workshop molddies

MANUAL WORKSHOP METHOD MARKING #1

2016-05-31T18:55:00.000-07:00

Marking means setting out dimensions with the help of a working drawing or directly transferring them from a similar part. The procedure of marking is as follows:

A-Fine Adjustment of nut B-Vernier slide C-Scriber clamp screw D – Scriber E – Vernier Scale F – Main Scale G – Base X,Y – Lock Screws

#1. The surface to be marked is coated with the paste of chalk or red lead and allowed to dry.

#2. Then the work is held In a holding device depending upon shape

and size. If it is flat, use surface plate, if it is round use V block and clamp, else use angle plate etc.

#3. Lines in horizontal direction are scribed by means of a surface gauge. Lines at right angles can be drawn by turning the work through 90 degree and then using the scriber. If true surface is available, try square can also be used.

#4. The centre on the end of a round bar can be located by using an odd leg caliper, surface gauge etc.

#5. The circles and arcs on a flat surface are marked by means of a divider.

#6. After the scribing work is over, indentations on the surface are made using dot punch and hammer.

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WORKSHOP MARKING TOOLS MANUAL #1

2016-05-24T18:49:00.000-07:00

Surface Plate

It is used for testing the flatness, trueness of the surfaces. It is made up of cast iron or graphite. Its upper face is planed to form a very smooth surface. It is also used in scribing work.

While not in use, it should be covered with a wooden cover.

Angle Plate

It is made up of cast iron in different sizes; it has two planed surfaces at right angles to each other and has various slots in each surface to hold the work by means of bolts and clamps.

Never do hammering on the angle plate to fasten (lighten) the nuts and bolts.

Scriber and Surface Gauge

It consists of a cast iron bass on the center of which a steel rod is fixed vertically. Scriber is made up of high carbon steel and is hardened from the front edge. It is used for locating the centres of round bars or for marking of the lines.

Punches

Punches are used for marking purposes. Dot punches are used for marking dotted line and centre punch is used to mark the centre of hole before drilling. Punches are made up of high carbon steel or high speed steels. One end is sharpened. Hammering is done on the second end while working. For dot punch, angle of the punching end is 60 degree while in centre punch; angle of punching end is 90 degree.

Try Square

It is used for checking squareness of two surfaces. It consists of a blade made up of steel, which is attached to a base at 90 degree. The base is made up of cast iron or steel. It is also used to mark the right angles and measuring straightness of surfaces. Never use try square as a hammer.

Vernier Height gauge:

A Vernier height gauge consists of a heavy base, a graduated beam, a sliding head with Vernier sliding jaws holding the scriber and a fine adjustment clamp. It is similar to large Vernier calipers in construction, except that it consists of a heavy base which allows the gauge to stand upright instead of a fixed jaw in a Vernier. The movable jaw of Vernier height gauge consists of a projection or extension which is levelled to sharp edge for scribing lines at any required height.

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MEASURING TOOLS WORKSHOP MOULD #1

2016-05-23T18:32:00.000-07:00

Steel Rule

These are made up of stainless steel and are available in many sizes ranging from 1/2 ft. to 2 ft. These are marked in inches or millimetres. All the faces are machined true. The edges of steel rule should be protected from rough handling.

Calipers

These are generally used to measure the inside or outside diameters. Different types are:

>Outside Caliper: It is used to measure the outside dimensions.

> Inside Caliper: It is used to measure the inside dimensions.

> Spring Caliper: Spring is provided to apply the pressure and lock nut is provided to lock any desired position.

> Hermaphrodite, Jenny or Oddleg Caliper: One leg is bent at the tip inwardly and the other has a straight pointed end. It is used to scribe lines parallel to the straight edges.

> Vernier Caliper: It is used for measuring the outer dimensions of round, flat, square components and also the inner size of the holes and bore. A narrow blade is used to measure the depth of bar slots etc. The reading accuracy in metric system is 0.02 mm and British system it is 0.001”. It is made of stainless steel.

