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| موضوع: كتاب Tool and Manufacturing Engineers Handbook - Volume II - Forming الإثنين 20 يونيو 2022, 6:04 pm | |
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أخواني في الله أحضرت لكم كتاب Tool and Manufacturing Engineers Handbook - Volume II - Forming Fourth Edition A reference bookf o r manufacturing engineers, managers, and technicians Charles Wick, CMfgE Editor-in-Chief John T. Benedict Senior Staff Editor Raymond F. Veilleux Associate Editor
و المحتوى كما يلي :
CONTENTS VOLUME II-FORMING Symbols and Abbreviations xi Sheet Metal Formability . 1-1 Die and Mold Materials . 2-1 Lubricants . 3-1 Sheet Metal Blanking and Forming . 4-1 Presses for Sheet Metal Forming 5-1 Die Design for Sheet Metal Forming 6-1 Expanding. Shrinking and Stretch Forming 7-1 Roll Forming 8-1 Spinning 9-1 Bending and Straightening . 10-1 Shearing 11-1 Punching 12-1 13-1 Swaging . 14-1 Hot Forging . 15-1 Casting 16-1 Drawing. Extruding and Upsetting Powder Metallurgy . 17-1 Special Forming Methods 19-1 Safety in Forming 20-1 Plastics Forming . 18-1 Index I-1 ixSYMBOLS AND ABBREVIATIONS The following is a list of symbols and abbreviations in general use throughout this volume. Supplementary and/or derived units, symbols, and abbreviations which are peculiar to specific subject matter are listed within chapters. A A Ampere ABS Acrylonitrile butadiene styrene or Adjustable-bed stationary press a-c Alternating current ADC Allyl diglycol carbonate AISI American Iron and Steel Institute AK Aluminum killed Al Aluminum Alnico Nickel-iron-aluminum-cobalt magnetic alloys amp Ampere AMSA American Metal Stamping Association ANSI American National Standards Institute AOD Argon-oxygen decarburization AS As sintered ASME American Society of Mechanical Engineers ASP Antisegregation process ASTM American Society for Testing and Materials B-C BDC BET Bhn BLS BMC BOD BOF BSA BS1 Btu c CAD/CAM CAOHC CCL CH, CIP CL CNC co co, COD CPM Cps Bottom dead center Brunauer-Emmett-Teller Brinell hardness number Federal Bureau of Labor Statistics Bulk molding compound Biological oxygen demand Basic-oxygen furnace Benzene sulfonic acid British Standards Institute British thermal unit Celsius, Coulomb, Carbon or Constant Computer-aided design/ computer-aided manufacturing Council for Accreditation in Occupational Hearing Conservation Carbon tetrachloride Methane Cold isostatic pressing Centerline Computer numerical control Cobalt Carbon dioxide Chemical oxygen demand Crucible Particle Metallurgy Cycles per second Cr Chromium Cr-Ni Chrome-nickel CRS Cold-rolled steel CRT Cathode ray tube Cu Copper CU20 Copper oxide CVD Chemical vapor deposition D-E DAP dB d-c deg or 0 deg/ft deg/m diam DIN DR EDM EDPT EHF EP Eq. ESR ETFE Diallyl phthalate Decibel Direct current Degree Degree per foot Degree per meter Diameter Deutscher Normenausschuss (German standards organization) Draw ratio Electrical discharge machining Examination, diagnosis, prescription and treatment Electrohydraulic forming Epoxy or Extreme pressure Equation Electroslag remelting Ethylene tetrafluoroethy lene copolymer F FA FDA Fe Fe~04 FEP Fig. FLD fpm fps ft ft’ ft-lb Fahrenheit Furfuryl alcohol Food and Drug Administration Iron Iron oxide Fluorinated ethylene propylene Figure Forming limit diagram Foot per minute Foot per second Foot Cubic foot Foot-pound g Gram or Gravity value GCA Grid-circle analyzer g/cc Gram per cubic centimeter M g/cm’ Gram per cubic centimeter g/m’ Gram per cubic meter GPa Giga pascal H-1 H, HAZ HERF Hg HIP H,O hp HRS HSLA HVF Hz IACS ID in. or “ in.2 in./ft in./in. in./in. /s in./s ipm ips Hydrogen gas Heat-affected zone High-energy-rate forming Mercury Hot isostatic pressing Water Horsepower Hot-rolled steel High strength, low alloy High-velocity forming Cycles per second International Annealed Copper Standard (Electrical Conductivity) Inside diameter Inch Square inch Inch per foot Inch per inch Inch per inch per second Inch per second Inch per minute Inch per second J-K-L J Joule JIC Joint Industry Conference kA KE kg kg/m2 kg/s kJ kN kN/m kPa ksi kV kW Kiloampere Kinetic energy Kilogram Kilogram per square meter Kilogram per second Kilojoule Kilonewton Kilonewton per meter Kilopascal 1000 pounds per square inch Kilovolt Kilowatt lb Pound lbf Pound force lb/s Pound per second LDR Limiting draw ratio LED Light-emitting diode LIM Liquid injection molding LP Liquid petroleum m mz max MDI MF Mg MHz MIG mil min MJ mm mm2 m/ min mm/ m mm/ min mm/ mm mm/mm/s mm/s MN Mn Mo MoS, MPa MPIF m/s Meter or Mass Square meter Maximum Manual data input Freon MF, Freon-11, CCIJF, trichlorofluoromethane Magnesium Megahertz Metallic inert gas 0.001 in. Minute or Minimum Megajotde Millimeter Square millimeter Meter per minute Millimeter per meter Millimeter per minute Millimeter per millimeter Millimeter per millimeter per second Millimeter per second Meganewton Manganese Molybdenum Molybdenum disulfide Megapascal Metal Powder Industries Federation meter per second N-O N N2 NaOH NASA NbC NC NEMA NFPA Ni Ni-Mo NiO NIOSH N/mm’ No. o* OBI OBS OD OSHA Oz Newton Nitrogen Sodium hydroxide National Aeronautics and Space Administration Niobium carbide Numerical control National Electrical Manufacturers Association National Fire Protection Association Nickel Nickel-molybdenum Nickel oxide National Institute for Occupational Safety and Health Newton per square millimeter Number Oxygen Open-back inclinable press Open-back stationary press Outside diameter Occupational Safety and Health Administration Ounce P P Pa Pc PCTFE PET PETN PM PP ppm PPO Ps psi psia psig PTFE PUR Pvc PVD Phosphorus, Poise or Crossover point Pascal Programmable controller Polychlorotrifluoroethy lene Polyethylene terephthalate Pentaerythritol tetranitrate Powder metallurgy Polypropylene Parts per million Polyphenylene oxide Polystyrene Pounds per square inch Pounds per square inch, absolute Pounds per square inch, gage Polytetrafluoroethy lene Polyurethane Polyvinyl chloride Physical vapor deposition R-S Rorr R A, B. Cor H rad RDX RIM rms rpm ss SA SAE SAN sec sfm Si S1 SMC Sn S02 spm Radius Rockwell hardness—A, B, C or H scales Radius Cyclotrimethylene trinitramine Reaction injection molding Root mean square Revolution per minute Second Sulfur Shape analysis Society of Automotive Engineers Styrene acrylonitrile Second Surface feet per minute Silicon International System of Units Sheet molding compound Tin Sulfur dioxide Strokes per minute T Ta Tantalum TAN-E Total acid number—electrometric TBN-E Total base number—electrometric TDC Top dead center TF Freon TF, Freon-1 13, CC 1F2-CC 1F2, dichloro-tetrafluoroethane TFE Teflon, tetrafluoroethy lene Ti Titanium TiC Titanium carbide TiCL TIG TIR TL TMC TMEH TNT tons/ in.: TSA Titanium tetrachloride Tungsten inert gas Total indicator reading Trim line Thick molding compound Tool and Manufacturing Engineers Handbook Trinitrotoluene Tons per square inch Talene sulfonic acid u-v-w UNS Unified numbering system USP United States Pharmacopoeia v Vanadium, Volt or Velocity VAD Vacuum-arc degassing VAR Vacuum-arc remelting V-Process A licensed vacuum molding method w Watt or Tungsten We-co Tungsten carbide with cobalt binder WS2 Tungsten sulfide x-Y-z XSA Exlene sulfonic acid Y203 Yttrium oxide