Tool and die making troubleshooter PDF
Preview Tool and die making troubleshooter
About the Book Conceived from years of problem solving, Tool and Die Making Troubleshooter is destined to be an indispensable guide for T designing, constructing, and maintaining o tools, dies, molds, and fixtures. The book o contains hands-on information, valuable l tooling tips, and procedural recommendations a regarding the selection, processing, and use of materials. This com- n Tool and prehensive reference is for anyone working with the selection, ap- d plication, and use of cast irons, cast steels, wrought tooling sheets, and aluminum and stainless steels. The subjects of basic metallurgy, D heat treating, machining, grinding, electrical discharge machining, Die Making i welding, quality, wear enhancements, surface coatings, and treat- e ments for tools and dies have been carefully organized and pre- M sented for quick reference. a TROUBLESHOOTER About the Author k i n Richard Leed began his career with Leed g Steel Company, a family-owned metal service center. In 1980, he became Vice T President and quickly realized the im- r portance of cost-effective tooling and its o impact on part quality and the financial u success of a production operation. With this in mind, he took a b strong interest in providing his customers with the technical and l e metallurgical assistance needed to optimize their tooling invest- ments. These services included technical discussions, training pre- s sentations, and specification and procedure upgrades for tool design, h material selection, machining, heat treating, finish machining o (grinding, welding, and electrical discharge machining), tool and o die failure analysis, and troubleshooting. Richard Leed is a tool t and die troubleshooting consultant to industry. He has authored e numerous technical papers and manuals that focus on improving r Richard M. Leed tool and die performance. Leed Society of Society of Manufacturing Manufacturing Engineers Engineers www.sme.org www.sme.org Association for Association for Forming & Fabricating Forming & Fabricating Technologies/SME Technologies/SME www.sme.org/afft www.sme.org/afft Tool and Die Making Troubleshooter prepages.pmd 1 10/29/02, 11:10 AM prepages.pmd 2 10/29/02, 11:10 AM Tool and Die Making Troubleshooter Richard M. Leed Society of Association for Manufacturing Forming & Fabricating Engineers Technologies/SME Dearborn, Michigan prepages.pmd 3 10/29/02, 11:10 AM Copyright © 2003 by the Society of Manufacturing Engineers 987654321 All rights reserved, including those of translation. This book, or parts thereof, may not be reproduced by any means, including photocopying, recording or microfilming, or by any information storage and retrieval system, without permission in writing of the copyright owners. No liability is assumed by the publisher with respect to use of informa- tion contained herein. While every precaution has been taken in the preparation of this book, the publisher assumes no responsibility for errors or omissions. Publication of any data in this book does not consti- tute a recommendation or endorsement of any patent, proprietary right, or product that may be involved. Library of Congress Catalog Card Number: 2002113502 International Standard Book Number: 0-87263-643-7 Additional copies may be obtained by contacting: Society of Manufacturing Engineers Customer Service One SME Drive, P.O. Box 930 Dearborn, Michigan 48121 1-800-733-4763 www.sme.org SME staff who participated in producing this book: Phil Mitchell, Senior Editor Eugene Sprow, Editor Rosemary Csizmadia, Production Supervisor Frances Kania, Production Assistant Kathye Quirk, Graphic Designer/Cover Design Jon Newberg, Production Editor Printed in the United States of America prepages.pmd 4 10/29/02, 11:10 AM About The Society of Manufacturing Engineers (SME) The Society of Manufacturing Engineers is the world’s leading professional society supporting manufacturing education. Through its member programs, publications, expositions, and professional development resources, SME promotes an increased awareness of manufacturing engineering and helps keep manufacturing pro- fessionals up to date on leading trends and technologies. Head- quartered in Michigan, SME influences more than half a million manufacturing engineers and executives annually. The Society has members in 70 countries and is supported by a network of hun- dreds of chapters worldwide. Visit us at www.sme.org. About AFFT/SME The Association for Forming & Fabricating Technologies of SME (AFFT/SME) focuses on the technologies and processes that effi- ciently make products from metal sheet, coil, plate, tube, or pipe stock. Typical industries served are automotive, off-highway, aero- space, defense, appliance, furniture, and consumer electronics products. Core processes include general pressworking—stamp- ing, drawing, forming, bending, and shearing, for example—as well as the fabricating technologies of punching, cutting, sawing, welding, and others. Many AFFT/SME members are manufacturing, tool, or pro- cess engineers specializing in keeping production forming or fab- ricating technologies current for their companies; general stamping, fabricating, welding, and assembly managers respon- sible for overseeing plant operations; and owners, partners, pro- prietors, and other company officials of relevant job shops. AFFT/ SME membership allows such people to more quickly identify in- novations that can lower costs while increasing product quality and yield. The AFFT/SME community also fosters learning among members to better manage their businesses and interact with customers, suppliers, and industry partners. prepages.pmd 5 10/29/02, 11:10 AM prepages.pmd 6 10/29/02, 11:10 AM This is dedicated to my wife, Nancy, and my children Richard and Carolyn. Together they gave me purpose, taught me the meaning of unqualified love, and gave me inspiration for the future. prepages.pmd 7 10/29/02, 11:10 AM Tool and Die Making Troubleshooter viii prepages.pmd 8 10/29/02, 11:10 AM Chapter 1: The Tooling Investment Table of Contents Preface .....................................................................................xiii Acknowledgments....................................................................xv 1 The Tooling Investment ........................................................ 1 Tooling Facts of Life........................................................................1 Time ................................................................................................3 2 Steelmaking Methods and Hot Working.............................. 7 The Origins of Steelmaking............................................................7 The Legend of Damascus Steel.....................................................9 Electric Furnace Melting...............................................................10 Quality Effects of Ingot Mold Solidification..................................12 Refining/Remelting Processes.....................................................14 Powder-metal Tool Steels.............................................................19 Hot Working of Tool Steels...........................................................21 Cast-to-shape Versus Wrought Tool Steels .................................24 3 Quality Considerations....................................................... 27 ISO 9000 Quality Systems ...........................................................27 Aircraft-quality Steel .....................................................................30 Mold-quality Steel.........................................................................31 4 Metallurgy and Engineering Considerations.................... 35 Basic Mechanical Properties........................................................35 Hydrogen Embrittlement..............................................................39 Alloy Segregation (Banding)........................................................40 ix prepages.pmd 9 10/29/02, 11:10 AM
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