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WORKSHOP WELDING #1

2016-05-01T18:04:00.001-07:00

Welding is a process for joining two similar or dissimilar metals by fusion. It joins different metals/alloys, with or without the application of pressure and with or without the use of filler metal. The fusion of metal takes place by means of heat. The heat may be generated either from combustion of gases, electric arc, electric resistance or by chemical reaction.

Welding provides a permanent joint but it normally affects the metallurgy of the components. It is therefore usually accompanied by post weld heat treatment for most of the critical components. The welding is widely used as a fabrication and repairing process in industries. Some of the typical applications of welding include the fabrication of ships, pressure vessels, automobile bodies, off-shore platform, bridges, welded pipes, sealing of nuclear fuel and explosives, etc.

Most of the metals and alloys can be welded by one type of welding process or the other. However, some are easier to weld than others. To compare this ease in welding term ‘weldability’ is often used. The weldability may be defined as property of a metal which indicates the ease with which it can be welded with other similar or dissimilar metals.

Elements of welding process used with common welding joints such as base metal, fusion zone, weld face, root face, root opening toe and root are.

Edge preparations

For welding the edges of joining surfaces of metals are prepared first. Different edge preparations may be used for welding butt joints.

Welding joints

Some common welding joints are shown in Figure. Welding joints are of generally of two major kinds namely lap joint and butt joint.

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TREATMENT of FEROUS MATERIALS

2012-05-13T18:47:00.001-07:00

Iron is the major constituent in the steel used in tooling, to which carbon is added in order that the steel may harden. Alloys are put into steel to enable it to develop properties not possessed by plain carbon steel, such as ability to harden in oil or air, increased wear resistance, higher toughness, and greater safety in hardening.

Heat treatment of ferrous materials involves several important operations which are customarily to under various headings, such as normalizing, spheroidizing, stress relieving, annealing, hardening, tempering, and case hardening.

Normalizing

This is the operation of heating to temperature about 100F to 200F above the critical range a cooling in still air. This is about 100F over the regular hardening temperature. The purpose of normalizing is usually to refine grain structure that have been coarsened in forging. With most of the medium carbon forging steels, alloyed and unalloyed, normalizing is highly recommended after forging and before machining to produce more homogeneous structures and in most cases improved machinability.

High alloy air hardening steels are never normalized, since to do so would them to harden and defeat the primary purpose.

Spheroidizing

This is a form of annealing which, in the process of heating and cooling steel, produces a rounded or globular form of carbide the hard constituent in steel.

Tool steel are normally spherodized for best machinability. This is accomplished by heating to a temperature of 1380-1400F for carbon steels and higher for many alloy tool steels, holding at heat one to four hours, and cooling slowly in the furnace.

Stress Relieving

This is a method of relieving the internal stresses set up in steel during forming, cold working, and cooling after welding or machining. It is the most simple heat treatment and is accomplished by merely heating to 1200-1350F followed by air or furnace cooling.

Large dies are usually roughed out, then stress relieved and finish machined. This will minimize change of shape not only during machining but during subsequent heat treating as well. Welded sections will also have locked in stress owing to a combination of differential heating and cooling cycle as well as to changes in cross section. Such stresses will cause considerable movement in machining operations.

Annealing

The process of annealing consist of heating the stell to an elevated temperature for a definite period of time and, usually, cooling it slowly. Annealing is done to produce homogenization and to establish normal equilibrium conditions, with corresponding characteristic properties.

Tool steel as purchased is generally in the annealed condition. Sometimes it is necessary to rework a tool that has been hardened, and the tool must then be annealed. For this type of anneal, the steel is heated slightly above its critical range and than cooled very slowly.

Finished parts may be annealed without surface deterioration by placing them in a closed pot and covering with compounds that will combine with the air present to form a reducing atmosphere. Partially spent carburizing compound is widely used, as well as cast iron chips, charcoal, and commercial neutral compounds.

Hardening

This is the process of heating to a temperature above the critical range, and cooling rapidly enough through the critical range to appreciably harden the steel.

A simplified theory of hardening steel is that iron has two distinct and different atomic arrangements, one existing at room temperature or gain near the melting point, and one above the critical temperature. Without this phenomenon it would be impossible to harden iron base alloys by heatreatment.