YPE Yield point elongation Zn Zinc Zr Zirconium INDEX - A ABS (adjustable-bed stationary) press (see Presses) Accuracy cold and warm extrusion, 13-26 cold and warm upsetting (heading), 13-42 electrohydraulic forming, 19-3, 19-11 electromagnetic forming, 19-3 explosive forming, 19-2 gap-frame presses, 5- I I , 5- I2 (Fig. 5-5) high-velocity forging, 19-3 hot extrusion, 13-12 hot forging, 15-8 peen forming, 19-3, 19-29 roll forming, 8-4 shearing, 11-3 spinning, 9-9 (Table9-1) straight-side presses, 5-13, 5-14 (Fig. 5-7), Additives (see Plastics) Adjustable-bed knee (horning) press (see Adjustable-bed stationary (ABS) press (see Air presses (see Presses, pneumatic) Alignment, die set, 6-3 Alloy steel (see Steel, alloy) Aluminum and alloys (see also Aluminum expanding, 7-2 forging lubricant, 15-53, (Table 15-20) forging of, 15- 1 1(Table 15-3, 15-16(Table formability, 1-16, 1-17 (Table 1-7), 4-37 forming limit diagram, 1-17 (Fig. l - f 3 ) hot extrusion, 13-15 (Fig. 13-15) laser cutting, 12-10(Table 12-4) plasma arc cutting, 12-7(Table 12-1), 12-8 powder metallurgy, 17-42 resistivity, 19-20 (Table 19-5) rod coils, for cold drawing, 13-4 shear strength, 11-16 (Table 11-3) shearing, 11-3 (Table l l - f ) ,11-4 spinning, 9- 12, 9- I 7 stretch forming, 7-14 stretch forming dies, 7-21 superplastic forming, 1-20, 1-21 (Table swaging, 14-4, 14-16 tolerances, punched hole, 4-63 ( Table4-13) Aluminum bronzes dies and molds 5-15 Presses) Presses) bronzes) 15-8) (Fig. 4-39) (Table 12-2) 1-8) alloys, 2-3 1 (Table2-14) applications, 2-30 die design, 2-30 machining and finishing, 2-3 I Ampco alloys (see Aluminum bronzes) Analytical methods (see Forming) Androforming applications, 7-23 machines, 7-23 (Fig. 7-31) tooling, 7-24 (Fig. 7-32) normal, 1-5 (Fig. 1-3), 1-10, 4-48 planar, 1-5, 4-48 strain ratio, 1-4 Anisotropy Annealing (see Heat treatment) Antimonial lead (see Lead) Antioch process (see Plaster molding) Arbor presses (see Presses, manual) ASEA Quintus presses (see Presses) Assembly Automation electromagneticforming, 19-21(Fig.19-18) swaging, 14-7 (Fig. 14-9) Automat ion (cant.) cold and warm forming, 13-57 cold extrusion, 13-35 forging, 15-40 8 Back rolls (see Forging equipment) Bar, cold drawing (see Drawing) Bar bending (see Bending) Beading dimensions, 4-57 (Table4-11) process, 4-57 typical shape, 4-56 (Fig. 4-66) Beads, draw, 6-35 Bend allowance (see Bending) Bending bend allowance, 8-15, 10-3, 10-4(Table10- I), 10-5 (Fig. 10-2) dies (see Press brakes) dies, sheet metal, 6-29 (Fig. 6-54) equipment (see Press brakes) force required, 10-3, 10-6 (Table 10-2),10- 9 (Fig. 10-5) calculation, 10-5 equation, 10-5, 10-8 nonferrous metal, 10-8 (Table l0-3) wiping, 10-8 fiber deformation, 10-2 neutral axis, 10-2 methods, 10-14 air, 10-15 bottom, 10-15 rotary, 10-16 nomenclature, 10-1 pipe bending hydraulic machine, 10-42 induction bending, 10-40 induction machine, 10-41 wall thinning, 10-42 double-pinch, four-roll machine, 10-23 initial-pinch machine, 10-22 machine selection, 10-23 (Table 10-4) pinch-pyramid machine, 10-22 press brakes, 10-22 roll benders, 10-22 vertical press, 10-23 principle, 4-5 (Table4-2), 10-26 roll bending machine types, 10-20 special equipment, 10-21 three-roll machine, 10-20 two-roll machine, 10-21 metal flow plate bending theory, 10-2, 10-25 tube bending automated bending, 10-38 CAD/CAM, 10-39, 10-40 (Fig. 10-53) compression bending, 10-29 design guidelines, 10-28, 10-33 draw bending, 10-29 equipment, 10-30 lubrication, 10-35 mandrel, 10-34, 10-36(Table 10-8) material selection, 10-25 metal flow, 10-27 methods, 10-29 minimum radius, 10-28 neutral axis, 10-27 power presses, 10-31 press bending, 10-29 principle, 10-26 ram benders, 10-31 roll benders, 10-31 rotary bending machines, 10-3I , 10-32 stretch bending, 10-30 theory, 10-25 Bending, tube bending (conr.) tools, 10-33 troubleshooting, 10-37 workpiece configuration, 10-25 types of bending contour, 10-11 flange, 10-11 straight, 10-10 types of equipment, 10-1 expanding, 7-2 roll forming, 8-1 (Fig. 8-1) Benelex, dies, 2-36 Beryllium coppers, dies and molds, 2-3 1 forging lubricant, 15-54 forging of, 15-1I (Table 15-3), 15-17 powder metallurgy, 17-42 resistivity, 19-20(Table 19-5) Billet preparation, hot extrusion, 13-24 Bismuth alloy dies, 2-32, 2-33 (Table 2-15) Blank development (see Drawing) Blankholding (see Drawing) Blanking Bend radii blank design, 4-23 die design, 6-23 (Fig. 6-42) force calculation, 4-17 force required, 4-18 (Table 4-5) forces, 6-22 bulging, 4- I4 fracture, 4-14 reaction, 4-14 layout, 4-39, 4-40 (Fig. 4-44) overview, 4-3 principle, 4-4 (Table4-2) process, 4-13, sequence; 4-14 (Fig. 4-3), 6-20 scrap, 4-40 (Fig. 4-45) slugs, cold extrusion, 13-39 steel rule dies, 6-25 terminology, 4-12 theory, 4- I7 tolerances, 4-62 zones, 4- I5 (Fig. 4-5) deformation, 4-16 penetration, 4-16 Borax coatings, cold drawing, 13-1I Brakes, mechanical press (see Clutches and Brass brakes) forming pipe, 6-31, 6-32 (Fig. 6-61) hot forging, 15-16 leaded, swaging, 14-4 resistivity, 19-20 (Table 19-5) shear strength, 11-16(Table 11-3) swaging, 14-4 Briquetting, 17-18 (see also Compacting) Bronze (see also Copper) powder metallurgy, 17-46(Table 17-16) resistivity, 19-20(Table 19-5) shear strength, 11-16(Table 11-3) hydrostatic, 4-54 mechanical, 4-54 principle, 4-8 (Table 4-2) Bull blocks, cold drawing, 13-4 Burr height (see Tolerance control) Bushings Buttons (steels), die, 6-9, 6-13 (Table 6-2 and Bulging die set guide-pin, 6-3 (Fig. 6-3) punch guide, 6-5 Fig. 6-21) C CAD/CAM casting, 16-9 (Fig. 16-2) cold and warm extrusion dies, 13-38 i-1INDEX CAD/CAM (cont.) hot extrusion dies, 13-22 hot forging, 15-51 sheet metal forming dies, 6-18 tube bending, 10-39 forming die, 6-31 (Fig. 6-57) transfer die, 6-45 (Fig. 6-84) automatic cold and warm forming, 13-57 cold and warm extrusion, 13-27 cold and warm upsetting (heading), 13-43 dieing machines, 5-76 die-set transfer presses, 5-87 electrohydraulic, 19-4 (Table 19-1), 19-12 electromagnetic forming, 19-5 (Table 19- explosive forming, 19-4 (Table 19-1) fine-blanking presses, 5-82 fluid-cell presses, 5-79 fluid-forming presses, 5-80 force, torque, and energy, press, 5-25,5-26 forging hammers, 15-2 (Table 15-13) forging presses, 15-2 (Table 15-14) four-slide machines, 5-83 gap-frame presses, 5-1 1 (Table 5-2 and high-velocity forging, 19-5 (Table /9-11), hot extrusion, 13-1I hydraulic presses, 5-68 lamination presses, 5-76 peen forming, 19-29 portal presses, 5-89 punch presses, 12-2 rubber-pad forming presses, 5-79 spinning machines, 9-19 straight-side presses, 5-12 transfer presses, 5-84 Capstan, cold drawing, 13-4 Carbides cemented tungsten Cams Capacities I ) , 19-22 (Tuble5-6) Table 5-3) 19-26 applications, 2-2 1 design considerations, 2-25 finishing, 2-28 grade classifications, 2-24, 2-25 (Table production, 2-21 properties, 2-22 (Table2-10) selection, 2-24 shrink allowances, 2-26 (Table2-13) troubleshooting, 2-29 cold and warm extrusion tooling, 13-35 cold and warm upsetting (heading), 13-56 cold drawing dies, 13-10 forming dies, sheet metal, 6-29 (Fig. 6-54) hot extrusion die inserts, 13-24 steel-bonded, 2-19 swaging dies, 14-19 2-11) Carbon steel (see Steel, carbon) Cast iron dies and molds, 2-3, 2-4 (Table2-2) expanding, 7-2 expanding shoes, 7-7 press frames, 