Tool and Manufacturing Engineers Handbook (Vol 2: Forming)

947 Pages·36.156 MB·English

by  Charles Wick

President Nathan A. Chiantella, CMfgE John E. Mungerson, CMfgE, PE
Reginald W. Barrett, CMfgE IBM Corporation Boeing Commercial Airplane
The Pyle National Company Company
Frank R. L. Daley, CMfgE, PE
Vice President
Gary J. Peterson, CMfgE, PE
Forrest D. Brummett, CMfgE John J. DiPonio, CMfgE, PE Ford Hewlett-Packard Company
General Motors Corporation Vice Motor Company
President Donald E. Gardiner Sam C. Petioles, CMfgE Ferris
State College
Marvin F. DeVries, CMfgE, PE General Electric Company
University of Wisconsin-Madison William H. Heffron, Jr., CMfgE Fred W. Randall, CMfgE, PE
Vought Corporation
Vice President Pitney-Bowes. Inc.
DCaotnearlpdi lGla.r ZToroakct,o Cr MCofg. E, PE Kenn Hurt, CMfgE FBroadnikn eJ .C Roirlpeyo,r aCtiMonfg E, PE The
Caterpillar Tractor Co.
Secretary/Treasurer Neal P. Jeffries, CMfgE, PE Center George W. Stambaugh, PE
John E. Mayer, Jr., CMfgE for Manufacturing Production Grinding. Inc.
Kennametal. Inc.
Technology Frank M. Trcka, CMfgE, PE
Robert C. Klassen, CMfgE Custom Bourns. Inc.
Engineering, Inc.
Earl E. Walker
HDeeVrbleiertg AM. aBcehyineer Company RUonbiteerdt ES.t aKtersa uAcrhm, Jyr ., CMfgE, PE CaCrro Lmapnaen My anufacturing
Douglas E. Booth, CMfgE, PE Chemical Research and
Livernois Automation Company Development Center
Paul F. Boyer, CMfgE, PE Union Jerry L. Lyons, CMfgE, PE Essex
Carbide Corporation Industries. Inc.
Charles F. Carter, Jr., CMfgE, PE Frank H. McCarty, CMfgE, PE WExiellciuamtiv Je. VHiicltey P resident
Cincinnati Milacron. Inc. Raytheon Company and General Manager

OFFICERS AND DIRECTORS, 1983-1984
SOCIETY OF MANUFACTURING ENGINEERS

ISBN No. 0-87263-135-4
Library of Congress Catalog No. 82-60312 Society
of Manufacturing Engineers (SME)
Copyright 1984,1976,1959. 1949 by Society of Manufacturing Engineers, One SME
Drive, P.O. Box930, Dearborn, Michigan 48121
All rights reserved, including those of translation. This book, or parts thereof, may not be reproduced in
any form without written permission of the copyright owner. The Society does not, by publication of data
in this book, ensure to anyone the use of such data against liability of any kind, including infringement of
any patent. Publication of any data in this book does not constitute a recommendation of any patent or
proprietary right that may be involved. The Society of Manufacturing Engineers disclaims any and all
responsibility for use of the information contained herein by readers and users of this Handbook.
First edition published 1949 by McGraw-Hili Book Co. in cooperation with SME under earlier Society
name, American Society of Tool Engineers (ASTE), and under title: Tool Engineers Handbook. Second
edition published 1959 by McGraw-Hili Book Co. in cooperation with SME under earlier Society name,
American Society of Tool and Manufacturing Engineers (ASTME), and under title: Tool Engineers
Handbook. Third edition published 1976 by McGraw-Hili Book Co. in cooperation with SME under
current Society name, and under title: Tool and Manufacturing Engineers
Printed in the United States of America
Handbook.
TMEH TM
The first edition, published as the Tool Engineers Handbook in 1949, established a
useful and authoritative editorial format that was successfully expanded and improved
upon in the publication of highly acclaimed subsequent editions, published in 1959 and
1976 respectively. Now, with continuing dramatic advances in manufacturing technology,
increasing competitive pressure both in the United States and abroad, and a significant
diversification of informational needs of the modern manufacturing engineer, comes the
need for further expansion of the Handbook. As succinctly stated
by Editor Frank W. Wilson in the preface to the second edition: "...no 'Bible' of the
industry can indefinitely survive the impact of new and changed technology. "
Although greatly expanded and updated to reflect the latest in manufacturing
technology, the nature of coverage in this edition is deeply rooted in the heritage of
previous editions, constituting a unique compilation of practical data detailing the
specification and use of modern manufacturing equipment and processes. Yet, the
publication of this edition marks an important break with tradition in that this volume,
dedicated solely to forming technology, is the second of five volumes to be published in
the coming years, to comprise the fourth edition. Volume I, Machining, was published in
March 1983. Other volumes of this edition will include:
Materials, Finishing and Coating; Quality Control and Assembly; and Management.
The scope of this edition is multifaceted, offering a ready reference source of
authoritative manufacturing information for daily use by engineers, managers, and
technicians, yet providing significant coverage of the fundamentals of manufacturing
processes, equipment, and tooling for study by the novice engineer or student. Uniquely,
this blend of coverage has
characterized the proven usefulness and reputation of SME Handbooks in . previous editions
and continues in this edition to provide the basis for acceptance across all segments of
manufacturing.
The scope of this volume encompasses both conventional and special forming methods,
covering in detail the fundamentals, capabilities and limitations, and applications of all
processes. Included are discussions of presses and machines used, dies and other tooling,
operating parameters, troubleshooting guidelines, and safety considerations. Individual
chapters are devoted to sheet metal formability, die and mold materials, lubricants, die
design, powder metallurgy, and plastics forming.
Every aspect of forming technology is provided in-depth coverage in this
volume, presented in a completely new, easy-to-read format. An exhaustive index that
cross references processes, equipment, tools, and work piece materials enhances
readability and facilitates the quick access of information. Liberal presentation of
illustrations, graphs, and tables speeds information gathering and problem solving.

