The Process of Metalworking

Not all of us are familiar with the process of metalworking. Some people may have heard it a couple of times from random people or may have read about it online or in books, but they are not aware of what exactly it is and what role it plays in our lives.

Metalworking is a very important process that is used in working with different kinds of metals. It is essential in many industries because it plays a significant role in the whole production process of certain goods. It has been around for millions of years and has undergone a lot of modifications and improvements over the years.

A long, long time ago, the ancient men were not aware of the existence of metal. They used to utilize stones and wood for cutting or hunting for their food. When they discovered metals, they began to replace their tools and weapons. Those that were made of metals turned out to be more durable and long lasting than those that were made out of wood or bones. That was when metalworking was born.

The process started out as something simple. No sophisticated equipment or technology was available at that time yet, so it was up to the men to learn how to make their lives easier and more comfortable. They used metals to hunt and cook for food. They also used them to make weapons. As time went on, metals were made into decorative ornaments for their homes and bodies. Religious artifacts, memorabilia and jewelry have started popping up. Metalworking has become a process that covers a very broad area.

In no time, several types of tools and machineries were invented to keep up with the continuous progress of metalworking. Manual labor was not enough to meet the demands anymore, so the addition of more modern innovations became apparent. Simple machineries such as presses, rollers and benders came out and proved to be extremely useful in metalworking. They made everything faster and more efficient.

Nowadays, metalworking is not only treated as a science. It is also a job and a hobby. More and more people have become interested in learning this process because of the different kind of fulfillment it gives once you see the end products of your hard work. Metalworking has indeed contributed a lot not only to the people in this industry but to the rest of the society as well.

3 Types of Plastic Molding Process

Commonly, there are two main types of plastic molding, such as thermosets and thermoplastics. The main difference between those two types of plastics is that the thermoplastics are meltable at high temperature while thermosets will harden at high temperature.

The difference above is mainly caused by the polymers which form those two plastics. Thermoplastics have polymer which look like a chain of atom in one dimensional string. Since they are melted at high temperature, it can be reshaped. On the other hand, thermosets are formed from a polymer with three-dimensional chains so that they are able to keep their shape. There are a lot of processes which are used for shaping or molding plastic using either thermopastics or thermosets. It is also possible to use the combination of those two types.

There are a lot of types of molding process such as extrusion, injection molding, and the combination of the two processes which is known as blowing molding.

Extrusion molding process starts with raw plastics like powder, pellets, and beads. Firstly, the plastic will be fed to a revolving chamber. The chamber which is also known as the extruder will turn and melt the plastic. The melted plastic can be formed to the shape you want. Then, the finished product is dropped on the conveyer belt to be cooled with water. The next step is cutting and finishing touch. The items which are commonly made through extrusion are films, sheets, and also pipes.

Injection molding is another process of molding. The principle used for this process is typically the same as the extrusion. The raw plastic will be fed into the melting chamber through a hopper. The difference is that the melted plastic is put into cold mold with high pressure. If the mold is cool, the product will be cleaned and finished. The items which are commonly made through injection molding are bottle caps, butter containers, lawn furniture, and also toys.

Blow molding is another type of plastic molding process which uses a blowing method after the extrusion or injection molding. The melted plastic in the extrusion process uses a die to create the heated plastic tube with the cool mold around it. In the extrusion blowing, the compressed air will be blown through the tube so that it will force the plastic to make a hallow shape inside. With this method, the manufacturer does not need to attach different injection-molded parts. On the other hand, injection blowing method blows the melted mold into the final shape in different cold.

4 Different Types of Steel

Steel is a catch-all phrase use to describe a group of iron alloys. These alloys all have one thing in common: malleability. Steels can all be melted down and used in the injection moulding process to create everyday items. Steels can be cast directly into moulds, or can be made into other forms which allow them to be heat-treated and worked on at a later stage. Here are four different types of steel:

• Standard Steels.
  • Carbon steel. A carbon steel only requires carbon to create a successful alloy. Other alloys will have minimum requirements for materials such as chromium, nickel, tungsten and a handful of other elements. Carbon steel can range from low-carbon to ultra-high carbon (1.0-2.0%) content. Generally, the greater the carbon content, the more the alloy can be hardened, increasing strength, wear and impact resistance.
  • Alloy steel. Steel is alloyed with other elements in order to improve its mechanical properties. The mixture of other elements can be anywhere from 1% to 50%, dividing alloys into two camps: low alloy steels and high alloy steels. The most common alloy steel is low alloy steel. Alloy steels are used to improve harden-ability and corrosion resistance. Often a low-alloy steel will have less carbon in it, as the low non-carbon alloy materials in combination with high carbon content can make it difficult to weld.
  • Stainless steel. This is the stuff kitchen benches are made out of. Also known as inox steel or corrosion-resistant steel (usually in the aviation industry), it is an alloy containing a large amount of chromium by mass (a minimum of 10.5%-11%). Stainless steel does not stain, rust or corrode as easily as ordinary steel (it is a myth that it will not corrode at all). The main difference between stainless steel and other types of steel alloy is the amount of chromium present. The chromium in the alloy acts as a film against the rust which usually plagues steel by forming a film of chromium oxide, which acts as a barrier, not allowing corrosion to spread from the surface inwards. Its resistance to corrosion and staining make it an ideal candidate for commercial applications, and there are over 150 different varieties in use, each with specific and differing properties.
  
  
• Tool steels. These are a collection of steels and alloys, collectively grouped because their particular properties make them ideal for use in making tools. They are commonly resistant to abrasion or corrosion, are hard, impact resistant and are able to hold a cutting edge. There are a number of different grades of tool steel, each with one or more of its properties enhanced for use in its industry. Tool steels are used in the creation of moulds for injection moulding, as they are able to withstand the production of thousands of parts without showing signs of abrasion.

Steel has thousands of applications, and each application has its own particular makeup of compounds. Steel's amazing properties mean that its makeup can be specifically targeted for the needs of the designer or engineer.

Welding Stainless Steel Tubing Boatrails - Tips for Welding and Fabrication

Welding stainless steel tubing boat rails can be a gravy job but can also be extremely challenging.

Boat owners can be very picky.

Welds not only need to be strong, but they need to look nice too. In fact many boat owners have come to expect welds on boat rails to be pretty much invisible.

And why not? Welds do not have to be ugly in order to be strong.

316 stainless steel is often used for marine hardware like boat rails and Stanchion feet fittings because 316 stainless steel is more corrosion resistant to salt water than most other grades of stainless like 304 for instance. But retaining the corrosion resistance all the way through the welding process requires some attention to detail. For welding stainless steel tubing for marine applications, follow these guidelines:

• always use a stainless steel wire brush that has never been used for anything else
• use the right filler metal - if the stainless tubing to be welded is 316L, then use 316L filler metal
• Pay attention to the fitup - a tight fit, with no gap results in a better joint
• back purge with argon or use a split sleeve backing ring
• use the right amperage - just enough to achieve desired penetration, but non enough to turn the metal gray
• for welds that will be subjected to salt air, a polish followed by a pickling paste helps increase corrosion resistance

In addition to the tips above, use a tig welding technique that lets you minimize heat input - like pulsing the current if your tig welding machine has pulse capability.

What is a Die Grinder?

A die grinder is a tool used to polish and buff the inside of cylindrical objects. A cylindrically shaped sanding attachment, called a grinding nose, attaches to the bottom of the die grinder in a similar fashion as a drill bit goes into a drill. When metal piping is cut, small metal spurs often result where the cut has been made. These spurs can wreak havoc on connections. A die grinder is used to grind the spurs away, making the area smooth and allowing for proper installation.

A die grinder can range in size from a small handheld die grinder to bench top models. When choosing a die grinder, it is important to consider its primary purpose, what attachments must be used, and the amount of time that will be spent grinding down materials. An incorrectly used die grinder can wear out quickly and cause injury to the operator.