Tempering

This is the process of heating quenched and hardened steel and alloy to some temperature below the lower critical temperature to reduce internal stresses set up in hardening. Thus the hard martensite resulting from the quenching operation is changed in tempering in the direction of the equilibrium properties, the degree being dependent on the tempering temperature and rate of cooling.

Case Hardening

The addition of carbon to the surface of steel parts and subsequent hardening operation are important phase in heat treating. The process may involve the use of molten sodium cyanide mixtures, pack carburizing with activated solid material, such as charcoal, or coke, gas, or oil carburizing, and dry cyaniding.

Whether a solid carbonaceous packing material is used, or a liquid gas, the objective is to produce a hard, wear resistant surface with a core of such hardness or toughness as is best suited for the purpose. The carbon content of the surface is raised to 0.80-1.20% and the case depth can be closely controlled by the time, the temperature, and the carburizing medium used. Pack carburizing is generally done at 1700F for eight hours to produce a case depth of 1/16 in, Light cases up to 0.005in. can be obtained in liquid cyanide baths and case depths to 1/32in. are economically practical in liquid carburizing baths.

Usually low carbon and low carbon alloy steel are carburized. The usual carbon range is 0.10 to 0.30% carbon, though higher carbon content steel may be carburized as well.

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MACHINING OPERATION WITH MACHINE TOOLS

2009-06-19T20:47:00.000-07:00

# TYPE OF MACHINES
# CARE and MAINTENANCE of MACHINE TOOLS
# ECONOMICAL PRODUCTION

A. TURNING OPERATIONS

Workpiece - Shapes, Technology
Turning Processes
Turning Lathes of Different Design
Turning Tools
Cutting Speed
Calculation of RPM

1. MANUFACTURE OF CYLINDRICAL BOLTS
Turning of Bolts
Measuring and Testing of Bolts
2. MANUFACTURE OF STEPPED BOLTS
Measuring and Testing With the Micrometer
Chucking of Short Cylindrical Parts in the Collet Chuck
3. MANUFACTURE OF SHAFT
4. MANUFACTURE OF ECCENTRIC SHAFTS
5. PROFILE TURNING
6. MACHINING OF HOUSINGS AND CASTINGS
7. MASS PRODUCTION OF TURNED PARTS

B. DRILLING AND BORING OPERATION

Holes in Different Workpieces
Movements While Drilling on Machine
Differents Types and Design of Drilling Machine
Drilling Tool
Special Drilling And Binr Tool
Chucking of Drills
Revolutions,Feed and Cooling While Drilling
1. DRILLING OF SIMPLE HOLES
2. COUNTERSINKING AND COUNTERBORING OPERATION

C. MANUFACTURE OF TAPPED PARTS

Tapper On The Lathe
Tapper Turning With Tapper Attachment
1. MEASURE OF A LATHE CENTRE
2. MANUFACTURE OF HOLES FOR TAPER PINS

D. MILLING OPERATIONS

Features of Workpieces Manufactured by Milling
Milling Methods
Design and Types of Milling Machines
Milling Tools
1. MILLING OF PLANE SURFACE
Testing Of Plane Surface
2. MILLING OF KEYWAYS
Testing Of Keyways
3. MILLING OF SLIDES
4. MILLING OF HEXAGONS

E. SHAPING AND PLANING OPERATIONS

Design of The Shaping Machines

Shaping and Planing Tools
Clamping of Workpieces
Calculation of the Machining time During The Planing Process
1. SHAPING OF V-BLOCKS
2. PLANING OF GUIDE GIBS

F. MANUFACTURE OF PART ON THE SLOTTING MACHINE

1. SLOTTING OF KEYWAYS
Measuring and Testing of Keyways

G. BROACHING OPERATIONS

Broaching Machines
Broaching Tools
1. BROACHING OF MULTIPLE SPLINE BORE

H. GRINDING OPERATIONS

Grinding Wheels
Sharpening of Tools
Fetting of Workpiece
Cylindrical Grinding and Cylindical Grinding Machines
1. GRINDING OF SHAFTS
Varous Methods Of Cylindrical Grinding,Cutting off Grinding
Calculation Of The Machine Time For Cylindrical Grinding
Internal Cylindrical Grinding
2. GRINDING OF BORES
Surface Grinding
Calculation Of The Machining Time For Grinding Operations
3. GRINDING OF PARALLELS
4. FINE FINISHING OPERATIONS

