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VII - SEM
Methods of V Location
Locating profile surface:
The irregular profile surfaces are located by pin and buttons. Flat
buttons or rest button is used when the surface is flat. Spherical radius
locators are used when the part is rough and irregular. The screw button
locators are used when a through hole is not possible to locate and therefore
it provides a way for easy loading and unloading.
Full Nest
Partial Nest
Strap Clamp
HYDRAULIC CLAMP:
Hydraulic actuated clamping systems are established in modern
machine tools. Today hydraulic clamping actuators are supported by external
pressure supply and controlled by machine control. The hydraulic actuators
are usually connected to the external pressure supply by horses, pipes and
coupling systems. These components have drawbacks concerning flexibility,
leakage and system bleeding at change of attachment.
Unlike air, hydraulic oils are almost incompressible consequently,
variation in load does not cause much speed variation in hydraulic systems.
It can be minimized further to be almost negligible by using pressure
compensated flow control valve. Operating pressure of hydraulic system
ranges from 7 to 250 atmospheres. High pressure permits use of small
compact cylinders to develop high force. However, hydraulic cylinders are
slow in operation in comparison with pneumatic actuators. Oil is circulated in
the system through a reservoir. Generally every machine or fixture would
have its own individual hydraulic reservoir and power unit. Large centralized
power units are rarely used. Hydraulic operation of a mechanism generally
requires substantial investment for hydraulic power pack and cylinders. The
figure shows the Hydraulic supports.
Hydraulic Clamp
The angular post jigs are primarily used to machine parts that cannot
be easily machined by plate type tooling. Sizes are varied according to the
size of the workpiece. The analysis and evaluation of the workpiece before
designing the angular post jig. The figure shows the angular post jig. It is a
welded construction. These are jigs are mostly used to make the intricate
angular holes. The drill bush is a renewable type extended drill bush, it
prevents the bending of the drill bit, and yet allow removal of the workpiece.
The clamping nut is of the quick action type because smallness of the
workpiece demands that the nut be removed when the workpiece is
removed.
12. (b) Face Plate Fixture
Face Plate Fixture can be used conveniently for machining of simple
and small components. Addition of locators and clamps on face plate help in
quick location and clamping of workpiece as shown in Figure. Face plate
fixture is useful for facing number of workpieces simultaneously on the lathe.
Face plate fixture A lathe face plate fixture is fastened to a standard
clamping and locating devices. It may be similar in appearance to a will
fixture, but it is quite different in that it is rotating around the lathe axis. The
base of the fixture may be a flat plate as shown in Figures.
Edge cutter
consists of two pairs of rolls, which feed the stock by friction. An eccentric
shaft fitted with the crank of the press or a hydraulic system drives the pairs
of roll. A simple stock feed system using eccentric crank is shown in the
figure. When the ram crank moves from Top Dead Centre (TBC) to Bottom
Dead Center (BDC), the eccentric crank is fed the stock into the working
zone. When the ram moves from BDC to TDC, a freewheeling clutch attached
in the roller is relieved the stock.
The sheet is pushed against the stopper in the tooling (shown in Figure).
When the ram moves downwards, the edge cutter notches a piece of stock of
width b and length L at the edge of the strip. The sheet can now be pushed
forwards by this length L (strip feed measurement). Depending on the
precision of the feed and material use of the strip (how it is used), one or two
edge cutters are employed.
Edge cutter
Swaging Dies
The spindle with die blocks rotates inside a ring with series of backer
rollers. When the die blocks occupy the space between rollers, die blocks are
moved out from center and will open the die. When the die blocks move to
the place of backer rollers, die blocks move towards the center and close the
die opening. It gives the radial movement to the dieblocks (hammering).
Radial forces are applied with short strokes. The continuous radial
hammering around the periphery of the rod forms the grooves on the rod
surface. The dies with only radial movement without rotary movement form
flat shapes. Screw driver blade is an example for the swaging without
rotating the die blocks.
The tube swaging process can be used to reduce or increase the
diameter of the tube. This is also similar to rod swaging. The only difference
is to control the tube thickness of a governing mandrel used inside the tube.
Figure shows below, the tube swaging process. From the figure we can
understand that when the diameter gets reduced without mandrel, the
thickness of the wall is increased in the die gap. The thickness of the wall can
be controlled by placing a andrel inside the tube. It also shows the governing
of wall thickness by a mandrel. When a mandrel is used, the final thickness
of the tube depends on the mandrel diameter. The mandrels with external
features produce the tubes with internal grooves or shapes. The internal
shapes that can be obtained in a tube with different shaped mandrels are
shown in the figure.
Various Cross-sections of
mandrels
Nowadays, the sheet metal designers use computer aids for the most
of activities in sheet metal forming, such as designing, drafting, optimizing
and formability analysis. The following are the functions of computer in sheet
metal forming:
1. to compute the blank size fir bent, formed and/or drawn
workpiece.
2. to optimize the sheet strip layout
3. to select the appropriate press tool to be used.
4. to decide the position of punch and shank centers
5. to compute the shear force and sizes of die, stripper, screws
6. to draft the assembly drawing, bill of materials and detailed
drawing.
7. to analyze the forming behavior of sheet metal.
Many softwares are used in sheet metal forming analysis. LS-Dyna
solver, HyperFormOne_Step, ARGUS are some of the commonly sed software
forsheet metalforming analysis. The sheet metal rming analysis consists of
the following steps.
1. Solid modeling
2. Determination of 3D coordinates of the component's surface
3. Strain distribution analysis
4. Thickness reduction analysis.
solid model of sheet metal parts to be formed can be modeled using
the CAD software programs, such as Unigraphics, Catia, or SolidWorks. The
solid model is analysed by any one of the above said sheet metal forming
analysis software.
15 (b) (ii) TOOLING FOR NUMERICAL CONTROLLED MACHINES:
Numerically controlled machines have not removed the need for
workholders, only the need for complex and expensive jigs and fixtures. The
trend is away from single-purpose tooling and toward multipurpose, universal
workholders.
Numerically controlled machines have forced the tool designer back to
the basics of jig and fixture design. Whereas with other machines only a
single surface can be machined at one time, numerically controlled machines
can machine several surfaces in each setup. Whereas conventional machines
require detailed and repeated tool referencing, numerical control requires
only initial referencing to the workholder. Whereas the goal of conventional
tool design was to transfer the needed accuracy from the operator to the
fixture, numerically controlled machines transfer the required accuracy from
the fixture to the machine tool. All of this, coupled with the speed, precision,
and repeatability of numerical control, has challenged the tool designer as
never before.