PRESS TOOL DESIGN | JIG AND FIXTURE | CNC MACHINE | PRESS TOOL TECHNOLOGY

THE DESIGN OF AUXILIARY OF EQUIPMENT

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The design of auxiliary equipment are:
the process of designing and developing auxiliary equipment, methods, and techniques required to improve efficiency and productivity of manufacturing, production with large production volumes and higher production speeds require special helper tools.
Tool design is always evolving because no single tool that is able
meet the entire manufacturing process.
The purpose of auxiliary equipment:
1. Reduces manufacturing costs
2. Maintaining quality
3. Increasing production

Terms of auxiliaries of good design:
1. Simple, easy to operate
2. Reduces manufacturing costs
3. Produce consistently high-quality parts
4. Increase the production rate with the tools / machinery
5.Foolproof, prevent the use / installation of the wrong
6. Using tools that ensure the material age
7. enough usage
8. Ensure operator safety

Outstanding design assistant tool in the manufacturing process: lies between the design (the product)
and production
Failed or successful tool is largely determined by its design

JIG AND FIXTURE

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INTRODUCTION
To reduce production costs, increase efficiency of manufacturing process of a product is very influential, especially by lowering its manufacturing process time. diidentisikasikan manufacturing process time by decreasing setup time and cutting process.

Jigs and fixtures are "tooling aid" that serves to hold and / or directing the work piece so that the process of manufacturing a product can be more efficient. In addition jigs and fixtures can also serve to get high quality product can be maintained as determined quality. With jigs and fixtures, you no longer need your service skills in performing manufacturing operations, in other words workmanship manufacturing process will be easier to get higher product quality or production rate is higher too.

The philosophy of the Group's technology is to benefit from grouping a number of products, both on an equal basis atupun design manufacturing processes on an equal basis. In this study, the similarity process into consideration to improve the efficiency of manufacturing processes.

Thus, the efficiency of the manufacturing process of a product can be increased (to reduce setup time and processing time expression), through the design of jigs and fixtures in the manufacturing process of a group of products.
DEFINITIONS jigs and fixtures
Jigs and fixture tool holder is used for production work piece in order to create a doubling components accurately. And straightness of the true relationship between the cutting tool or other tool, and workpiece should be maintained. To do this then use jigs or fixtures that are designed to hold, support and positioning of each part so that any drilling, machining carried out in accordance with the specification limits.
Jig is defined as a tool / special tool that holds, propped or placed on the component to be machined. This tool is a production tool is made so that he not only placing and holding the workpiece but also to direct the cutting tool when the current operation. Jigs are usually equippedwith hard steel bushing to guide the eye auger / drill (drill) or other cutting tools. Basically, small jigs are not not used bolt / clamp mounted on the table auger (drill press table). Yet for over 0.25 inches in diameter drilling, jigs usually need to be installed with full force on the table.
Fixture is a place of production equipment, holding and supporting

workpiece firmly so that the necessary engineering work to be done. Measuring block or feeler gauge is used in fixtures for reference / setting cutting tools to the workpiece. Fixture must be mounted fixed to the machine table where the workpiece is placed

CALCULATING PUNCH AND DIE CLEARANCE

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Any cutting operation performed Punch and Die always have value
clearances are taken.
For thick plate (s) ≤ 3 mm
Us = C.S.
1
τ
Where:
Us
= Allowances for each side (mm)
Dp
Punch = Diameter (mm)
Dd
= Die diameter (mm)
C
= Factor of work (0.005 ÷ 0.025)
S
= Thickness of plate (mm)
τt
= Material shear stress (N/mm2)

PILLAR FOR PRESS TOOL

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GUIDE LIFTER ONE OF MANY PRESS TOOL COMPONENT

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SAMPLE PROFILE DIE INSERT FROM PRESS TOOL COMPONENT

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PROFILE PUNCH FOR BENDING

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PROFILE PUNCH FOR CUTTING

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CUTTING TOOLS (DEFINATION OF OPERATIONS)

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A tool which is used to cut or/and form sheet metal is know as a presstool. Usually this cutting and forming is done in combination with a machine, called press, (excenter press, mechanical press, hydraulic press). A press tool is made in order to manufacture hundreds and thousands of indentical components in comparetively short time. This means that a press tool makes it possible to produce sheet metal parts in on economical way, economical in terms as long as mass production is required and/or regular dimensions have to be maintenence.