All die grinders have rotations per minute (RPM) ratings and no-load speeds. RPM measures how often the die grinder spins while in use. No-load speeds refer to the rotations of the tool’s spindle when it is idling. If the RPM rating is higher than the no-load speed, the die grinder could shatter upon use. It is essential to pay close attention to these ratings when purchasing a die grinder.

The RPM rating of the die grinder is the deciding factor in the tool’s usage. A die grinder with a lower RPM is best used for fine grinding and finishing work. Speeds lower than 10,000 RPM are best for this function. A die grinder with an RPM between 10,000 and 20,000 is great for creating rough finishes and minor buffing jobs. If the die grinder will be used to remove metal burrs or to cut metal, it must have an RPM rating of over 20,000 and a no-load speed of at least 30,000 depending on the RPM rating.

A die grinder can also utilize additional attachments. The most common attachments are large sanding disks capable of covering more space in a short time. Metric sized couplers can also be handy when using larger or smaller grinding noses.

When running a die grinder, it is important to follow some simple safety rules. Never wear loose jewelry while operating the grinder. Neck chains can easily become caught in the die grinder and cause strangulation. Safety goggles should also be worn at all times.

The operator must keep a strong hold on the die grinder at all times. Similarly, the component being ground should be held in a bench-top vice or clamp. Fingers should be kept out of range of the die grinder. When the die grinder is not in use, it should be unplugged.

What is a Knurling Tool?

A knurling tool is used in conjunction with a lathe to emboss the ends of metal tubes and shafts. The embossed grooves may act as hand grips for the user or better traction for rubber or plastic covers. The knurling tool itself consists of multiple rotary cutters which are held against the metal shaft as it turns on the lathe at a relatively slow speed (500 rpm on average). Turning is a method by which cylindrical pieces of metal or wood are spun in place by a variable-speed electric motor. As the piece spins, various cutting tools can be placed against it to remove material or cut shapes. A knurling tool falls somewhere between an engraver and an embosser.

There are generally three shapes generated by most knurling tools - straight lines, diagonal lines and a diamond pattern. Knurling tools do come in a variety of sizes and cutting designs, depending on the purpose of the piece. The diamond pattern is most common with hand grips because it creates the most traction between a user's hand and the shaft. Diagonal and straight knurls are generally used to give extra traction to an external handle or other connective piece.

In order to create a knurl pattern, the lathe must hold the metal piece perfectly straight - a condition machinists call 'true'. As the lathe begins to turn, a special holder for the knurling tool is attached to the work table. The knurling tool itself is clamped into the holder and carefully directed to the turning piece with a small crank. Since knurling is an abrasive process, the machinist should use a generous supply of machine oil on the turning shaft. A knurling tool rarely makes a complete imprint the first time it is pressed against the shaft. Machinists usually make several passes with the knurling tool, allowing the individual cutters to make small bites into the metal.

A knurling tool is best suited for softer metals such as aluminum or standard grade steel. Hard metals such as titanium would most likely ruin the tool before any embossing could take place. In commercial tool and die shops, it is not unusual to see apprentices and entry-level workers assigned to the knurling lathe set-up. Knurling shafts for screwdrivers and other hand tools can be very repetitive and time-consuming, which makes the task ideal for workers with little seniority. But running a knurling operation successfully can lead to more advanced lathe work with more interesting cutting techniques.

The Benefits of Shearing Metal Fabrication

A process of metal fabrication used in cutting straight columns on smooth metal stock is called shearing. During this process, both the upper and lower blades are enforced to pass each one with the gap between them identified by an essential offset. Usually, any of the two blades stays stationary.

The characteristics of the shearing procedure include:
- Its capacity to create straight-line slices on smooth sheet stock
- It has metal placement amid the lower and upper shear blades
- Its capability to cut comparatively tiny lengths of objects at any instance because the cutting sharp edges can be fixed at a slant to lessen the needed cutting force required.
- The trademark manufacture of rough and slightly malformed metal edges.

During the process the upper cutting blade breaks the piece of metal put in place by means of the holding devices and then the trimmed piece falls away. In general, the higher shear sharp edge is fixed at a slant to the blade bellow that is usually mounted horizontally. The cutting procedure performs only basic straight-line slicing however, any geometrical form having accurate line cut may be formed on the shear.
Metal cutting can be done on sheets, bars, plates, strips and also angle stock. Bar and angle objects can be sheared only to length, but many forms can be made by shearing sheet and plates. Materials that are usually sheared include: brass, bronze, aluminum, mild and stainless steel.

Slitting

This is another type of shearing process, however, rather than creating cuts at the edge of work piece such as shearing, slicing is being used to incise an extensive coil of metal in some narrower coils since the principal coil is stirred through the slicker. Throughout the slitting procedure, the metal loop passes lengthways by means of the circular blades of the slitter.

The characteristics of the slitting procedure include:

- Its capacity to be utilized on ferrous and also non-ferrous metals
- It is restricted only to cut relatively slim materials
- It leaves remains of burrs in slit ends of narrower coals
- Its classification as high creation is designed to manage the width of metal coil.

Slitting may be utilized equally well intended for the sheet as well as coil rolls. The slicing blades are intended depending in the work required. The three important determinants of the pattern of the blade include:

- The kind of objects to be cut
- The thickness of the piece of material
- The forbearances that should be held while doing the slitting.

The Tool and Die Making Machines

The tool and die making industry is among the most profitable industries there is. Tool and die making is a process that requires a lot of knowledge and know-how. People who decide to enter this field would need to spend several years studying everything about it and learning its different applications. In short, it is no joke to venture a career in this field.

People who are in this kind of profession are regarded highly by their fellow skilled workers. Their job is to make tools, die them, and make sure that all the objects and products created are in its best possible condition. They also manufacture clothes, pieces of furniture and equipment and car or aircraft parts. They may be found in large industrial and manufacturing plants or in average-sized machine shops.

In order for a tool and die maker to be efficient, he or she should be educated with even the littlest details about how to manufacture stamping dies, jigs, fixtures and plastic molds. Different types of materials would require varying techniques. For example, in stamping dies, force is required from the maker. However, in plastic molding, no force is needed.

As the years went on, the machineries and tools used in tool and die making have developed greatly. One notable person who played a great role in this process is Eli Whitney, an American manufacturer and inventor. His notion of interchangeable parts in planned manufacturing was revolutionary. Because of his studies, he was able to successfully mass-produce firearms and weapons for a war that occurred in 1812.

Since then, tool and die making machines have evolved greatly. The power press came out, then there's the press die, and more. Alongside this, injection molding and die casting took a leap, resulting to more demands for more advanced tools.

Tools and dies are often designed by tool designers and engineers, but a well-experienced and extremely skilled tool and die maker could also do the job. They would be asked to visit a customer's place to check out the whole operation. This would enable them to know if there's something in there that needs improvement.

Back then, they would use blueprints to plan out the necessary steps to proceed with the operation. Everything would then be done manually. Fortunately, today, CAD or computer-aided design and more modern tools and machineries are already available, making things much simpler and faster to accomplish.

Making a Fiberglass Mould tips

Fiberglass moulds are commonly used to make multiple copies of a part which may have a complex shape. Some of the advantages of using a fiberglass mould are: they are easy to make, the materials are inexpensive, and they will last for many years and can be used to produce hundreds of parts. The process starts with a pattern that you wish to copy. In this case, has started with a vacuum formed cowl from a model kit. This is a common part that any modeler may want to copy in fiberglass. The pattern could also be shaped from balsa or foam and finished to achieve a glossy surface.