5- 10 spinning chucks, 9-23 swaging dies, 14-19 Cast steels, dies and molds, 2-3,2-5 ( lhhle2-3) Casting (see also Sand-mold, Metal-mold, and Plaster and ceramic-mold casting) basic elements, 16-2 (Fig. 16-1) computer operations, 16-3 general characteristics, 16-1 modeling, 16-6, 16-10 (Fig. 16-3) nomenclature, 16-7 process selection, 16-2, 16-3 (Table 16-1), 16-4( Table 16-2) Casting (cont.) process summary, 16-6 ( Table 16-3) Centrifugal casting (see Metal-mold casting) Ceramic-mold casting (see Plaster a n d Ceramics ceramic-mold casting) cold drawing dies, 13-10 expanding shoes, 7-8 hot extrusion die inserts, 13-24 stretch forming dies, 7-22 swaging dies, 14-I9 C-frame presses (see Presses) Chamfering (pointing), cold drawing, 13-4 Checklist, die design, 6-14 Chromium plating cold drawing dies, 13-10 roll forming guides, 8-1 1 roll forming rolls, 8-19, 8-28 (Table8-1) tool steels, 2-18 Chucks, spinning, 9-22, 9-23 (Fig. 9-31) Circular forms, producing on four-slide, 6-5 1 Circular grid analysis (see Formability) Cleaning cold drawing, 13-3 cold extrusion, 13-39 lubricant removal, 3-18 punches, 12-21 die cutting, 6-20, 6-21 (Fig. 6-38), 6-22 draw dies, 6-33 (Table 6-8) Clearance (Table6-3) Clickers (see Steel rule dies) Closed-die forging, 15-4, 15-9 (see also lmpression-die forging) Clutches and brakes, mechanical press brake-system monitoring, 5-45 constant-energy drives, 5-37 eddy-current clutches and brakes, 5-37 friction clutches and brakes, 5-36, 5-37 full-revolution clutches, 5-35, 5-36 part-revolution clutches, 5-35 positive clutches, 5-36 (Fig. 5-26) two-speed clutch, 5-37 (Fig. 5-28) wet clutch, 5-37 cold drawing, 13-3, 13-1 1 hot extrusion dies, 13-24 slugs, cold extruded, 13-39 vapor deposition, 2- 18 Coil rods, cold drawing, 13-4 Coil width (Fig. 5-27) Coatings blanking, 4-40 roll forming, 8-3 dies, sheet metal, 6-38 (Fig. 6-70) materials, 4-56 pressure, 4-56 principle, 4-8 (Table 4-2) slugs, cold extrusion, 13-39 Coiling and uncoiling, cold drawing, 13-4 Coining Cold drawing of bar, wire and tube (see Cold-flow forming (see Upsetting, cold and Columbium Drawing) warm) forging lubricant, 15-54 forging of, 15-18 resistivity, 19-20 (Table 19-5) Combination dies, 6-40 (Fig. 6-74) Compacting, powder metallurgy, 17-18 Composition aluminum bronzes, 2-3 1 (Table2-14) bismuth alloys, 2-33 carbon and alloy steels, 2-2 (Table 2-1) cemented tungsten carbide, 2-25 (Table steels, cold and warm extrusion, 13-28 2-11) Composit io n (con1. ) tool steels, 2-7 (Table2-5) zinc alloys (Kirksite), 2-32 Compound dies, sheet metal, 6-39 (Fig. 6-72) Compression molding (see Plastics forming) Compression operations (see Coining, Sizing, Compression spinning (see Shear forming and Computer (see also Machine controls) and Swaging) Spinning) analysis (see Formability) casting, 16-3 designing forming dies, 6- I8 forging, 15-51 modeling (see Formability) roll forming tooling, 8-21 Conform extrusion (see Extrusion, cold and Controlled-flow heading (see Upsetting, cold Cookie-cutter dies (see Steel rule dies) Coolants warm, continuous) and warm) spinning, 9-28 swaging, 14-21 Cooling, hot swaging machines, 14-12, 14-13 Connections (pitmans) four-point suspension, 5- I5 press slides, 5-14 single-point suspension, 5- I5 two-point suspension, 5- 15 Controls (see Machine controls) Copper (see also Beryllium coppers) forging lubricant, 15-53 forging of, 15- 1 1 (Table 1-53),15- 16( lable hot extrusion, 13-I5 powder metallurgy, 17-45 resistivity, 19-20 (Table 19-5) rods for cold drawing, 13-4 shear strength, 11-16 (Table 11-3) spinning, 9- 12 swaging, 14-4 Cork dies, 2-36 Corrosion resistance (Fig. f4-17) 15-9) cemented tungsten carbide, 2-24 powder metallurgy parts, 17-I3 Corrugating principle, 4-9 (Table4-2) Counterbalances, press slide air, 5-18 hydraulic press, 5-72 safety, 5-19 spring, 5- I8 Counterblow hammer (see Hammers, forging) Cup drawing (see Drawing) Curling principle, 4-9 (Table 4-2) Cushion, die (see Die cushions) Cutoff dies, 8-22 machines (see Shearing) principle, 4-3 (Table 4-2),4-13 slugs, cold extrusion, 13-39 tooling, cold and warm upsetting (heading), tooling, four-slides, 6-49, 6-50 (Fig. 6-89) laser, 12-8, 12-9 (Fig. 12-11), 12-10 (Table plasma arc, 12-6, 12-7 (Table 12-1), 12-8 13-51 (Fig. 13-55) Cutting 12-3 and Table 12-4) (Fig. 12-8 and Table 12-2) D Datum (see Tolerance control) Deep drawing (see Drawing) Deflection gap-frame presses, 5-12 (Fig. 5 - 3 , 5-13 (Table5-4) 1-2INDEX Deflection (cunt.) press bed or slide, 5-10 straight-side presses, 5-12, 5-14 (Fig. 5-7) cemented tungsten carbide, 2-25 (Table PM parts, 17-11, 17-12 (Table 17-6) cold and warm extrusion tooling, 13-35 cold and warm upsetting (heading) tooling, cold drawing dies, 13-8 forging machine dies, 15-48 hot extrusion dies, 13-22 impression forging dies, 15-46 PM parts, 17-10 roll formed parts, 8-1 (Fig. 8-1) sheet metal forming dies, 6-1 Demarest process (see Forming) Density 2-11) Design 13-52 bending and flanging, 6-29 (Fig. 6-54) checklist, 6-14, 6-18 drawing, 6-31, 6-33 (Fig. 6-62) four-slide (multislide), 6-46, 6-48 (Fzg. process planning, 6- I5 progressive, 6-42, 6-43 (Fig. 6-79) transfer, 6-44, 6-45 (Fig. 6-84) use of CAD/CAM, 6-18 Detectors, misfced, 6-9, 6-1 I (Fig. 6-17) Device, press safety (see Safety, press) Diamond dies, cold drawing, 12-10 Die and mold materials Androforming, 7-24 carbon and low-alloy steels, 2-1,2-2 (Table cast irons and steels, 2-3, 2-4 (Table 2-2) cemented tungsten carbide, 2-21 cold drawing of bar, wire and tube, 13-10 cold and warm extrusion, 13-35, 13-36 6-87) 2-11 (Table 13-8) cold and warm upsetting (heading), 13-56 (Table 13-12) electrohydraulic forming, 19-13 electromagnetic forming, 19-22 expanding shoes, 7-7 explosive forming, 19-10 high-velocity forging, 19-27 hot extrusion, 13-22 (Table 13-4) hot forging forging machine dies, 15-49 impression dies, 15-48 open dies, 15-45 nonferrous metals, 2-30 other nonmetallic materials, 2-35 plastics, 2-33 powder metallurgy, 17-24 roll forming cutoff dies, 8-23 forming rolls, 8-18 selection, 2-1 stainless and maraging steels, 2-6 steel-bonded carbides, 2-19 stretch forming, 7-21 tool steels, 2-6, 2-7 (Table2-4) Die buttons, 6-9,643 (Table6-2and Fig. 6-21) Die casting (see Metal-mold casting) Die changing, 5-9, 13-19 (Fig. 13-17), 13-61 Die cushions air pressure requirements, 5-20 draw dies, 6-33 (Fig. 6-62) hydropneumatic, 5-20 (Fig. 5-13) pneumatic, 5-19 (Fig. 5-12) straight-side hydraulic presses, 5-68 cold and warm extrusion, 13-35, 13-37 Die design (Fig. 13-38) cold and warm upsetting (heading), 13-52 (Fig. 13-56) Die design ( c w z t . ) cold drawing of bar, wire and tube, 13-8, electrohydraulic forming, 19-12 electromagnetic forming, 19-22 explosive forming, 19-10 forging, 15-46 hot extrusion, 13-21 (Fig. 13-20) roll forming, 8-17 sheet metal forming, 6-1 components, 6-3 (Fig. 6-1) contours for drawing, 6-3 1 cutting dies, 6-20 (Fig. 6-37) design checklist, 6-14, 6-18 draw dies, 6-32, 6-34 forming dies, 6-29 (Fig. 6-54) four-slide (multislide), 6-46, 6-48 (Fig. locating stampings, 6-14 (Fig. 6-24) multiple-operation, 6-39 process planning, 6-15,6- I6 (Fig. 6-26) progressive dies, 6-42, 6-43 (Fig. 6-7Y) transfer dies, 6-44, 6-45 (Fig. 6-84) use of C A D / C A M , 6-18 forging dies, 15-55, 15-57(Table 