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Chapter 1 Stamping Forming and Die Design 1

1.1 Introduction 1

1.2 Blanking and Punching Dies 4

1.2.1 Blanking 4

1.2.2 Blanking Deformation Process 6

1.2.3 Blanking Workpiece Quality 8

1.2.4 Blanking and Punching Dies 9

1.2.5 Blanking Tools 14

1.3 Bending Dies 20

1.3.1 Simple Bends 20

1.3.2 Bending Allowance 21

1.3.3 Bending Tool 22

Chapter 2 Plastics Molds 24

2.1 Introduction 24

2.2 The Properties of Plastics 25

2.2.1 Thermosets 26

2.2.2 Thermoplastics 26

2.2.3 Fillers 27

2.2.4 Properties of Plastics 27

2.3 Injection Molds 35

2.3.1 Injection Molding 35

2.3.2 Injection Molds 37

2.3.3 Mold Machine 40

2.4 Other Molding Processes 44

2.4.1 Compression Molding 44

2.4.2 Transfer Molding 45

2.4.3 Co-injection Molding 46

2.4.4 Gas-Assisted Injection Molding 47

2.4.5 Extrusion Molding 48

2.4.6 Blow Molding 49

Chapter 3 Casting Dies 51

3.1 Casting 51

3.2 Sand Casting 52

3.2.1 Sands 53

3.2.2 Types of Sand Molds 54

3.2.3 Patterns 55

3.2.4 Cores 56

3.2.5 Sand-Molding Machines 56

3.2.6 The Sand Casting Operation 58

3.3 Die Casting 61

3.3.1 The Die Casting Cycle 62

3.3.2 Die Casting Alloys 62

3.3.3 Die Casting Dies 63

3.3.4 Die Casting Machines 65

Chapter 4 CNC Machining 68

4.1 Introduction to CNC 68

4.1.1 Concept of NC and CNC 68

4.1.2 Basic Component of NC Machine Tools 69

4.2 The CNC Program 71

4.2.1 Axes 71

4.2.2 Programming 73

4.2.3 CAM System Programming 78

4.3 Machining Centers 80

4.4 Automation of Manufacturing 82

4.4.1 Introduction 82

4.4.2 Flexible Manufacturing System 84

4.4.3 Computer Integrated Manufacturing System 84

Chapter 5 Mold Special Machining 87

5.1 Electrical Discharge Machining 87

5.1.1 Principle of EDM 87

5.1.2 Wire EDM 89

5.2 Electrochemical Machining 93

5.2.1 Working Principle of ECM 93

5.2.2 ECM Equipment 94

5.2.3 Applications of ECM 95

5.3 Rapid Prototying Manufacturing 98

5.3.1 Overview of Rapid Prototyping 98

5.3.2 The Basic Process 99

5.3.3 RP Techniques 100

Chapter 6 CAD/CAM/CAE 105

6.1 The Computer in Die Design 105

6.2 CAD/CAM 107

6.2.1 CAD 107

6.2.2 CAM 109

6.3 CAE 110

6.3.1 MPI Introduction 111

6.3.2 MPI Modules 112

6.3.3 CAE Example of MPI 116

Glossary 122

References 136