Plug preparation

To make a mould, a plug is needed. A plug is the exact shape and dimension that the final part will be. Many times, a replica is being made of an existing part, such as a bumper for a car or a canoe. Other times, modeling clay, wood, or sheet metal is formed into the final shape. If the plug is porous, such as wood, plaster, it will need to be sealed first with lacquer or resin. The plug should be buffed and sealed with products such as PR-301 and PR-311. A coat of mould release will need to be applied. Five coats is a good number to make sure it is well coated, each time buffing afterwards. Three coats should be applied if you want the best possible release. Spraying with a fine paint sprayer works the best. The first coat should be a ‘mist’ coat and the following 2 coats a bit thicker.

Gelcoat

Tooling gelcoat is used to give the mould surface a strong, scratch resistant surface. Tooling gelcoat comes in black or orange to be able to tell the difference between the part and mould. Spray (recommended) a thick layer of gelcoat on the plug. The layer should be between 15 and 20 mils. Allow to cure for 2 to 4 hours, or until the gelcoat can not be scratched with your fingernail, but still tacky.

Fiber glassing

A layer of 1 oz Chopped Strand Mat should be layed down as the first layer. General Purpose Polyester resin is commonly used as the resin. The resin should be mixed with 1% to 2% MEKP. Wet the mat out with a brush or spreader. Work the resin in with bristle roller. Afterwards, use a aluminum roller to force out all the air. When it is done, there should be no white fibers or air pockets visible. Allow the resin to cure. When the resin is hard, but still tacky, it is time to put the next layer on. Never cure multiple layers at one time because this may cause warping, especially in large moulds. Add additional layers of mat and/or cloth to give the mould strength. An additional 3 layers of 1.5 oz mat is usually sufficient, depending on the application. Be sure to allow adequate curing time between layers.

Removing the Plug

Allow 2 or 3 days for the mould to cure completely. Use a plastic wedge or sharpened paint stirrer (never use hard or metal tools) to slide between the mould and plug. Separate the entire edge of the mould from the plug. You should be able to remove the plug from the mould.

It is time now to prepare the mould for use. Most times, the mould will need to be sanded and polished.

The Cnc Milling Process

CNC milling finds application making a wide range of custom parts. CNC milling is a cutting process in which material is removed from a block metal or plastic by a rotating tool. In CNC milling the cutting tool (called a “mill”) is moved in all three dimensions to cut a desired shape from stock.

In this process, the material is usually removed by both the end and the side of the cutting tool. Unlike a drill which removes material only from the end, in CNC milling the cutting tool rotates about an axis that is perpendicular to the table that holds the work. Cutting tools of various profile shapes are available including square, rounded, and angled. A wide variety of part shapes and geometries are possible. The most common are the “end mill” which finishes to a flat bottom surface while a “ball mill” has a rounded end.

A wide variety of 2D and 3D shapes are possible in the process. Some of the examples of CNC milling are engine components, custom jigs and mold tooling, complex mechanisms, enclosures, etc.

The thing CNC Milling does especially well is create complex shapes block material. While CNC milling can be used on 2D projects, there are lots of other choices for thin stock. Waterjet cutting and plasma cutting, for example, come to mind. But thick stock, needing metal removed? That’s where CNC milling shines. The CNC Milling process proves to be cost effective for short runs.

CNC machine tools

In a general sense CNC is a contrast to manually controlled tools(via levers, as an example). CNC means that machines are managed by the commands intended for it. CNC commands are encoded on a storage medium. To clarify technical poition of CNC machines it is necessary to add that these equipment are totaly automated, from the first to the last point of technological chain, using computer-aided design and computer-aided manufacturing programs.


The 1 analogue of CNC machines was made in the 40s years of past century. Years later cnc machines were modified and augmented with PC very quickly and changed abbreviation on CNC (computer numerical controlled).


CNC machines' using for company means costs' cutting with increasing company's incomes. That is why term "proliferation" is used while speaking about CNC application in different kind of industry. But CNC standards were changed rapidly. Sometimes it was done without neccesity. Inspide the 1 of numerous standards became common for most of world manufacturers. Its name is "G" code, developed to Gerber Scientific plotters.


Since occurrence computer numerical controlled tools are always advancement. With a support of logical commands (named parametric programming).
What is an advantage of CNC machines application? It cuts down expenses and increasing company's incomes. Every manufacturer needs these machines, looks for appropriate CNC tools, cnc machines' suppliers in order to optimize technology process.

DIY leather belt

Leather belts are a good craft project for those new to leather crafts. Except for being one of the less complicated craft projects, they also make good presents. Contrary to what you will believe, it is essentially quite simple to make a leather belt.

If you plan to tool or dye the leather, it is ideal to pick a plant leather. This sort is easier to work with than other kinds.

Note the width of the inside of the belt buckle. Measure the waist rim of the individual who will be dressed in the belt. The size will be that of the interior of the belt buckle and the length one foot longer than the waist circumference measurement. To ensure an even cut, employ a straight edge such as yardstick. Many folks like to round the end.

Taking the other end of the belt, fold the leather back 1 inches to make a crease. Line up a slot punch with the middle of the crease.

using a rotary or drive punch, make two rivet holes in. The holes should be inch from each side of the belt. Fold back the belt on the crease and mark where the bolt holes overlap the leather.
use a belt beveller to trim belt edges smooth. Use a leather dye to paint the belt. Bear in mind that the dye in the container may appear clearly different to the finished version. When selecting a dye, Look at finished samples to be certain you are getting the color you would like.

permit dye to dry completely, flexing the leather often in the drying process. Once dry, clean with Neat's foot oil or leather soap soap and buff dry with a clean material.

Insert rivets from the inside of the belt and apply rivet caps employing a rubber mallet.

Put on the Do it yourself leather belt">belt and define where a hole is needed to ensure a close fit. Employ a rotary punch to punch a hole that is targeted from the perimeters of the belt. Working from this punched hole, punch a series of holes 1 inch apart.

Pressure Die Casting

Pressure die casting is a process where metal is melted and forced into steel dies. The metal hardens into the desired shape. Molten metal is injected into a die cavity through a channel by movement of a plunger. After a preset solidification time, the plunger reverses direction, the part is ejected, and the machine is ready for the next cycle.
In hot chamber casting a plunger traps a certain volume of molten metal and forces it into the die cavity through a gooseneck and nozzle. Metals having low melting points such as zinc, copper, magnesium and lead are cast using hot chamber die casting. In cold chamber casting molten metal is poured into the injection cylinder. The metal is forced into the die cavity at high pressures. High melting point alloys of aluminum and copper are normally cast using cold chamber die casting.

Pressure die casting creates parts with no joints by eliminating other processes such as welding and fastening. Integral fastening elements such as bosses and studs can be included. Good dimensional accuracy and detail is possible. No further machining required usually. Casting offers low cost after amortization of tooling.

Pressure die casting can produce a wide variety of complex 3D shapes provided that the shape can be ejected from the mold. Typically this requires walls with draft.

Some examples of use of die casting include engine blocks, toy components, bushings, levers, gears, and assorted parts used in the automotive, aerospace and medical industries, etc.

Pressure die casting can process nonferrous alloys that have low melting points: aluminum, zinc, magnesium, copper, lead, tin, silver, etc.
The process requires custom steel tooling in the negative shape of the final part.
To reduce costs, minimize size, complexity and material volume.

Pressure Die Casting Design Considerations
A parting line (location where the two mold halves meet) will occur.
Some flashing will occur at the parting line.
Marks from ejector pins (rods that push the part out of the mold) may occur.
Provide a shape that can easily be ejected from the mold.
Keep wall thickness uniform.

Die casting

Die casting is the process of forcing molten metal under high pressure into mold cavities . Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead, pewter and tin based alloys, although ferrous metal die castings are possible. The die casting method is especially suited for applications where a large quantity of small to medium sized parts are needed with good detail, a fine surface quality and dimensional consistency.

This level of versatility has placed die castings among the highest volume products made in the metalworking industry.
In recent years, injection-molded plastic parts have replaced some die castings because they are cheaper and lighter. Plastic parts are a practical alternative if hardness is not required and little strength is needed.