15-22and forming dies, 6-56 13-9 (Table 13-2) 6-87) Die failure Table 15-23) Die forger hammer (see Hammers, forging) Dieing machines (see Presses) Die pull, cold drawing of bar, wire and tube, Dies cold and warm extrusion, 13-35, 13-36 cold and warm upsetting (heading), 13-51, cold drawing of bar, wire and tube, 13-8, drawing, 2-20 (Fig.2-2),2-26 (Table2-12), electrohydraulic forming, 19-12 electromagnetic forming, 19-22 explosive forming, 19-10 extrusion, 2-29 forging, 15-44 high-velocity forging, 19-26 hot extrusion, 13-20, 13-21 (Fig. 13-20) ironing, 4-5 1 materials (see Die and mold materials) powder metallurgy, 17-23 press brake, 2-14 (Table2-8), 10-16 roll forming cutoff, 8-14, 8-22 (Fig. 8-35) sheet metal forming, 6-1 13-3 (Tahje 13-8) 13-52 (Fig. 13-56) 13-9 (Table 13-2) 4-42 (Fig. 4-51) components, 6-3 (Fig. 6- I ) cutting, 6-20 (Fig. 6-37) design checklist, 6-14, 6-18 drawing, 6-3 1 , 6-33 (Fig. 6-62) forming, 6-29 (Fig. 6-54) four-slide (multislide), 6-46, 6-49 (Fig. multiple-operation, 6-39 process planning, 6-15 progressive, 6-42, 6-43 (Fig. 6-7Y) rectangular parts, 6-34 transfer, 6-44, 6-45 (Fig. 6-84) use o f C A D / C A M , 6-18 6-88) stretch forming, 7-21 swaging, 14-8 (Fig. 14-10), 14-17 (Fig. four-slide (multislide), 6-47 sheet metal forming, 6-3 (Fig. 6-1) steel rule dies, 6-27 Die-set transfer press (see Presses) Die-setting presses (see Presses) Dimpling, principle, 4-9 (Table 4-2) Dinkers (see Steel rule dies) 14-24) Die sets Distortion spinning, 9- 10 tool steels, 2-12 (Table2-7) Double-action press (see Presses, number of Draw beads slides) deep drawing, 4-39 (Fig. 4-43) definition, 6-2 Drawbenches, 13-6, 13-7 (Fig. 13-7) Drawing bar, wire and tube, 13-1, 13-2 (Fig. 13-1) continuous machines, 13-5 (Fig. 13-5) die pull, 13-3 dies, 13-8, 13-9 (Table 13-2) draft and area reduction, 13-1 drawbenches, 13-6, 13-7 (Fig. 13-6) lubricants, 13-10 other methods, 13-8 percentage of elongation, 13-3 bull blocks, 13-4 (Fig. 13-4) blank development, 4-48, 6-35 blank diameter, 4-49, 4-50 blankholder force, 4-34, 4-38 (Fig.4-40), comparison with spinning, 9-8 compound, 3-6 4-47 (Fig. 4-57) cup drawing, 1- 10,4-38 (Fig.4-40 and Fig. 4-41) cup draw length, 4-34 (]able4-8) deep drawing, 4-7 (Table 4-2), 4-39 (Fig. dies, sheet metal, 6-31, 6-33 (Fig. 6-62) 4-43) clearances, 6-33 (Table 6-8) design rules, 6-18 draw beads, 6-36 large parts, 6-34, 6-38 (Fig. 6-69) progressive, 6-42 reverse redrawing, 6-33,6-35 (Fig.6-66) transfer, 6-44 earing, 1-5, 4-47, percent, 4-48 forming, 1-3 limits, 4-4 I lubricants, 3-7 ( Table 3-5),3-8 (Table3-6) metal flow (see Metal flow) parameters, 4-48 percent draw, 1-31 process, 4-33 redrawing, 4-34, 6-33 4-9) number of operations, 4-34,4-37 (Table percent reduction, 4-34,4-35 (Fig.4-37) reverse, 4-4 1 (Fig. 4-49) shell diameter, 4-36 (Fig. 4-38) speed (see Press speed) stress, 4-46 (Fig. 4-54) stretch/draw separation, 1-31 Drives, press (see Press drives) Ductile (nodular) irons, dies and molds, 2-3 E Earing (see Drawing) Edges, die-cut, 6-21 (Fig. 6-39) EDM (see Electrical discharge machining) Electrical discharge machining (EDM),cemented tungsten carbide, 2-29 Electrohydraulic forming accuracy, 19-3, 19-1I advantages, 19-4 (Table 19-i),19-1 1 applications, 19-12, 19-14 (Fig. 19-8) characteristics, 19-4 (Table 19-1) description, 19-10 (Fig. 19-5) die materials, 19-13 equipment, 19-12, 19-I5 (Fig. 19-9) exploding bridge wires, 19-11 (Table 19-4) limitations, 19-4 (Table 19-1), 19-1I materials formed, 19-12 spark discharge, 19-10 1-3INDEX Electrohydraulic forming (cant.) tooling design requirements, 19-I2 workpiece sizes, 19-3, 19-4 (Table IY-I), 19-12 Electromagnetic forming accuracy, 19-3 advantages, 19-4 (Table IY-I), 19-18 applications, 19-20 characteristics, 19-5 ( Table 19-1) drivers, 19-18 equipment, 19-22 field shapers, 19-22, 19-24 (Fig. 19-21) forming dies, 19-22 forming techniques, 19-24 limitations, 19-4 ( Table IY - I ) , 19-I8 materials formed, 19-I8 safety, 19-24 theory, 19-16 (Fig. IY-12 and Fig. 19-13) workcoils, 19-18, 19-22, 19-23(Fig. lY-20) workpiece s i ~ e s ,19-3, 19-5 (Table IY-I), cold and warm extrusion, 13-27 cold and warm upsetting (heading), 13-43 cold drawing of bar, wire and tube, 13-3 stretch forming 19-22 Elongation limits aluminum alloys, 7-14 stainless steels, 7-14 titanium and alloys, 7-15 Embossing principle, 4-7 (Table4-2) process, 4-56 End flare, roll forming, 8-4, 8-16, 8-30 (Table Energy requirements, mechanical presses, Epoxies, dies and molds, 2-34 (Fig. 2-15) Equations air consumption, pneumatic presses, 5-74 air pressure, pneumatic cushions, 5-20 area reduction, in cold drawing bar, rod bend allowance, 10-3 blanking or punching force, 4-17 coil width, blanking, 4-40 compressor powcr, pneumatic presses, 5-74 die closure time, mechanical presses, 5-46 die pull, in cold drawing bar, rod and wire, draft, in cold drawing bar, rod and wire, draw forming ratio, 1-3I drawing 8-3) 5-25, 5-29 and wire, 13-2 13-3 13-2 blank diameter, 4-48, 4-49, 4-50 cup height, 4-46 earing, 4-48 final reduction, 4-47 force required, 4-42 rectangular shell, 4-44 round shell, 4-44 strain hardening, 1-5, 1-8 strain rate hardening, 1-5, 1-15 strain ratio, 1-4, 1-5 bar, rod and wire, 13-3 elongation percentage, in cold drawing engineering strain, 1-7 engineering stress, 1-7 expanding force requirements, 7-6 springback, 7-3 flanging pad force, 4-28 flywheel energy, mechanical presses, 5-29 force required, bending, 10-5, 10-8 force required, straightening, 10-45 (Fig. force required, wiping, 10-8 forging 10-60) hammer energy, 15-42 Equations, forging (cont.) forming ratio, 1-31 forming severity, 1-32 height reduction in upsetting, 13-46 ironing, 4-54 minimum radius, tube bending, 10-28 noise reduction, 20-22 number of stock diameters in upset, 13-45 percent draw, 1-31 powder metallurgy, die dimensions, 17-25 pressure requirements, hot extrusion, punching compressive stress in a punch, 12-13 form height, 12-I8 punch center distance, 12-I7 scallop height, 12-I6 redrawing percent reduction, 4-34 roll forming bend allowance, 8-15 number of passes, 8-14 safety distance, mechanical presses, 5-45 section modulus, tubing, 10-30 shape analysis, 1-26 shearing, force requirements, 11-15 spinning press force, 15-41 13-24 (Table 13-5) cost and time, 9-8 formability index, 9-I3 stock requirement, 4-22 strain calculation, 1-22 strain measurement, 1-22 strain rate sensitivity, 1-15, 1-20 strain, stretch flange, 4-29 stretch forming, force requirements, 7-22 stripping force, 4-22 swaging Expanding dimensional changes, 14-2 machine capacity, 14-7 advantages, 7-1, 7-3 (Fig. 7-2) applications, 7-3, 7-4 (Fig. 7-4) combined with shrinking, localized, 7-12 fluid (hydrostatic), 7-9, 7-10 (Fig. 7-12 ) machines (Fig. 7-17) hot, 7-8 cone angle, 7-6 controls and accessories, 7-7 force requirements, 7-5 numbers of forming shoes, 7-7 operation, 7-4, 7-5 (Fig. 7-5) elongation, 7-2 physical properties, 7-2, 7-3 (Fig. 7-3) springback, 7-3 materials, 7-2 methods, 7-1 multiple panels, 7-8, 7-9 (Fig. 7-11) tooling, 7-7 (Fig. 7-59, 7-8 (Fig. 7-10) workpiece sizes, 7-3 Explosive forming accuracy, 19-2 advantages, 19-4 (Table IY-I), 19-9 applications, 19-9 characteristics, 19-4 (Tab/e 19-1) combustible gas, 19-9(Fig. fY-3 and Table equipment and tooling, 