite element method (FEM) and its contribution to the materials forming industry. It presents an overview of FEM methodologies and applications in the order of their usage in typical manufacturing (bulk forming process) process sequence: primary materials processing, hot forging and cold forming, and product assembly. The article discusses the material fracture and dies stress analysis and presents the optimization techniques used in 2-D and 3-D preform die design.