Process
There are four major steps in the die casting process. First, the mold is sprayed with lubricant and closed. The lubricant both helps control the temperature of the die and it also assists in the removal of the casting. Molten metal is then shot into the die under high pressure; between 10—175 MPa (1,500—25,000 psi). Once the die is filled the pressure is maintained until the casting has solidified. The die is then opened and the shot (shots are different from castings because there can be multiple cavities in a die, yielding multiple castings per shot) is ejected by the ejector pins. Finally, the scrap, which includes the gate, runners, sprues and flash, must be separated from the casting(s). This is often done using a special trim die in a power press or hydraulic press. An older method is separating by hand or by sawing, which case grinding may be necessary to smooth the scrap marks. A less labor-intensive method is to tumble shots if gates are thin and easily broken; separation of gates from finished parts must follow. This scrap is recycled by remelting it. Approximately 15% of the metal used is wasted or lost due to a variety of factors.

The high-pressure injection leads to a quick fill of the die, which is required so the entire cavity fills before any part of the casting solidifies. In this way, discontinuities are avoided even if the shape requires difficult-to-fill thin sections. This creates the problem of air entrapment, because when the mold is filled quickly there is little time for the air to escape. This problem is minimized by including vents along the parting lines, however, even in a highly refined process there will still be some porosity in the center of the casting.
Most die casters perform other secondary operations to produce features not readily castable, such as tapping a hole, polishing, plating, buffing, or painting.


Pore-free casting process
When no porosity is required for a casting then the pore-free casting process is used. It is identical to the standard process except oxygen is injected into the die before each shot. This causes small dispersed oxides to form when the molten metal fills the dies, which virtually eliminates gas porosity. An added advantage to this is greater strength. These castings can still be heat treated and welded. This process can be performed on aluminium, zinc, and lead alloys.


Heated-manifold direct-injection die casting
Heated-manifold direct-injection die casting, also known as direct-injection die casting or runnerless die casting, is a zinc die casting process where molten zinc is forced through a heated manifold and then through heated mini-nozzles, which lead into the molding cavity. This process has the advantages of lower cost per part, through the reduction of scrap (by the elimination of sprues, gates and runners) and energy conservation, and better surface quality through slower cooling cycles.


Equipment
There are two basic types of die casting machines: hot-chamber machines (a.k.a. gooseneck machines) and cold-chamber machines. These are rated by how much clamping force they can apply. Typical ratings are between 400 and 4,000 short tons.

Hot-chamber machines rely upon a pool of molten metal to feed the die. At the beginning of the cycle the piston of the machine is retracted, which allows the molten metal to fill the "gooseneck". The gas or oil powered piston then forces this metal out of the gooseneck into the die. The advantages of this system include fast cycle times (approximately 15 cycles a minute) and the convenience of melting the metal in the casting machine. The disadvantages of this system are that high-melting point metals cannot be utilized and aluminium cannot be used because it picks up some of the iron while in the molten pool. Due to this, hot-chamber machines are primarily used with zinc, tin, and lead based alloys.




Cold-chamber machines are used when the casting alloy cannot be used in hot-chamber machines; these include aluminium, zinc alloys with a large composition of aluminium, magnesium and copper. This machine works by melting the material, first, in a separate furnace. Then a precise amount of molten metal is transported to the cold-chamber machine where it is fed into an unheated shot chamber (or injection cylinder). This shot is then driven into the die by a hydraulic or mechanical piston. This biggest disadvantage of this system is the slower cycle time due to the need to transfer the molten metal from the furnace to the cold-chamber machine.

The dies used in die casting are usually made out of hardened tool steels because cast iron cannot withstand the high pressures involved. Due to this the dies are very expensive, resulting in high start-up costs. Dies may contain only one mold cavity or multiple cavities of the same or different parts. There must be at least two dies to allow for separation and ejection of the finished workpiece, however its not uncommon for there to be more sections that open and close in different directions. Dies also often contain water-cooling passages, retractable cores, ejector pins, and vents along the parting lines. These vents are usually wide and thin (approximately 0.13 mm or 0.005 in) so that when the molten metal starts filling them the metal quickly solidifies and minimizes scrap. No risers are used because the high pressure ensures a continuous feed of metal from the gate. Recently, there's been a trend to incorporate larger gates in the die and to use lower injection pressures to fill the mold, and then increase the pressure after its filled. This system helps reduce porosity and inclusions.

In addition to the dies there may be cores involved to cast features such as undercuts. Sand cores cannot be used because they disintegrate from the high pressures involved with die casting, therefore metal cores are used. If a retractable core is used then provisions must be made for it to be removed either in a straight line or circular arc. Moreover, these cores must have very little clearance between the die and the core to prevent the molten metal from escaping. Loose cores may also be used to cast more intricate features (such as threaded holes). These loose cores are inserted into the die by hand before each cycle and then ejected with the part at the end of the cycle. The core then must be removed by hand. Loose cores are more expensive due to the extra labor and time involved.

A die's life is most prominently limited by wear or erosion, which is strongly dependent on the temperature of the molten metal. Aluminium alloy die usually have a life of 100,000 cycles, if the die is properly maintained. Molds for die casting zinc last approximately 10 times longer than aluminium die casting mold due to the lower temperature of the zinc. Dies for zinc are often made of H13 and only hardened to 29-34 HRC. Cores are either made of H13 or 440B, so that the wearing parts can be selectively nitrided for hardness, leaving the exposed part soft to resist heat checking. Molds for die casting brass are the shortest-lived of all. Other failure modes for dies are:

* Heat checking: surface cracks occur on the die due to a large temperature change on every cycle
* Thermal fatigue: surface cracks occur on the die due to a large number of cycles

Advantages and disadvantages
Advantages:
* Excellent dimensional accuracy (dependent on casting material, but typically 0.1 mm for the first 2.5 cm (0.005 in. for the first inch) and 0.02 mm for each additional centimeter (0.002 in. for each additional inch).
* Smooth cast surfaces (1–2.5 micrometres or 0.04–0.10 thou rms).
* Thinner walls can be cast as compared to sand and permanent mold casting (approximately 0.75 mm or 0.030 in).
* Inserts can be cast-in (such as threaded inserts, heating elements, and high strength bearing surfaces).
* Reduces or eliminates secondary machining operations.
* Rapid production rates.
* Casting tensile strength as high as 415 MPa (60 ksi).

Disadvantages:
* Casting weight must be between 30 grams (1 oz) and 10 kg (20 lb).
* Casting must be smaller than 600 mm (24 in
* High initial cost.
* Limited to high-fluidity metals.
* A certain amount of porosity is common.
* Thickest section should be less than 13 mm (0.5 in).
* A large production volume is needed to make this an economical alternative to other processes.

Die casting materials
The main die casting alloys are: zinc, aluminium, magnesium, copper, lead, and tin. Specific dies casting alloys include: ZAMAK, zinc aluminium, AA 380, AA 384, AA 386, AA 390, and AZ91D magnesium. The following is a summary of the advantages of each alloy:

* Zinc: the easiest alloy to cast; high ductility; high impact strength; easily plated; economical for small parts; promotes long die life.
* Aluminium: lightweight; high dimensional stability for complex shapes and thin walls; good corrosion resistance; good mechanical properties; high thermal and electrical conductivity; retains strength at high temperatures.
* Magnesium: the easiest alloy to machine; excellent strength-to-weight ratio; lightest alloy commonly die cast.
* Copper: high hardness; high corrosion resistance; highest mechanical properties of alloys die cast; excellent wear resistance; excellent dimensional stability; strength approaching that of steel parts.
* Lead and Tin: high density; extremely close dimensional accuracy; used for special forms of corrosion resistance.