19-10 (Fig. 19-4) high-explosive, 19-6, 19-7 (Table 19-2) limitations, 19-4 (Table IY-I), 19-9 workpiece skes, 19-3 (Table 19-1) Extrolling (see Extrusion, cold and warm, Extrusion (see also Plastics forming) carbide punches and dies, 2-29 cold and warm 19-3) continuous) advantages, 13-26 (Table 13-7) applications, 13-29 Extrusion, cold and warm (cont.) backward, 13-29, 13-30 (Fig. 13-27) combination, 13-3I (Fig. 13-31) continuous, 13-32, 13-33 (Fig. 13-34) forward, 13-30 (Fig. 13-29) impact, 13-3I , 13-32 (Fig. 13-32) limitations, 13-27 materials extruded, 13-27 presses, 13-33 pressure requirements, 13-40 (Fig. radial, 13-3I safety considerations, 13-41 shapes and sizes produced, 13-27 slug production, 13-38 slug treatment and lubrication, 13-39 speeds, 13-4I tooling and die design, 13-35, 13-36 13-43) (Table 13-8) hot advantages, 13-11, 13-12 (Fig. 13-9) billet piercing and loading, 13-19, 13-20 billet preparation, 13-24 butt separating and unloading, 13-19 dies, 13-21 (Fig. 13-20) direct, 13-13 (Fig. 13-10) heating, stretching, and pulling, 13-20 history, 13-1I hydrostatic, 13-14, 13-15 (Fig. 13-13), indirect, 13-13, 13-14(Fig. 13-12) limitations, 13-12 lubrication, 13-25 materials extruded, 13-15 presses, 13-16, 13-17 (Fig. 13-16 and pressure requirements, 13-24 (Table safety considerations, 13-25 stem speeds, 13-25 (Table 13-6) tooling, 13-20, 13-2I (Fig. 13-20) tooling materials, 13-22 (Table 13-4) (Fig. 13-18) 13-20, 13-21 (Fig. 13-fY) Table 13-3), 13-20 f3-5) metal separation, 4-12 P M parts, 17-39 F Feedback, swaging, 14-1 Feeding chines, 13-6I automatic cold and warm forming macold and warm extrusion presses, 13-35 hot extrusion presses, 13-I9 misfeed detectors, 6-9, 6-1 I (Fig. 6-17) presses blanks and stampings, 5-55 (Fig. 5-40), coil lines, 5-6 I , 5-62 (Fig. 5-49) 5-56 (Fig. 5-41), 5-84 coil stock, 5-57 (Fig. 5-24,5-’58 (Fig. 5-45). 5-85 spinning machines, 9-21 swaging machines hand, 14-15 power, 14-15, 14-I6 (Fig.14-22) Feed rates spinning, 9-26, 9-27 (Table 9-7) swaging, 14-19 43 (Table 17-46) Ferro-Tic, 2-I9 Ferrous metals, powder metallurgy, 17-8, 17- Fine blanking advantages, 4-24 applications, 4-25 cycle, 4-25 limitations, 4-25 materials, 4-25 presses, 5-82, 5-83 (Fig. 5-72) 1-4INDEX Fine blanking (cont.) Finishing process, 4-26 dies and molds aluminum bronze, 2-3 I cemented tungsten carbide, 2-28 steel-bonded carbide, 2-19 tool steel, 2- I8 zinc-based alloys, 2-32 plastics parts, 18-59 PM parts, 17-35 Fire precautions, powder metallurgy, 17-5I Fire protection (see Safety) Flanging dies, sheet metal, 6-29 edge strain, 4-30 (Table 4-7) force, 4-28 formability, 4-30 (Fig. 4-29) hemming (see Hemming) problems splitting, 4-29 (Fig. 4-26) wrinkling, 4-29 recoil, 4-28, 4-29 (Fig. 4-24) springback, 4-30,4-31 (Fig. 4-31) (see also Flanging, recoil) tooling, 4-28 types, 4-26 hole, 4-7 ( Table4-2), 4-3 I (Fig. 4-32) jogged, 4-6 (Table4-2) reverse, 4-6 (Table4-2) shrink, 4-6 (Table4-2), 4-26,4-27 (Fig. straight, 4-6 (Table 4-2), 4-26, 4-27 stretch, 4-6 ( Table4-2),4-26,4-27 (Fig. 4-20) (Fig. 4-20 and Fig. 4-21) 4-20) Flexible-die forming presses (see Presses) Floating plugs, cold drawing (see Plugs, floatFloturning (see Shear forming and Spinning) Flow, metal (see Metal flow) Flow turning, principle, 4-8 (Table 4-2) (see Fluid cell (see Forming) Fluid expanding (see Expanding) Force requirements 1%) also Shear forming and Spinning) blanking or punching, 4-17, 4-18 (Table 4-5), 4-20 (Fig. 4-9), 4-21 (Fig. 4-10), drawing, 4-43 (Fig. 4-52), 4-45 (Fig. 4-53) expanding, 7-5 forging press, 15-41 (Fig. 15-48) hot extrusion, 13-16 hydraulic presses, 5-66, 5-67 (Fig. 5-58) ironing, 4-53 mechanical presses, 5-25, 5-26 (Table 5-6) shear, 4-22 shearing, 11-15 spinning, 9-26, 9-27 (Table 9-5) stretch forming, 7-22 stripping, 4-20, 4-22, calculation, 4-22 common tests for, 15-10 index, 15-43 (Table 15-16) influencing factors, 15-10 (Table 15-2) Forgeability index (see Forgeability) Forgeability tests (see Forgeability) Forging (see also Forging, high-velocity and 4-22, 6-22 rectangular shell, 4-44 round shell, 4-42 Forgeability Swaging) advantages, 15-8 applications, 15-9 (Table 15-1) automation, 15-40 (Fig. 15-47) computer applications, 15-51 cost considerations, 15-44 defects in workpieces, 15-55, 15-56 (Table 15-21) Forging (conr.) die failure, 15-55, 15-57 (Table 15-22 and energy calculations, 15-42 equipment Table 15-23) auxiliary equipment, 15-39 forging machines, 15-30 forging rolls, 15-34 hammers, 15-19 hot formers, 15-32 hydraulic presses, 15-26 mechanical presses, 15-23 radial forging machine, 15-36 ring rolling machine, 15-38 screw presses, 15-29 selection, 15-11 (Table 15-4, 15-19 wedge rolling, 15-35 force calculations, 15-41 (Fig. 15-48) glossary of terms, 15-I lubricants application, 15-54 requirements, 15-5 1 selection, 15-52, 15-53 ( Table 15-20) types, 15-52 (Table 15-19) materials forged, 15-9, 17-32 number of blows, 15-43 PM parts, 17-32 processes electric upsetting, 15-8 (Fig. 15-11) Gatorizing, 15-6 impression-die, 15-4 (Fig. 15-2) incremental forging, 15-7 isothermal forging, 15-6 open-die, 15-4 orbital forging, 15-6 radial forging, 15-5 (Fig. 15-3) ring rolling, 15-6 (Fig. 15-7) roll forging, 15-7 wedge rolling, 15-7 safety, 15-57 speed, 15-43, 15-44 (Table 15-17) tolerances, 15-8 tooling forging machine, 15-48 impression dies, 15-45 (Fig. 15-53) open dies, 15-44 (Fig. 15-50) radial forging, 15-5 1 ring rolling, 15-5 I roll forging, 15-50 trimming and punching dies, 15-50 wedge rolling, 15-51 workpiece temperature, 15-12 (Table 15-4) forging machines, 15-30 forging rolls (reducer rolls, back rolls, gap rolls), 15-34 furnaces and heaters, 15-39 hammers, 15-19 high-velocity, 19-25 hot formers, 15-32 hydraulic presses, 15-26 material handling, 15-39 mechanical presses, 15-23 radial forging, 15-36 ring rolling, 15-38 screw presses, 15-29 wedge rolling, 15-35 advantages, 19-5 (Table 19-1), 19-25 applications, 19-25 (Table 19-6) limitations, 19-5 (Table l9-1), 19-25 machines, 19-25, 19-26 (Fig. 19-22) tooling, 19-26 application of, 15-31 capacities, 15-3 I description, 15-30 Forging equipment Forging, high-velocity (see also Forging) Forging machines (see also Forging, equipment) Forging machines (writ.) operation, 15-30 Forging rolls (see Forging, equipment) Forging temperatures aluminum alloys, 15-16 (Table 15-8) beryllium, 15-17 carbon and alloy steels, 15- I2 ( Table 15-4) columbium, 15-I8 copper alloys, 15-16 ( Table 15-9) magnesium alloys, 15-17 (Table 15-10) molybdenum, 15-18 stainless steel, 15-15(Table15-6 and Table superalloys, 15-18 (Table 15-12) tantalum, 15-I8 titanium alloys, 15-7 (Table 15-11) tool steels, 15-13(Table 15-5) tungsten, 15-18 aluminum, 1-I6 aluminum, steel, 4-37 (Fig. 4-39) analytical methods 15-7) Formability application, 1-32 (Fig. 1-38) circular grid, 1-22, 1-28 computer, 1-23, 1-25 (Fig. 1-26), 1-27 forming limit diagram, 1-23, 1-28 modified forming limit diagram, 1-29, shape analysis, 1-24, 1-26(Table 1-10), 1-30 (Fig. 1-33) 1-30, 1-32 application, 1-32, 1-33 (Fig. 1-39) classification, 1- 13 (Table 1-3) definitions of terms, 1-1 description, 1 - 1 drawing, 1-3, 6-35 drawing sheet metal, 6-34, draw beads, evaluation 6-35 circle grid, 1-28, 1-29 (Fig. 1-31) forming limit diagram, 1-28, 1-29 (Fig. modified FLD, 1-29 