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WORKSHOP MOLD MAINTENAND

2009-06-15T19:58:00.000-07:00

Of the means of production found in plastics processing operation,the molds represent the greatest value by far.
The ideal storeroom is a separate building or a solidly constructed,windowless room within the main plant.
The only combustible material in the storeroom should be the grease applied to the molds to prevent rust.Shelves and pallets should not be made of wood or plastic but the steell.I the storeroom in within the plant itself,the door should be equipped with an automatic closing mechanism that is activated in the event of a fire alarm.
It is also recommended that the local fire department be invited for a visit so that in case of a fire the fire fighting can be concentrated on the mold.

In addition to appropriate storage,the risk of loss or damage demands adequate insurance.
This should preferable be determined in conjunction with the owner of molds.
Aspects such as loss production,inability of the mold to be used for production and posible reduction in value with time,depending on the market value of the molded part,must not be oveloocked when determining the amount of insurance.
Above All,it is important that the owner and holder or the molds reach a clear agreement about the insurance who will carry the insurance,how much insurance,who is entitled to the insurance,etc.

Clomplate documentation on each mold is recommended not only for insurance purposes but also to simplify inventory and handling of the molds,e.g.spare parts procurement and so that origin owner ship,purchase price or manufacturing cost,technical details etc are accurately recorded.

On the other hand ,the desire to maintain quality and hard won know how requeres that all data for operations of an individual mold i.e instructions relating to material,material preparation and set up and part removal for production along with maintenance instructions.be clearly specified.
Such a system should be establised on the basic of the organizational means available within a company.
The maner in which this is accomplished and the effort devoted to it are quite irrelevant as long as purpose is fulfilled;documentation of all economic and technical information and guidelines for maintenance and recording of maintenace cost so that the plant management may continually monitor the productivity and cost of each individual mold during its service life.
The system presented here is one of many possible system that achieve the desire objective.The following principles apply;

A. The course of the mold is always from the storeroom to the machine,from the machine to the workshop for maintenance or any repair,from the workshop to the storeroom.

B. Along this path the mold is continually subject to observatium and recording of all events and any resulting action and costs.

C. Every individual along the parh of the mold sign for his observations and actions taken,so that on the one hand the completion of all prescribed actions is responsibly documented and on the other responsibility is always transferred to the next individual involved.
A few comments and reccomendations on the aforementioned system;The entire front of the mold setup sheet shown on the following pages holds data used for indetification on the mold and for production setup)selection of machine,material and aids ).
A separate mold setup sheet should be filled out for each injection molding machine on which the mold may be economically run.

A job number should be assigned already when issuing the order convering the first step taken in the manufacture of a new mold.
This number should then appear on every drawing and document,especially when is is a matter or receips for time or money spent,until the mold has been completed.
The collected documents provide information on the actual procurement value in relation to the preliminary estimate and serve as a reliable reference for establising the amortization rate.For instance,the job number can be composed of the year and the current mold number for the year.
The job number should be permanently stamped into the mold,following a consistent principle as to the location of indentification so that each mold may be readily indetified.
After the mold has been tested and optimized for production and those responsible for production have reached agreement with those responsibly for quality control or acceptance by the customer,the production manager should record all essential data for the setup of the mold on mold setup sheet,authorizing these data as the applicable and compulsory manufacturing instructions by affixing his signature.

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WorkShop/MoldDies Shop

2008-11-02T06:11:00.000-08:00

Mold prices and delivery deadlines are always the critical point in production planning and sales negotations.

The price of mold dies has mayor effect on the price of part to be producted,mold die making today is moving toward more specialization.

Various machine operation on milling,lathe,CNC,EDM or grinding machine manufacture parts of the finished mold-dies separately.at the final stage all these parts are brought together and assembled by the mold-dies maker,he has the overall responsibility for the fungtioning the mold-dies which is also a result of team works.

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