How to Make Your Own Leather Belt

Leather belts are an excellent craft project for those new to leather crafts. Aside from being one of the easier craft projects, they also make nice gifts. Contrary to what you may believe, it is actually quite easy to make a leather belt.

First, purchase leather and a belt buckle. If you plan to tool or dye the leather, it is ideal to choose a vegetable leather. This type is easier to work with than other kinds.

Note the width of the inside of the belt buckle. Measure the waist circumference of the individual who will be wearing the belt. Using a razor knife, cut the leather. The width will be that of the inside of the belt buckle and the length one foot longer than the waist circumference measurement. To ensure an even cut, use a straight edge such as yardstick. The end of the belt that will be fed through the belt buckle can be cut to your preference. Many people like to round the end.

On the other end of the belt, fold the leather back 1 ½ inches to create a crease. Line up a slot punch with the center of the crease. Hold the punch firmly by the handle and use a wooden mallet to hammer it in until the leather has been punctured fully.

Using a rotary or drive punch, make two rivet holes ¼ inch from the end of the belt before the crease. The holes should be ¼ inch from each side of the belt. Fold back the belt on the crease and mark where the rivet holes overlap the leather. Make two more rivet holes where you have marked. When the belt is folded on the crease, the rivet holes should perfectly align.

Use a belt beveller to trim belt edges smooth. If you plan to decorate the belt, do so now. Tools and design stamps can be used to add individual touches to the leather. Some people choose to add studs. Use a leather dye to color the belt. Keep in mind that the dye in the container may appear distinctly different from the finished version. When choosing a dye, look at finished samples to be sure you are getting the color you want.

Allow dye to dry completely, flexing the leather occasionally during the drying process. This will ensure the fibers do not stiffen up too much. It can take up to several hours for dyed leather to dry completely. Once dry, clean with Neat's foot oil or saddle soap and buff dry with a clean cloth.

Push the prong of the belt buckle through the hole made in the crease. Fold the leather back and align the rivet holes. Insert rivets from the inside of the belt and apply rivet caps using a rubber mallet.

Put on the belt and determine where a hole is needed to ensure a snug fit. Use a rotary punch to punch a hole that is centered from the edges of the belt. Working from this punched hole, punch a series of holes 1 inch apart.

Leather Cutting Dies

A clicker press is a machine that cuts shapes out of rolls of soft material, such as rubber, cardboard, or leather, using a sharp metal piece called a die. A metal tool and die shop will take a pattern, and bend, weld and form pre-sharpened steel into a die. A cutting die is usually a steel cutting tool to be used with a clicker press.

Cutting Dies are appropriate for cutting paper, leather, rubber, plastic and numerous others including envelope cutting dies, label cutting dies, clicker dies, window dies, punch dies, gasket cutting dies, washer dies, trimming dies, high dies, threaded punch dies, rotary panel cutters, corner blades, strap dies and more. Beverly Clicker Dies, Single Edge Dies, Double Edge Dies, Gang Dies, Precision Milled Dies, and Serrated Edge Dies are the six basic types of cutting dies. These dies are crafted from steel and will usually last for tens of thousands of cuts.

The Beverly Clicker Die is used primarily in the Shoe and Leather Garment Industries. It is simply a clicker die constructed around a center plate, which acts as a brace like reinforcement, creating a very strong and durable die. Double edge dies are used in applications with an identical right and left piece. To greatly reduce die cost the double edge die may be used . Such applications would be the shoe and glove trades. A good example would be a moccasin die with a distinct left and right size. By constructing a two sided die the price is less than making two distinct dies for right and left size.Gang dies are standard clicker dies in multiple configurations for high volume or multiple part situations.

A good example of a gang die would be a key fob in which you have orders for 10,000 pieces. Rather than just die cut one at a time it would be productive to cut a 2 up or 3 up gang die to do the cutting job efficientlyPrecision Milled Dies are an highly accurate die milled from high grade tool steel. The solid steel milled die is better used in very close tolerance high production situations. Precision dies are often used where super tight corners and fine tolerances are required.

This type of die may be unaffordable as it requires a fair amount of time and skilled labor and expensive machinery.New technology in cutting dies features a serrated edge that allows for the die to permeate multiple layers of materials much easier than conventional edge cutting dies. These particular edge dies also help eliminate fusing with many materials. A fine use of this type of dye would be cutting of multiple layers of vinyl.

What is Shearing ?

Shearing is a metal fabricating process used to cut straight lines on flat metal stock. During the shearing process, an upper blade and a lower blade are forced past each other with the space between them determined by a required offset. Normally, one of the blades remains stationary.

The shearing process characteristics include:

• Its ability to make straight-line cuts on flat sheet stock
• Metal placement between an upper and lower shear blades
• Its trademark production of burred and slightly deformed metal edges
• Its ability to cut relatively small lengths of material at any time since the shearing blades can be mounted at an angle to reduce the necessary shearing force required.

The illustration that follows provides a two-dimensional look at a typical metal shearing process. Note how the upper shear blade fractures the metal workpiece held in place by the workholding devices. The sheared piece drops away.

Typically, the upper shear blade is mounted at an angle to the lower blade that is normally mounted horizontally. The shearing process performs only fundamental straight-line cutting but any geometrical shape with a straight line cut can usually be produced on a shear.

Metal shearing can be performed on sheet, strip, bar, plate, and even angle stock. Bar and angle materials can only be cut to length. However, many shapes can be produced by shearing sheet and plate.

Materials that are commonly sheared include:

• Aluminum
• Brass
• Bronze
• Mild steel
• Stainless steel

The shearing process uses three types of tool systems. They are used for shearing:

1. Sheet metal and plate using a squaring or bow tie shear
2. Angle materials using and angle shear, and
3. Bar stock using a bar shear.

What is Metal Fabrication?

When using metal materials such as metal plate and wire for the purposes of jewelry making, very often the jewelry maker is required to shape and form the metal. The techniques used to do this are considered fabrication techniques where you use methods such as sawing, filing, and hammering to reform the metal piece into a different structure and shape.

Fabrication, therefore, is different than other types of metal techniques such as casting where you might have some kind of mold and your pour the hot metal into the mold to create the structure you need for a jewelry piece. With fabrication, you use hand tools, some finesse, and a little elbow grease to come up with the desired results.


While casting and soldering may get all the glory when it comes to metalsmithing, neither is really possible without first learning how to fabricate metal. In fact, you can’t really do either without also doing at least a little fabrication. For example, you may cast a metal charm, but you still need to file off the rough parts and polish the finished piece. You may need to solder two pieces of metal together, but unless the metal has been cut, filed, and cleaned properly, you won’t have soldering success.

How to Make Die-Cut Stickers

Die-cut stickers are a wonderful and decorative tool for scrapbookers, card makers and even for those creating posters for school projects. Die-cut stickers also make great gifts for younger children love to stick stickers everywhere. They can be made in almost every shape imaginable, and are much less expensive to make at home than they are to buy in craft stores.

1. Cover the back of a piece of decorative paper with double-sided carpet tape, leaving the protective paper on the other side of the tape.

2. Adhere your paper to your cutting mat, with the tape side down.

3. Place the desired cartridge in your Cricut and the key overlay on the keypad of your Cricut. Turn on the Cricut.

4. Select the design that you want to cut using the key overlay, also selecting any special features that you want to use to make the cut.

5. Set the Cricut blade on Depth 5 to ensure that it cuts through the paper and tape. Set the speed and pressure to the appropriate settings for the design you chose. It may be beneficial to do a test run on a regular piece of paper to determine the best speed and pressure settings before attempting to cut your stickers.

6. Load your cutting mat with the paper attached to it into the Cricut machine, move the blade to the top right-hand corner of the paper, set the paper size and then press "Cut.".

7. Unload the paper from the machine once it has finished the cut and remove your sticker from the mat using the Cricut spatula.