shape analysis, 1-30, 1-32 deformation, 1-12 die design, 1-I2 lubrication, 1-12 part design, 1-1 2 high-strength steel, 1-13 low-carbon steel, I- 13 map, 1-23 modeling, 1-27 nonferrous metal, 1-16, I-18 prediction, 1-27, 1-28 sheet steel, 1-13 spinning, 9-13, 9-14 (Fig. 9-18) stretch/draw separation, 1-31 stretching, 1-5, 1-10, 1-1 1 tests 1-32) factors Erichsen, 1-18 Fukui, 1-19 hemispherical punch, 1-19 Olsen, 1 - 1 8 Swift, 1-18 variables, 1-2 (Table 1-1) zinc, 1-17 Androtorming (see Androforming) automatic, cold and warm advantages, 13-57 applications, 13-57 (Fig. 13-47) limitations, 13-57 machines, 13-60 materials formed, 13-57 shapes and sizes formed, 13-57 Forming bending (see Bending) bulging (see Bulging) 1-5INDEX Forming (conr.) compression (see Stretch forming and creep, 4-57 deformation, 1-7 Demarest process, 4-59 die design for sheet metal, 6-1 dieless, 4-58 drawing (see Drawing) flanging (see Flanging) fluid cell, 4-58, 5-79, 5-80 (Fig. 5-67) fluid forming, 4-59 high-energy-rate forming (HERF), 19-1 limit diagram, 1 - 1 1 (Fig. 149, 1-17, 1-23 limits, 1-10 metal flow, 1-12 modes, 1-9 (Fig. l-5),1-10 (Fig. 1-6) Shrinking) bending, 1-9, 1-10 cup drawing, 1-9 straightening, 1-9, 1-10 stretching. I -10 overview, 4-3 peen, 19-28 ratio, 1-31 roll (see Roll forming) rubber die, 4-58 rubber pad Guerin process, 4-58, 5-78 marforming, 4-58, 5-78 sheet metal, 1-9 stretch (see Stretch forming) stretching (see Formability) superplastic, 1-20, 4-59 advantages, 1-2I key factors, 4-59 limitations, 1-21 process selection, 1-21 typical process, 4-59, 4-60 (Fig. 4-70) turret press, 12-17 Formulas (see Equations) Four-slide machines (see Presses) dies, 6-46, 6-48 (Fig. 6-87) Fractures (see Rupturing) Furnaces die casting, 16-35 forging, 15-39, 15-40 (Fig. 15-45) heat treating, 2-17 sintering, 17-21 G Gage numbers (see Thickness) Gages, die (see Stops) Gap-frame presses (see Presses) Gap rolls (see Forging equipment) Gatorizing, 15-6 (see also Forming, superplastic) Gibbing (see Guiding, press slide) Glossary (see Nomenclature) Grain flow, forging operations, 15-1 (Fig. 15- I ) , 15-8 (see also Metal flow) Gravity drop hammer (see Hammers, forging) Grindability cemented tungsten carbide, 2-28 steel-bonded carbides, 2-20 tool steels, 2-12 (Table 2-7) Guards, press 5-48 (Fig.5-33),5-49 (Fig.5-34) Guerin process blanking and piercing, 4-58 drawing, 4-58 presses, 5-78 tooling, 4-58 (Fig. 4-67) Guides, stock, 6-5, 6-9 (Fig. 6-13) Guiding, press slide accuracy (see Parallelism and Runout) gibbing, 5-16, 5-17 (Fig. 5-9) H Hammers, forging (see also Forging equtpment) description, 15-19 die forger, 15-21, 15-23 (Fig. 15-15) gravity drop, 15-19, 15-20 (Fig. 15-12) high-energy-rate, 15-23, 19-25 horizontal counterblow (Impacter), 15-23 opcn-die, 15-23, 15-24 (Fig. 15-16) operation, 15-19 power drop, 15-20, 15-22 (Fig. 15-14) power-lift, 15-19, 15-2 1 (Fig. 15-13) selection, 15- 1 I ( Table 15-4, 15-19 ( Tuhle vertical counterblow, 15-21 Hardboards, dies, 2-36, 6-26 Hardening, work, spinning, 9- 12 Hardness 15-13) cemented tungsten carbides, 2-22 (Table powder metal parts, 17-13 spinning, 9-12 spun parts, 9-9 stainless and maraging steels, 2-6 steel-bonded carbides, 2-2 I steel rules for dies, 6-27 steels after cold extrusion, 13-26 stretch-draw formed parts, 7-18 stretch formed parts, 7- 13 swaged parts, 14-2, 14-3 tool steels, 2-12 (Table2-7) 2-10), 2-25 Hardwoods, dies, 2-35 (see also Hardboards and Wood, densified) Hastelloys (see Superalloys) Heading (see Upsetting) Heading machines (see Forging machines and Heating hot extrusion, 13-20, 13-24 spinning, 9-7 Heat treatment aluminum, before hot extrusion, 13-24 annealing Machine t001s) cold drawing of bar, wire and tube, spinning, 9-12 steels, cold extrusion, 13-28, 13-39 swaging, 14-3 before cold drawing, 13-3 PM parts, 17-33 steel-bonded carbides, 2-2 1 swaging dies, 14-19 tooling, cold and warm extrusion, 13-35 tool steels, 2-10, 2-16 (Table 2 4 ) Heels, die set, 6-5, 6-9 (Fig. 6-14) Helical extrusion (see Extrusion, cold and Hemming 13-2 warm, continuous) die, 4-32 (Fig. 4-34) principle, 4-9 (Table 4-2) quality, 4-33 tooling, 4-32 types of hems, 4-32 (Fig. 4-33) High-energy-rate forging (see High-velocity High-energy-rate forming forging) advantages, 19-2 characteristics, 19-4 (Table 19-1) description, 19-1 electrohydraulic forming, 19-10 electromagnetic forming, 19-16 explosive forming, 19-6 high-velocity forging, 19-25 limitations, 19-2 materials formed, 19-2 selection criteria, 19-3 workpiece sizes and tolerances, 19-2 High-velocity forging accuracy, 19-3 advantages, 19-25 applications, 19-25 (Table 19-6) characteristics, 19-5 (Tuble 19-1) limitations, 19-25 machines, 19-25, 19-26(Fig. 19-22and Fig. tooling, 19-26 workpiece sizes, 19-5 (Table 19-1) 19-23) High-velocity forming (see High-energy-rate History forming) casting, 16-I hot metal extrusion, 13-1I powder metallurgy, 17-1 Holders, pilot, die set, 6-9, 6-1 1 (Fig. 6-16) Hooker process (see Extrusion, cold and warm, Horning (adjustable-bed knee) press (see Hot formers (see also Forging, equipment) application, 15-32 capacity, 15-32 description, 15-32, 15-34 (Fig. 15-33) operation, 15-32 Hydraulic presses cold and warm extrusion, 13-34 forging (see Presses, forging) hot extrusion, 13-16 sheet metal forming (see Presses) impact) Presses) Hydroform (see Presses) Hydrospinning (see Shear forming and Spinning) Hydrostatic extrusion (see Extrusion, hot) I Impact extrusion (see Extrusion, cold and Impacters (see Hammers, forging) Impregnation, PM parts, 17-34 lmpression-die forging applications, 15-8 description, 15-4 tooling, 15-45 warm) Inclinable press (see Presses) lncoloys (see Superalloys) lnconels (see Superalloys) Incremental forging (see Forging, processes) Injection molding (see Molding and Plastics forming) inspection forgings, 15-55 mechanical presses, 5-53 (Fig. 5-39) sand castings, 16-28 Investment casting (see Plaster and ceramicIron, cast (see Cast iron) Ironing after drawing, 6-35 computation, 4-5 I force required, 4-53 (Fig. 4-64) thickness reduction, 4-52 (Fig. 4-63) principle, 4-7 (Table 4-2),4-5 I (Fig. 4-62) process, 4-51 tooling, 2-30, 4-5 1 Ironworker (see Shearing) Isostatic pressing cold, PM parts, 17-36 hot, PM parts, 17-36 mold casting) Isothermal forging (see Forging, processes) J Jaws, stretch forming, 7-21 (Fig. 7-30) Joggling (see Flanging) 1-6INDEX K Kickback (see Feedback) Kicker (shedder) pins, die, 6-5 Kicker tools, four-slide, 6-5 1, 6-52 (Fig. 6-95) Kirksite (see also Zinc alloy) dies and molds, 2-32 expanding shoes, 7-7 stretch forming dies, 7-21 Knockouts, die, 6-4 (Fig. 6-7) L Lamination presses (see Presses) Lancing, principle, 4-5 (Table 4-2) Lead antimonial, dies, 2-32 hot extrusion, 13-I5 resistivity, 19-20 (Table 19-5) shear strength, 11-16 (Table 11-3) spinning, 9- 12 swaging, 14-I6 Lime coatings, cold drawing, 13-1I Linex extrusion (see Extrusion, cold and warm, Loading/ unloading automatic cold and warm forming macold and warm extrusion presses, 13-35 cold a n d warm upsetting (heading) hot extrusion presses, 13-19 punching machines, 12-10, 12-1 I (F;g. spinning machines, 9-21 swaging machines, 14-16 (Fig. 14-23) Locating stampings in dies, 6-14 (Fig. 6-24) Lost-wax process (see Investment casting) Lubricants continuous) chines, 