PREFACE
The Society of Manufacturing Engineers is a professional engineering society dedicated to
advancing manufacturing technology through the continuing education of manufacturing engineers,
managers, and technicians. The specific goal of the Society is "to advance scientific knowledge in
the field of manufacturing engineering and to apply its resources to research, writing, publishing,
and disseminating information."
The Society was founded in 1932 as the American Society of Tool
Engineers (ASTE). From 1960 to 1969, it was known as the American Society of Tool and
Manufacturing Engineers (ASTME), and in January 1970 it became the Society of Manufacturing
Engineers.
The changes in name reflect the evolution of the manufacturing engineering profession, and the
growth and increasing sophistication of a technical society that has gained an international
reputation for being the most
knowledgeable and progressive voice in the field. The Society has some 70,000 members in 65
countries, most of whom are affiliated with SME's 270-plus senior chapters. The Society also
sponsors more than 110 student chapters at universities and colleges.
As a member of the World Federation of Engineering Organizations, S ME is the universally
acknowledged technical society serving the manufacturing industries.

SME
SME staff who participated in the editorial development and production of this volume include:
Thomas J. Drozda
Division Manager. Editorial Susan J. Leinart Johanne.D. Kanney
Assistant Supervisor Assistant Manager
Charles Wick
Manager, Reference Publications Shari L. Rogers Michael McRae
Typesetter Operator Key liner
John T. Benedict
Senior Staff Editor Christine Marie
Keyliner
Raymond F. Veilleux
Associate Editor
Gerri J. Andrews
Technical Copy Editor
Shirley A. Barrick
Editorial Secretary
Judy A. Justice
Word Processor Operator
The reference material contained in this volume is the product of incalculable hours of unselfish
contribution by hundreds of individuals and organizations, as listed at the beginning of each chapter. No
written words of appreciation can sufficiently express the special thanks due these many forward-thinking
professionals. Their work is deeply appreciated by the Society; but more important, their contributions
will undoubtedly serve to advance the understanding of forming technology throughout industry and
will certainly help spur major productivity gains in the years ahead. Industry
as a whole will be the beneficiary of their dedication.
Further recognition is due the members of the SME Publications Committee for their expert guidance
and support as well as the many members of the SME Technical Activities Board, particularly the
members of the Material Forming Council.
The Editors

EDITORIAL
TYPESETTING GRAPHICS
Symbols and Abbreviations...............................................................................................................xi
Sheet Metal Formability......................................................................................................................1-1
Die and Mold Materials......................................................................................................................2-1
Lubricants...................................................................................................................................... 3-1
/SheetMetalBlankingandForming.........................................................................................................4-1
Presses for Sheet Metal Forming......................................................................................................5-1
/DieDesignforSheetMetalForming.......................................................................................................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
Drawing, Extruding and Upsetting ..;.............................................................................................13-1
Swaging.......................................................................................................................................14-1
Hot Forging..................................................................................................................................15-1
Casting.........................................................................................................................................16-1
Powder Metallurgy.......................................................................................................................17-1
Plastics Forming...........................................................................................................................18-1
Special Forming Methods..............................................................................................................19-1
Safetyin Forming..........................................................................................................................20-1
Index...................................................................................................... .......................................1-1