How to Become a Tool and Die Maker

Tool and die makers are highly skilled workers in the manufacturing arena. The tool and die maker works to produce devices that allow machines to manufacture a wide range of products such as parts for vehicles, appliances for our homes and clothing.

1. Get a high school diploma or a GED. You must be good at math, taking and reading measurements and reading blueprints. Take advantage of computer courses as well. Know how to use a computer. Most of the product designs for machine parts are done on computer.

2. Learn to use different types of machine tools and become familiar with precision measuring instruments. Study about the different properties of various metals, plastics and other materials. If you become a tool and die maker you will make machines, parts for machines and tools that are used to form and cut materials for manufacturing all kinds of products. You may even work with designers and engineers in the planning stages, once you gain experience.

3. Find work in a company that offers apprenticeship programs. Most tool and die making companies actually prefer to train their employees. You can start at entry-level with a company and get paid to work as you learn the trade. It usually takes four or five years to become a highly skilled craftsman in this specialized career.

4. Plan to become a specialist in a certain field. Most tool and die makers eventually focus on one type of tool, mold or type of die that they have become proficient in. Be prepared for detail-oriented work as you complete on-the-job training.

5. Consider taking courses at a community college or vocational school to give yourself a leg up in the field. These schools offer courses in tool design and advanced math such as algebra. These courses will be quite helpful if you plan to become a tool and die maker.

Die (manufacturing)

A die is a specialized tool used in manufacturing industries to cut or shape material using a press. Like molds and stencils, dies are generally customized to the item they are used to create. Products made with dies range from simple paper clips to complex pieces used in advanced technology.

Die forming

Forming dies are typically made by tool and die makers and put into production after mounting into a press. The die is a metal block that is used for forming materials like sheet metal and plastic. For the vacuum forming of plastic sheet only a single form is used, typically to form transparent plastic containers (called blister packs) for merchandise. Vacuum forming is considered a simple molding thermoforming process but uses the same principles as die forming. For the forming of sheet metal, such as automobile body parts, two parts may be used, one, called the punch, performs the stretching, bending, and/or blanking operation, while another part, called the die block, securely clamps the workpiece and provides similar, stretching, bending, and/or blanking operation. The workpiece may pass through several stages using different tools or operations to obtain the final form. In the case of an automotive component there will usually be a shearing operation after the main forming is done and then additional crimping or rolling operations to ensure that all sharp edges are hidden and to add rigidity to the panel.

Die components

* Die block
* Punch plate
* Blank punch
* Pierce punch
* Stripper plate
* Pilot
* Dowel Pin
* Back gage
* Finger stop

Die operations and types

Die operations are often named after the specific type of die that performs the operation. For example a bending operation is performed by a bending die. Operations are not limited to one specific die as some dies may incorporate multiple operation types...

* Bending: The bending operation is the act of bending blanks at a predetermined angle. An example would be an "L" bracket which is a straight piece of metal bent at a 90° angle. The main difference between a forming operation and a bending operation is the bending operation creates a straight line bend (such as a corner in a box) as where a form operation may create a curved bend (such as the bottom of a drinks can).
* Blanking: A blanking die produces a flat piece of material by cutting the desired shape in one operation. The finish part is referred to as a blank. Generally a blanking die may only cut the outside contour of a part, often used for parts with no internal features.

Three benefits to die blanking are:

1. Accuracy. A properly sharpened die, with the correct amount of clearance between the punch and die, will produce a part that holds close dimensional tolerances in relationship to the parts edges.
2. Appearance. Since the part is blanked in one operation, the finish edges of the part produces a uniform appearance as opposed to varying degrees of burnishing from multiple operations.
3. Flatness. Due to the even compression of the blanking process, the end result is a flat part that may retain a specific level of flatness for additional manufacturing operations.
* Broaching: The process of removing material through the use of multiple cutting teeth, with each tooth cutting behind the other. A broaching die is often used to remove material from parts that are too thick for shaving.
* Bulging: A bulging die expands the closed end of tube through the use of two types of bulging dies. Similar to the way a chefs hat bulges out at the top from the cylindrical band around the chefs head.

1. Bulging fluid dies: Uses water or oil as a vehicle to expand the part.
2. Bulging rubber dies: Uses a rubber pad or block under pressure to move the wall of a workpiece.

* Coining: is similar to forming with the main difference being that a coining die may form completely different features on either face of the blank, these features being transferred from the face of the punch or die respectively. The coining die and punch flow the metal by squeezing the blank within a confined area, instead of bending the blank. For example: an Olympic medal that was formed from a coining die may have a flat surface on the back and a raised feature on the front. If the medal was formed (or embossed), the surface on the back would be the reverse image of the front.
* Compound operations: Compound dies perform multiple operations on the part. The compound operation is the act of implementing more than one operation during the press cycle.
* Compound die: A type of die that has the die block (matrix) mounted on a punch plate with perforators in the upper die with the inner punch mounted in the lower die set. An inverted type of blanking die that punches upwards, leaving the part sitting on the lower punch (after being shed from the upper matrix on the press return stroke) instead of blanking the part through. A compound die allows the cutting of internal and external part features on a single press stroke.
* Curling: The curling operation is used to roll the material into a curved shape. A door hinge is an example of a part created by a curling die.
* Cut off: Cut off dies are used to cut off excess material from a finished end of a part or to cut off a predetermined length of material strip for additional operations.
* Drawing: The drawing operation is very similar to the forming operation except that the drawing operation undergoes severe plastic deformation and the material of the part extends around the sides. A metal cup with a detailed feature at the bottom is an example of the difference between formed and drawn. The bottom of the cup was formed while the sides were drawn.
* Extruding: Extruding is the act of severely deforming blanks of metal called slugs into finished parts such as an aluminum I-beam. Extrusion dies use extremely high pressure from the punch to squeeze the metal out into the desired form. The difference between cold forming and extrusion is extruded parts do not take shape of the punch.
* Forming: Forming dies bend the blank along a curved surface. An example of a part that has been formed would be the positive end(+) of a AA battery.
* Cold forming (cold heading): Cold forming is similar to extruding in that it squeezes the blank material but cold forming uses the punch and the die to create the desired form, extruding does not.
Roll forming:is a continuous bending operation in which sheet or strip metal is gradually formed in tandem sets of rollers until the desired cross-sectional configuration is obtained. Roll forming is ideal for producing parts with long lengths or in large quantities.
# Horning: A horning die provides an arbor or horn which the parts are place for secondary operations.
# Hydroforming: Forming of tubular part from simpler tubes with high water pressure.
# Pancake die: A Pancake die is a simple type of manufacturing die that performs blanking and/or piercing. While many dies perform complex procedures simultaneously, a pancake die may only perform one simple procedure with the finished product being removed by hand.
# Piercing: The piercing operation is used to pierce holes in stampings.
# Progressive die: Progressive dies provide different stations for operations to be performed. A common practice is to move the material through the die so it is progressively modified at each station until the final operation ejects a finished part.
# Shaving: The shaving operation removes a small amount of material from the edges of the part to improve the edges finish or part accuracy. (Compare to Trimming).
# Side cam die: Side cams transform vertical motion from the press ram into horizontal or angular motion.
# Sub press operation: Sub-press dies blank and/or form small watch, clock, and instrument parts.
# Swaging: Swaging (necking) is the process of "necking down" a feature on a part. Swaging is the opposite of bulging as it reduces the size of the part. The end of a shell casing that captures the bullet is an example of swaging.
# Trimming: Trimming dies cut away excess or unwanted irregular features from a part, they are usually the last operation performed.

Thread cutting
Another device also called a die is a nut-like thread cutting device for making screw threads on rod stock. This device may also be used to restore damaged threads - a method called chasing. (Other methods are generally used to produce machine screws and small bolts in quantity — they are formed by a process called rolling.)