13-6 I machines, 13-5 1 12-13) additives, 3-1 1 , 3-12 (Table 3-9) application methods airless spray, 3-16 air spray, 3- 15 dip, 15-54 drip, 3- 13 electrostatic, 3- 16 flooding, 3- I6 manual, 3-13 roller, 3-14 spray, 3- 15, 15-54 swab, 15-54 alkaline cleaners, 3- I8 cleaner selection, 3- 18 solvent cleaners, 3- I8 types of cleaners, 3-18 cleaning cold and warm extrusion, 13-39 cold drawing, 13-10 dry-film, 3-6 (Table 3-4, 3- I0 formulations, 3-8 compounded oil, 3-9 emulsions, 3-10 eutectic salts, 3-10 extreme-pressure oil, 3-9 glass, 3-10 liquids, 3-9 mineral oil, 3-9 natural oil, 3-9 solutions, 3-10 synthetic oil, 3-9 hot extrusion, 13-25 hot forging, 15-5I , 15-52 (Table 15-19) ingredients, 3-7 metalforming, 3- I oil-based, 3-7 (Table 3 - 9 , 15-52 properties, 3-6 (Table 3-4) punching, 12-19 Lubricants (conr.) purging, P M parts, 17-22 quality control standards, 3-19 testing, 3-19 roll forming, 8-28 (Table8-1) selection, 3-4 (Table 3-1), 15-52 factors, 3-5 (Table3-3) high-pressure, 3-5 (Table3-2) solid-film, 3-2 solids lamellar inorganic solid, 3-10 metallic film, 3-1 I nonlamellar solids, 3- I I organic solids, 3-1 I soap, 3-10, 3-1 1 (Table 3-8) solvent-based, 3-8 special, 3-8, 3-9 (Table 3-7) spinning, 9-27, 9-28 (Table 9-8) stretch forming, 7-22 swaging, 14-2 I synthetic, 3-7, 15-52 troubleshooting lubricity, 3-2 1 mixture, 3-20 viscosity, 3-20 types, 3-6, 15-52 waste disposal biodegradability, 3- 17 treatment, 3-17 water-based, 3-7, 3-8 (7able 3-6), 15-52 Lubrication, metalforming cold and warm extrusion, 13-39 cold drawing, 13-3 formability role, 1-1 2 hot extrusion, 13-25 ironing, 3-2 (Fig. 3-2) mechanical presses, 5-5 1 , 5-52 (Fig. 5-38) parameters active, 3-3 coated, 3-6 inactive, 3-3 normal, 3-3 surface properties, 3-3 bound a ry-fi 1m, 3-2 film theory, 3-1 mixed-film, 3-2 solid-film, 3-2 thick-film, 3-1 thin-film, 3-2 regimes, I -12 tube bending, 10-35 principles LKder's lines (see Surface integrity) M Machinability steel-bonded carbides, 2-20 tool steels, 2-12 (Table 2-7) Machine controls automatic cold and warm forming machines, 13-62 expanding, 7-7 fine-blanking presses, 5-82 hydraulic presses, 5-71 mechanical presses, 5-38, 5-39 (Fig. 5-29) portal presses, 5-89 punch presses, 12-4 (Fig. 12-7) spinning machines, 9-19, 9-20 (Fig. 9-27) stretch forming, 7-20 transfer presses, 5-86 Androforming, 7-23 (Fig.7-31) automatic cold and warm forming Machines (see Machine tools) Machine tools (see also Presses) controls, 13-62 noise reduction, 13-62 Machine tools, automatic cold and warm forming (con?.) operation, 13-60 safety considerations, 13-63 tooling, 13-63 tooling changeover, 13-61 workpiece transfer, 13-6I bull blocks, cold drawing, 13-4 cold and warm upsetting (heading) progressive (transfer) headers, 13-5 1 single-stroke headers, 13-50 cold drawing, 13-5 (Fig. 13-5), 13-7 (Fig. cone-type expanding, 7- I, 7-2 (Fig. 7-1) expanding, 7-4, 7-5 (Fig. 7-5) forging, 15-18, 19-25, 19-26 (Fig. 19-22) notching, 12-12 (Fig. 12-16) presses (see Presses) punching, 12-I roll forming, 8-5 (Fig. 8-11) shearing, 11-4 slitting, 11-10 (Fig. 11-10) spinning, 9-1, 9-16 (Fig. 9-26) stretch forming, 7-15 swaging, 14-7, 14-8 (Fig. 14-10) dies and molds aluminum bronzes, 2-3 I cemented tungsten carbides, 2-28 steel-bonded carbides, 2-20 zinc-based alloys, 2-32 plastics parts, 18-59 PM parts, 17-35 slugs for cold extrusion, 13-38 Magnesium and alloys forging lubricant, 15-53 forging of, 15- 1 1 (Table 15-3, 15-I7 ( Table hot extrusion, 13-15 powder metallurgy, 17-42 resistivity, 19-20 (Table 19-5) stretch forming, 7-15 13-6) Machining 15-10) Magnetic pulse forming (see Electromagnetic forming) Maintenance forming dies, 6-56 (Table6-9) mechanical presses, 5-52 PM presses, 17-31 punch presses, 12-20 roll forming machine, 8-30 tool (see Tool maintenance) Management, safety program, 20-2 Mandrels (see also Chucks) cold drawing, 13-10 spinning, 9-22, 9-23 (Fig. 9-31) swaging, 14-19 (Fig. 14-27) Manual (arbor) presses (see Presses, manual) Maraging steels (see Steel, maraging) Marforming presses, 5-78 process, 4-58 tooling, 4-58 (Fig. 4-68) dies and molds, 2-36 stretch forming dies, 7-21 automatic cold and warm forming, 13-57 cold and warm extrusion, 13-26, 13-28 cold and warm upsetting (heading), 13-42, dies and molds cemented tungsten carbide, 2-22 (Fig. tool steels, 2-10 (Fig. 2-1) expanding, 7-1, 7-3 (Fig. 7-2),7-8 hot extrusion, 13-12, 13-15 hot forging, 15-9, 15-10 (Table 15-2) roll forming, 8- 1, 8-3, 8-4, 8- 14 Masonite Material requirements 13-46 2-4) 1-7INDEX Material requirements (cont.) shearing, 11-4 spinning, 9-12 stretch-draw forming, 7-18 stretch forming, 7-13 swaging, 14-7 (Fig. 14-8) Materials, die and mold (see Die and mold Mechanical presses materials) cold and warm extrusion, 13-34 forging (see Presses, forging) sheet metal forming (see Presses, mechanical) Meehanite expanding shoes, 7-7 stretch forming dies, 7-22 Metal flow (see also Formability) control, draw beads, 4-39 (FIg. 4-43) drawing, 4-31 cylindrical cup, 4-37 rectangular shell, 4-38 wrinkling, 4-38 drawing sheet metal, 6-34 forming, 1-12 roll forming, 8-16 spinning, 9-9 swaging, 14-1, 14-2 (Fig. 14-1) Metal-mold casting centrifugal casting, 16-48 advantages, 16-50 equipment, 16-50, 16-51 (Fig. 16-32 and Fig. 16-33) methods, 16-50, 16-5 I speeds, 16-52 (Fig. 16-35) automation, 16-34 cold chamber, 16-31, 16-32 (Fig. 16- critical speed, 16-33, 16-35(Table 16-16) design, 16-40 die materials, 16-38, 16-39( Table 16-17) die production, 16-39 dies, 16-35, 16-37 (Fig. 16-21 and Fig. draft required, 16-42 (Fig. 16-26) ferrous metal, 16-39, 16-40 (Table furnaces, 16-35 high pressure, 16-30 hot chamber, 16-31 (Fig. 16-14) machines, 16-30 new technology, 16-32 pore-free process, 16-34 process control, 16-36 (Fig. 16-19) tolerances, 16-42 (Table 16-21), 16-43 (Table 16-22 and Table 16-23) vacuum die casting, 16-34 wall thickness, 16-41 (Table 16-19) basic steps, 16-44 (Fig. 16-27) casting production, 16-46 design, 16-43 equipment, 16-46, 16-47 (Fig. 16-29) graphite molds, 16-47 low-pressure process, 16-46 mold design, 16-45 semipermanent mold, 16-48 shell molding, 16-49 (Fig. 16-30) slush casting, 16-46 die casting, 16-30 15), 16-33 (Fig. 16-16) 16-22) 16-18) permanent mold, 16-42 Metal powders, 17-4 Models for sheet metal formingdies, 6- 17 (Fig. Molding,injection, PM parts, 17-39 Molybdenum 6-27) forging lubricant, 15-54 forging of, 15-18 resistivity, 19-20 (Table 19-5) swaging, 14-4 Motor, press drive, 5-29 adjustable-speed, 5-33 constant-speed, 5-33 Multislide machines (see Four-slide) N ~ ~~~ Near-net-shaped forging, 15-4, 15-6 Necking, principle, 4-8 (Table 4-2) Net-shaped-forging, 15-4 Nibbling (see also Notching) definition, 4- I3 deformation, 4- 16 (Fig. 4-6) machines (see Punching) punch center distance, 12-17 scallop height, 12-I6 speed, 12-16 troubleshooting, 12-22 (Table 12-8) Nickel and nickel alloys die and mold materials stainless and maraging steels, 2-6 tool steels, 2-9 hot extrusion, 13-16 shear strength, 11-16 (Table 11-3) spinning, 9- I2 hot extrusion dies, 13-24 tool steels, 2-18 Nitriding Nitrogen die cylinders, definition, 6-2 Noise control automatic cold and warm forming mamechanical presses, 5-46 swaging, 14-3 bending, 10- I blanking, 4- I2 casting, 16-7 die design, 6-1 