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.