For high production a die head may be used. Its operation is very similar but does not require "unthreading" at the end of the cut. The head's construction permits the die head to expand at the required length of thread, disengaging the chasers (cutting tips) and permitting the tools retraction without interfering with the work pieces rotation. Die heads are available and are commonly used for both cut threads and rolled threads. A popular machine that regularly uses a die head is a screw machine.

Products created by forming dies

Metal spoon, fork, and knives

• Aluminum cans
• Car fender, bumper, door, hood, piston, rods, and frame
• Clothing zipper and buttons

Wire pulling

Wire-making dies have a hole through the middle of them. A wire or rod of Steel, copper, or other metals or alloy, enters into one side and is lubricated and reduced in size. The leading tip of the wire is usually pointed in the process. The tip of the wire is then guided into the die and rolled onto a block on the opposite side. The block provides the power to pull the wire through the die.

The die is divided into several different sections. First is an entrance angle that guides the wire into the die. Next is the approach angle which brings the wire to the nib which facilitates the reduction. Next is the bearing and the back relief. Lubrication is added at the entrance angle. The lube can be in powdered soap form. If the lubricant is soap, the friction of the drawing of wire heats the soap to liquid form and coats the wire. The wire should never actually come in contact with the die. A thin coat of lubricant should prevent the metal to metal contact.

For pulling a substantial rod down to a fine wire a series of several dies is used to obtain progressive reduction of diameter in stages.

Standard wire gauges used to refer to the number of dies through which the wire had been pulled. Thus, a higher-numbered wire gauge meant a thinner wire. Typical telephone wires were 22-gauge, while main power cables might be 3- or 4-gauge.

Tool design tips=Design and Construction Tips

Tool design strategies and methods constantly are evolving. Although there are a variety of approaches, the following methods seem to produce the best results at a minimal cost:

1. Part orientation—Parts that will be coated should be placed with the largest surface facing up, which eliminates or reduces the possibility that tooling components will drag across or come into contact with the main surface. For example, parts such as computer covers that require cosmetic stamping can be positioned to eliminate contact marks on critical surfaces from die lifters and rails. Otherwise, lifters will create longitudinal marks, visible through paint, along the entire surface of the part during the progressive feed cycle.

2. Lifters or rails—Particularly vulnerable parts can benefit if the plunger-type lifter or lifting rail design uses a material such as Delron®, a substance similar to hard nylon. Such materials are less likely to mar the surface of parts. A protective contact surface can be helpful when, for example, part specifications such as burr direction require the main surface of the part to be face down.

Delron can be used just at the steel lifter’s contact points, or the entire unit can be made of it. A lifter made entirely of Delron, with a steel retention washer, will not damage the die if it comes out of the tool during operation. The lifter will be crushed with minimal effect on the tool.

3. Hole locations—Wherever possible, through-holes, such as stripper bolts or screw holes, should be avoided in critical areas. Given the size and complexity of today's progressive tooling, strippers usually employ extreme amounts of pressure. This pressure is translated onto the part, and burnishing may occur at the construction holes.

4. Stripper plate and die steel sections—These components should be sectioned along areas of scrap or in noncritical areas of the part. If stripper plates are sectioned in critical areas, a kink or burnishing might occur. This common defect is difficult to detect in an uncoated part, but it becomes strikingly clear after coating.

5. Hardened stripper inserts—Tooling components such as stripper plates and die blocks are becoming increasingly large. With the addition of CNC machining and huge wire electrical discharge machining (EDM), there are few reasons to create a tool of small die sections. This can result in stripper surfaces that are 30 by 60 inches or larger.

Common causes of stamping imperfections are nicks, dings, and slug marks in the plates' faces. To keep costs low and performance high, stripper faces should be inserted with a 1¼4-inch-thick plate. The stripper can be made of any machine steel, but it should have the durability of hardened metal to ensure a clean, smooth contact surface.

6. Direction of surface grinding—In finish surface grinding (the final phase of tool construction), the direction of the grind is important. Plates, blocks, and inserts always should be ground in the same direction of the grain of the raw material used in the die. With a progressive die, plates and blocks should be finish-ground left to right, allowing imperfections in the grinding to be camouflaged by the material grain.

Attention to grind direction is especially critical if the tooling is being bottomed for flatness or coining. If the grinding is perpendicular to the grain marks of the material, it is almost certain to be detected after coating. Tool designers should, therefore, specify grind direction and surface root mean source (RMS) average (a measurement of surface finish).

7. Rocker forming—Rocker forming has been around for many years and is a helpful method for forming precoated or surface-critical products. One of its drawbacks, though, is that often it leaves a strike or bite mark where the rocker contacts the steel and subsequently pivots.

Designers can overcome this problem by designing a stripper plate to cover the entire form up to the bend line. In this design, the stripper is machined down to 1/4 inch thick and 3/4 inch back from the form, and the rocker is mounted above it. The machined step, instead of the rocker, becomes the contact point, and the rocker performance is not affected.

INDRODUCTION TO TOOL ENGINEERING

The field of Tool Engineering takes participation in the refinement of product design and the design of machinery and also machine tools gauges etc.
Industries utilize millions of men,production tools,machines,processes,material handling devices, buildings,other related facilities and millions of rupees in order to shape and produce materials to meet the needs of mankind.

The competitive system forces a methodical selection and utilization of the factors of production in the manufacture of high quality products of low cost.
The many alternative processes available to change the size and shape of materials require complementary tooling. Ingenuity is required in the design of this tooling to facilitate scheduled and economic machining, casting, joining and press working of the many Engineering materials. The field of tool and manufacturing engineering encompasses a wide variety of industries.It is concerned with the manufacture of airplanes, food handling equipments, glassware,refrigerators, communication equipments, textiles,electronic equipments, sewing machines, sporting goods, automobiles,machine tools, furniture, packaging equipments, missiles, farm equipments, space capsules, stores and soon.

The field of tool and manufacturing is a necessary function in unit or high volume production and in large or small enterprises. The tool and manufacturing engineer articulates in an environment which requires a through understanding of scientific and engineering principles.The tool manufacturing engineers must understand the broad manufacturing aspects of the industry in which he is employed and he must also be able to design specific production tooling.

TOOL ENGINEERING COURSE:
Today many Engineering courses are available for studying such as Mechanical Engineering, Electrical and Electronics Engineering, Textile Engineering, Civil Engineering,Automobile Engineering, Aeronautical Engineering, Marine Engineering etc..
Tool Engineering is one of part of the Mechanical Engineering. It is a Diploma course.It is very valuable and useful course. This course is available in Government and Private polytechnic colleges.

After completion of this courses, students have a good job. And also they have opportunities in foreign countries. Some others to start own industries. After completion of this course students are positioning for the following jobs in different industries.Tool and Die maker post, Supervisor, Quality control department, Tool Room Manager, Production Manager, Tool designer etc..
In Tool Engineering course, students have known Tool manufacturing processes and Tool designing principles. And also have knowledge on machines such as Lathe, Milling machine,Grinding machine, shaping and planner machine, Drilling machine, power hack saw cutting machine and some CNC machines.
Educational Qualification: 10th standard with good percentage of marks.

METAL FORMING PROCESSES

Introduction:
Metal forming is a process of forming the metal into the required shape. In this process no chips removed from the metal. The metal is formed into shape by applying force on the metal.

A press working operation, generally completed by a single application of pressure often results in the production of a finished part in less than one second. Press working forces are setup, guided and controlled in a machine referred to as PRESS. Metal is formed in two different stages such as 1.Cold working 2.Hot working.

Cold working
In this process metal is formed in the cold condition. In cold working the metal is pressed or cut, to get the required shape. The metal is stretched beyond its elastic limit.cold working can be done only on ductile metals. The machine used for pressing the metal in cold working is called a "cold forming press".
Hot working:
In this process metal can also be formed in hot condition. Here the metal is heated to a temperature, so that recrystalysation takes place. At this hot condition the metal is pressed to get the required shape. The machine used for pressing the metal in hot working is called "hot working press"

PRESS TOOLS
The tool which is used on press machines with punch and die is known as press tool.Punch is the male part of the tool, which is fastened to the ram and forced into the die.Die is the female part of the tool,which is rigidly held on the bed of the press machine.Die has an opening in perfect alignment with the punch.