formability, 1- 1 hot forging, 15-1 mechanical press safety, 5-4 I mechanical press terms, 5-89 plastics forming, 18- 1 powder metallurgy, 17-4 press brakes, 10-12 shearing, 1 1 - 1 sheet metal blanking and forming, 4-9 sheet metal forming presses, 5- 1 spinning processes, 9- I backward extrusion parameters, 13-42 bend allowance, 10-5 (Fig. 10-2) bending force, 10-9 (Fig. 10-5) diameter reduction, drawing, 4-35 (Fig. drawing force, 4-43 (Fig. 4-52), metric, forging press force, 15-41 (Fig. 15-48) forward extrusion parameters, 13-41 (Fig. punching force, 4-19, 4-20 (Fig. 4-9), metric, 4-21 (Fig. 4-10) shell diameter, drawing, 4-36 (Fig. 4-38) thickness reduction, drawing, 4-52 upset dimensioning, 13-44 machines, 12-I2 (Fig. 12-16) principle, 4-4 (Table 4-2), 4- 13, 12-12 roll forming, 8-2, 8-1 1 (Fig. 8-19) tooling, 12-12 chines, 13-62 Nomenclature Nomograph (Fig. 13-46) 4-37) 4-45 (Fig. 4-53) 13-45) Notching 0 OBI (open-back inclinable) press (see Presses) OBS(open-back stationary) press (see Presses) Oils (see Lubricants) Open-back inclinable (OBI) press (see Presses) Open-back stationary (OBS) press (see Presses) Open-die forging description, 15-4 hammers, 15-23 tooling, 15-44 Open-die forging hammer (see Hammers, Orbital forging (see Forging, processes) Orbital forming (see Upsetting, cold and warm) OSHA (see Safety) Overload protection, press, 5-33, 5-34 (Fig. Oxidizing, tool steels, 2-18 forging) 5-24) P Parallelism, press slide to bed, 5-15 Parting, principle, 4-4 ( Table 4-2), 4- I3 Payoff tray (stand or reel), cold drawing, 13-4 Peen forming (Fig. 13-3) accuracy, 19-29 advantages, 19-28 applications, 19-29 (Table 19-7) description, 19-28 (Fig. 19-27 and Fig. limitations, 19-28 machines, 19-29, 19-30 (Fig. 19-30 and Fig. materials formed, 19-29 stress peen forming, 19-28 workpiece siLes, 19-3, 19-29 dies, 6-24 (Fig. 6-44) principle, 4-4 ( Table 4-2), 4- 13 19-28) 19-31) Perforating Perforators (punches), 6-5, 6-10 (Fig. 6-15), Permanent-mold casting (see Metal-mold Phosphate coatings cold drawing, 13-1 I cold extrusion, 13-39 Physical properties (see Properties) Piercing (see also Punching) principle, 4-4 ( Table 4-2), 4-12 tolerances, 4-62 Pilots, die, 6-2, 6-9, 6-1 1 (Fig. 6-16) Pinch-trimming dies (see Trimming) Pins, die set, 6-3 (Fig. 6-2) Pipe bending (see Bending) Plaster and ceramic-mold casting 6-1 1 (Table 6-1) casting) ceramic cores extruded, 16-65 molded, 16-65 investment casting, 16-55 advantages, 16-58 alloys, 16-57 ( Table 16-25) aluminum, 16-6 I automated plant, 16-58, 16-60 (Fig. cleaning and finishing, 16-60 comparison, 16-59 (Table 16-27) cost considerations, 16-61 iron, 16-61 pattern production, 16-58 process, 16-56 (Fig. 16-36), 16-58 prototyping, 16-61 (Fig. 16-38) tolerances, 16-57 (Table 16-26) plaster molding, 16-52 Antioch process, 16-55 applications, 16-52 burnout, 16-55 foam plaster, 16-54 methods, 16-54 parting agents, 16-54 patterns, 16-53 16-37) 1-8INDEX Plaster and ceramic-mold casting, plaster molding (coni.) tolerances, 16-53 ( Table 16-24) advantages, 16-65 applications, 16-62 Shaw process, 16-63 (Fig. 16-39) tolerances, 16-62 (Table 16-28) Unicast process, 16-63, 16-64 (Fig. solid-ceramic molding, 16-61 16-40) Plastics (see also Plastics forming) additives, 18-8 dies and molds advantages, 2-33 construction, 2-34 (Fig. 2-15) limitations, 2-33 plastics used, 2-33 expanding shoes, 7-8 fillers, 18-9, 18-10 (Table 18-3) laser cutting, 12-8, 12-10 (Table 12-3) materials, 18-4, molecular structure, 18-5 part design factors, 18-1 I material selection, 18-12 threads, 18-12 thermoplastic, 18-5, 18-6 (Table 18-1), thermoset, 18-5, 18-8 (Table 18-2), processing methods, 18-14(see also Plastics principal types 18-15 (Table 18-5) 18-35 forming) properties, 18-9 thermoplastic, 18-15 (Table 18-5) thermoset, 18-16 (Table 18-6) standard tests, 18-13 (Table 18-4) creep, 18-13 fatigue, 18-14 shrinkage, 18-14 thermal expansion, 18-13 stretch forming dies, 7-21 blow molding Plastics forming (see also Plastics) extrusion, 18-54 injection, 18-54 stretch, 18-54 casting, 18-56, 18-58 compression molding equipment, 18-17 method selection, 18-17 (Table 18-7) mold construction, 18-18 mold types, 18-18 process, I8- I7 dies, 18-3I equipment, 18-30 multiscrew extruders, 18-31 process, 18-30 calendering, 18-58 cell casting, 18-59 extrusion, 18-59 film casting, 18-59 extrusion film and sheet forming, 18-58 forging, 18-58 high-pressure laminates, 18-53 injection molding advantages, 18-23 automatic injection, 18-26 equipment, 18-23 hot-runner molds, 18-26 limitations, 18-23 liquid injection molding, 18-55 mold design checklist, 18-26 molds, 18-24 process, 18-23 troubleshooting, 18-29 types of gates, 18-25 (Fig. 18-12) machining and finishing, 18-59 Plastics forming, machining and finishing (cwnr.) buffing, 18-65 drilling, 18-64, 18-65(Table 18-23) embossing, 18-64 filing, 18-62 gear cutting, 18-62 guidelines, 18-59 polishing, 18-65 punching, 18-64 routing, 18-62 sawing, 18-63 threading and tapping, 18-63 turning, 18-59, 18-62 variables, 18-60 (Table 18-21) nomenclature, 18-I reaction injection molding advantages, 18-32 applications, 18-32 limitations, 18-32 materials, 18-32 mold, 18-35 process, 18-33 reinforced reaction injection molding, typical properties, 18-33 (Table l8-10) bulk molding compound, 18-38 filament winding, 18-44 hand lay-up, 18-40 high-volume processes, 18-35 low-volume processes, 18-40 production processes, 18-36 (Table pulforming, 18-39 pultrusion, 18-39 resin injection, 18-43 sheet molding compound, 18-35 thick molding compound, 18-37 vacuum bag, 18-41 wet preform, 18-42 rotational molding, 18-55 structural foam molding, 18-56, comparthermoforming, 18-44 heat transfer rate, 18-48 ( Table 18-17) machinery, 18-44 mechanical forming, 18-50 pressure forming, 18-50 prestretching, 18-50 radiant heating, 18-45 (Table 18-14) rigidizing, 18-53 techniques, 18-49 temperature, 18-49 (7able 18-19) tooling, 18-46 twin sheet forming, 18-51 vacuum, 18-45, 18-49 conditions, 18-22 equipment, 18-19 mold design, 18-22 processes, 18- 19 18-33, 18-34(Table 18-1I ) reinforced plastics, 18-35 18-13) ison, 18-57 (Table 18-20) transfer molding, 18- I7 (Table 18-7),I8- I9 Plate bending (see Bending) Plates, heel and wear, die, 6-5, 6-9 (Fig.6-14) Plating (see Chromium plating) Plugs, floating, for cold drawing, 13-4 (Fig. Pneumatic presses (see Presses, pneumatic) Pointing (chamfering)for cold drawing, 13-4 Polishing, cemented tungsten carbide, 2-29 Polyester molds, 2-33 Polymers (see Plastics) Polyurethanes, dies, 2-34 Pore-free casting (see Metal-mold casting) Porosity, powder metal parts, 17-1I Post-cut method, roll forming (see Roll Powder metallurgy 13-4) forming) Powder metallurgy (conr.) advantages, 17-4 blending (see Powder mixing) compacting, I7- 18, die pressing, 17-I9 definition, 17-1 die design, 17-24 die materials, 17-24 hot extrusion, 13-16 limitations, 17-4 metal powders, 17-4 atomization, 17-5 characteristics, 17-6 ( Table l7-2) chemical reduction, 17-6 electrolysis, 17-6 ferrous, 17-8 production, 17-5, 17-7 (Table 17-3) properties, 17-9, 17-10 reduction, 17-5 specifications, 17-8 ( Table 17-4) types, 17-6 (Table 17-1) Cost, 17-13 mixing (see Powder mixing) nomenclature, 17-4 nonferrous metals
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