Professional Documents
Culture Documents
Design
Chapter 3
Tooling materials and
production processes
1
Tooling materials
Ferrous tooling materials
Nonmetallic tooling materials
Nonferrous tooling materials
Material selection depends on its use
Location
Clamping
Friction
2
Material properties
Strength
Ability to resist the action of external loads or
forces
It is the amount of smoothly applied pull force
(N) per cross sectional area (mm2) that the
material will withstand before it breaks
Plasticity
It is the ability of a material to deform without
breaking
3
Material properties
Elasticity
It is the ability of a material to recover its original size
and shape after it has deformed
Stiffness
It is the ability of a material to resist elastic
deformation
Elastic limit
Is the maximum load per unit area (N/mm2) that can
be applied without producing permanent deformation
Toughness
The material ability to absorb energy and deform
plastically before failure
4
Material properties
Hardness
It is the ability of a material to resist penetration,
scrathing, abrasion or cutting
Machinability
Is the adaptability of a material to cutting
It depends on hardness and toughness of the material
Also depends on cutting speed, cutting tool material
and quality, cutting tool angles,
Also depends kind and quality of coolant
Also depends rigidity of machine and tool support
5
Cost of material
An important factor to ensure competitive
pricing of jig or fixture
Should balance between
Material properties and
Design requirements
Wrong selection
Cheapest material may be expensive in long
run
Expensive material over the specification
requirements, hence extra cost without added
value
6
Ferrous tooling materials
Die steels
Unalloyed carbon steels
Alloy cold-work steels
Heat treated die steels
High speed steel (HSS)
7
Material and application in jig & fixture
Material AISI DIN JIS ASSAB Use
Hot work tool H13 X40 CrMoV5 1 SKD61 8407 Extrusion dies, die casts,
steel X38 CrMoV5 3 ~QRO 90 screws, nuts, rivets, pins.
35 – 55HRC
Hot work ~0.38 2.7 ~5.2 ~1.4 0.3~ 0.9 0.2 ~ 1.1
tool steel
Pre- 0.38 ~ 1.9 ~ 14.3 0.2 ~ 0.6 0.3 ~ 0.7 0.45 ~ 1.5
hardened 0.4
steel
9
Part & application: ferrous-based
Part Example Condition Use
10
Heat treatment
Is a process capable of changing the
physical properties of a metal by
subjecting it to a combination of heating &
cooling.
It may harden, soften, toughen, stress-
relieve, increase machinability, strengthen
the material or a combination of these.
The rate of heating & cooling will depend
upon the properties required.
11
Heat treatment processes
Normalising
Annealing
Hardening
Quenching
Tempering
12
Iron-Carbon Diagram
Ferrous-carbon diagram
Temperature
16
Quenching
Is cooling a heated piece of metal.
Cooling using cooling media such as
brine, water, oil caustic soda in water,
molten salt and still air.
17
Hardening
To improve or give strength to part &
increase its wear resistance property.
Process: heat the steel slightly above its
hardening tempt & quenching it in the
proper medium.
18
Tempering
A process where a certain degree of
hardness is sacrificed to relieve strains &
increase toughness.
Process: reheating the steel after
hardening to a tempt much lower than the
hardening heat.
Done in baths of oil, salts, or lead, whose
tempt are pyrometer-controlled.
19
Nonmetallic tooling materials
Plastic
Nylon
Polyurethane
Fibre
Rubber
Wood
20
Nonferrous tooling materials
Sintered carbides
Carbide of tungsten, titanium and tantalum
held together with cobalt binder
Cast nonferrous alloy
Zinc alloy
Bismuth alloy
Magnesium
21
Machining process
Standard processes
Milling
Turning
Grinding
Wirecut EDM
Diesink EDM
Boring
22
Limits and fits
Limit
Permissible dimension of a shaft or hole
Largest permissible dimension of a shaft or
hole is called the ‘high limit’
Smallest permissible dimension of a shaft or
hole is called the ‘low limit’
The difference between high and low limits is
called tolerance. They are the permissible
variation
23
Limits and fits
Tolerance
Unilateral tolerance allows only +0.02
20 -0.00
one side tolerance of the nominal
dimension
Bilateral tolerance allows both side 20
+0.02
-0.01
tolerance of the nominal dimension
24
Limits and fits
Fit describes the condition and functional
requirements of assembled parts
Four classes of fits
Running fit
Push fit
Press fit
Force fit
25
Limits and fits
Running fit
Easy rotation & axial movements of shaft
(male) in the hole (female)
Push fit
Hand-push of shaft (male) into hole (female)
Press fit
Minimum force using tool (hammer) to locate
shaft (male) into hole (female)
Force fit
High force using press tool to locate shaft
(male) into hole (female)
26
Assembly, testing and commissioning