Types of Dies:
1.Based on the operations
1.Shearing, 2.Blanking, 3.Piercing, 4.Punching, 5.Cutting off, 6.Parting off, 7.Notching, 8.Slitting, 9.Lancing, 10.Bending (angle bending and edge bending), 11.Curling,
12.Forming, 13.Drawing or cupping, 14.Plunging, 15.Squeezing, 16.Coining, 17.Embossing,
18.Deep drawing, 19.Flatening or planishing, 20.Trimming.
2.Based on construction
1.Simple die, 2.Progressive die, 3.Compound die, 4.Combination die, 5.Inverted die.

PRINCIPLE OF METAL CUTTING:

The cutting of sheet metal in press work is a shearing process.The punch and die have same shape of the part.The sheet metal is held between punch and die.The punch moves down and presses the metal into the opening of the die.

There is a gap between the punch and die opening.This is called as “Clearance”. The amount of clearance depends upon the type and thickness of the material. The punch touches the metal and travels downward. The material is subjected to both tensile and compressive stresses. By this pressure, the metal is deformed plastically.

The plastic deformation takes place in small area between punch and die cutting edges. So the metal in this area is highly stressed. When the stress exceeds the ultimate strength of the material,fracture takes place. The cutting edge of the punch starts the fracture,in the metal from the bottom.The cutting edge of the die starts the fracture from the top. These fractures meet at center of the plate. As the punch continuous tomove down, the metal under the die is completely cutoff from the sheet metal. The cut out portion of the metal drops down through the die opening.To make the metal to drop down freely,a die relief is given in the die block. If the clearance is too large or too small cracks do not meet and a ragged edge results due to the material being dragged and torn through the die.

What is Die Cutting?

Die cutting is a manufacturing process used to generate large numbers of the same shape from a material such as wood, plastic, metal, or fabric. The die cut shapes are sometimes called “blanks,” because they are usually finished and decorated before being sold. The process is widely used on an assortment of materials all over the world, and many manufactured products contain several die cut components, often assembled together in a series of steps to create a finished product.

Sharp specially shaped blades are used in die cutting. The blade is bent into the desired shape and mounted to a strong backing. The result is known as a die. The material being cut is placed on a flat surface with a supportive backing, and the die is pressed onto the material to cut it. Depending on what is being made, a single die might cut one piece of material, or it might be designed to slice through multiple layers, generating a stack of blanks.

Many consumers find it helpful to consider a cookie cutter when thinking about die cutting. The cookie cutter is a type of die which is capable of cutting out a potentially infinite amount of blanks. Each blank will be exactly the same shape and size, meaning that the blanks can be cooked uniformly together and decorated at will for individuality. The alternative is cutting out each cookie by hand, a painstaking process which would result in irregular final products.

Creating dies is meticulous work. The die must be designed so that it efficiently cuts the desired material with minimal waste. Most factories which use die cutting as part of their manufacturing process have techniques for recycling material left over from die cutting, but they want to avoid excess if possible. Often, multiple dies are fitted together on one mount, nestled with each other for maximum efficiency. Material left over from the die cutting process may be melted down and reused, or reworked into other components.

Common examples of die cut items include keys, paper products, and flat plastic pieces which can be snapped together. Die cutting is limited, because it can only really be used to produce flat objects. For more dimensional shapes, other manufacturing techniques such as molds need to employed. Dies can also range widely in size from cookie cutters to massive machines designed to cut out ship components. With large dies, it is important to observe safety precautions while die cutting, as an industrial die designed to slice through metal can also remove a limb without difficulty.

Tool and die maker

Tool and die makers are highly skilled workers in the manufacturing industry. Tool and die makers make jigs, fixtures, dies, molds, machine tools, cutting tools , gauges, and other tools used in manufacturing processes.Depending on which area of concentration a particular person works in, he or she may be called by variations on the name, including tool maker (toolmaker), die maker (diemaker), mold maker (moldmaker), tool fitter (toolfitter), etc.

Die makers are skilled craftspeople who typically learn their trade through a combination of academic course-work, hands-on instruction and a substantial apprentice period.

Job description

Traditionally, working from engineering drawings, tool makers marked out the design on the raw material , then cut it to size and shape using manually controlled machine tools and hand tools . Many tool makers now use computer-aided design , computer-aided manufacturing and CNC machine tools to perform these tasks.

Tool making

Tool making typically make tooling used to produce products. Common tools include metal forming rolls, lathe bits, milling cutters, and form tools. Tool making may also include precision fixturing or machine tools used to manufacture, hold, or test products during their fabrication. Due to the unique nature of a tool maker's work, it is often necessary to fabricate custom tools or modify standard tools.

Die making

Die making is a subgenre of tool making that focuses on making and maintaining dies. This often includes making punches, dies, steel rule dies, and die sets. Precision is key in die making; punches and dies must maintain proper clearance to produce parts accurately, and it is often necessary to have die sets machined with tolerances of less than one thousandth of an inch.

Overlap

One person may be called upon for all of the above activities, and the skills and concepts involved overlap, which is why "tool and die making" is often viewed as one field.

Training

Although the details of training programs vary, many tool and die makers begin an apprenticeship with an employer, possibly including a mix of classroom training and hands-on experience. Some prior qualifications in mathematics, science, engineering or design and technology can be valuable. Many tool and die makers attend a 4- to 5-year apprenticeship program to achieve the status of a journeyman tool and die maker. Today's employment relationships often differ in name and detail from the traditional arrangement of an apprenticeship, and the terms "apprentice" and "journeyman" are not always used, but the idea of a period of years of on-the-job training leading to mastery of the field still applies.

Job outlook

Employment of tool and die makers is expected to decline in some countries due to increased use of automation, including CNC machine tools and computer-aided design,computer-aided manufacturing. On the other hand, tool and die makers play a key role in building and maintaining advanced automated manufacturing equipment.

Jig maker

A jig maker is another term for a tool and die maker or fixture maker, usually in woodworking or in the metal industries. Actually a jig is what mounts onto a work piece, and a fixture has the work piece placed on it, into, or next to it. The terms are used interchangeably though throughout industry. A jig maker needs to know how to use an assortment of machines to build devices used in automation, robotics, welding, tapping, and mass production operations.

They are often advised by an engineer to do the pre- planned work of building the much needed devices. In a production shop they need to know about an extensive assortment of machines, tools, and materials, and are often the most experienced toolmakers or woodworkers. They are often the ones who create from the original plans, the jigs, the fixtures and devices designed by and with the occasional assistance of the production engineer.

The reason jig makers need to be experienced is so that they can make suggestions for efficient alterations and needed repairs. They sometimes assist and monitor the progress of the jig or the fixture's gauging, locating, and innovative ability. Those who graduate to the level of jig and fixture makers often go on to gain automation skills, and the use of air, and electronic clamping procedures, and automation principles and equipment. They often need to know not only how to use basic machines to cut and machine steel and wood. For the most advanced, they need to be familiar with switches and the use of air supply equipment, various instruments, switches, hydraulic clamps, gauges, and more.

Properly built jigs and fixtures reduces waste, and produce perfect fitting parts, cutting out too much expensive hand work, mistakes and waste. Most are portable, and can be built or even moved throughout a facility. Some jigs and fixtures are as big as a car for placing a whole fender or chassis into them for assembly. It is how every volume shop works. The need for jigs and good gauging is necessary in furniture making for controlling quality and repeatability. A jig maker focuses on building tools in order to avoid placing parts incorrectly.