The presstools can be basically divided into the two following categories :
a. Cutting Tools
b. Forming (non cutting) tools,

Cutting Tools (Punching Tools)

Blanking
The operation of punching about a complete contour is called blanking. The product is a blank. The blank is punched (cut) out as a plain stockstrip (coil).
A scrap coil is easily identified : in reguler intervals openings (scrap openings) of identical shape appear. The scrap - share per blank is high. In this respect blanking is not very economical. However, if the shape of the component makes it necessary we use this method. Blanks are produced in blank through tools (Component falls through die on bottom plate) or in inverted blanking tools (Components is ejected, from the die which is fixed on the top plate) .

Piercing
When opening(eg. holes) are punched (cut) into a blank or a semifinished product, the operation is know as piercing. The unwanted material (scrap) is called slug.

In the same books to the operation what we define (within these notes) as piercing, is referred to as "punching" (for round, oval or square openings) and slotting for cutting slots. We combine cutting of any shaped openings in the some ter piercing.

Notching
Notching is some how similar to piercing but the punch does't cuton all sides. It might act on 2 sides (free corners prior to bending) or three, but never on all. Nothing is used to fee sheet metal for drawing and forming (in progressive dies, see later) and to cut step by step the contour comlicated shaped blanks (also progressive dies). The cut out material is scrap.

Scropping
This is a scrapless operation. The width of the components is equal to the strip-width. The length of the part id determined by the feed. This method is used when the components shape is not comlicated. Moreover burrs have to be accepted on each opposite side once.

Parting
This operation is semi scrapless, scrap occurs only where the part is cut off (separated) from the strip. This method is frequeintly used when the component shapes are more complicated in one diricttion and straight in the other. The tours of the two shaped and might be different to each other.The burrs appear on the same side (toward the die opening).

Lanzing
When part of the material is cut (sheared) and the so feed portionis bent we know it as lanzing. Cutting is done at 3 edges. Bending takes place dring the same presstroke. Scrapless operation - combination shearing/bending. (Sometimes this operation is refered to as semi piercing).

Semi-Notching
This is a similar operation as lanzing. Cuttinng(shearing) is done at te most on 2 edges only since semi - notching is performed on least one outer board of the part.
Cutting and bending are done at the same press-stroke. Srapless operation combination shearing/bending. Sometimes this operation is included in "lanzing"

Shaving
Shaving is the only sheet metal cutting method which is not based on the shearing(fracture)principle, it is a chipping operation. Shaving is used when we want a high quality surface of a previously cut edge or dimensional accuracy or both. Blanks as well as pieroed holes an be shaved.
A very small amount of the fractured edge is removed. In extreme cases more than one shaping is recomended. This applies for very thick components and or extremely high accuracy. No cutting clearance is made.
In order to obtain good shaving results it is important that the previous cutting operation has produced awell finished cutting edge.

Trimming
Trimming is another finishing operation. This method is applied to remove excess material of forged or deep drawn parts. If the trimming cut is done in 90 degrees to the usual (vertical) direction we call it horizontal trimming.

Non cuttng tools defination of operation

Bending
Bending is defined as shaping sheetmetal around a stright axis which extend ompletely across the width or leght of the part. If during that bending the metal is stessed beyond the elastic limit but below the ultimate tnsile stereght it results in a permanent new countour.
The new countour is at an angle to the original (partlu remaining) one. Bende are made (in addition to obtail new countours) also to achive more rigidity.

Flanging
It is a similar operation as bendinbg. It is difficult to say where flanging ends and bending begins, The operation is known as flanging when the amount formed down is small compared to the remaining one. If the shape anyway shape of the flange (bend) is curved we call it anyway flanging.

Coining or stamping
Coining makes two sided impression or projextions by means of compressing the material in or arround the desired shape. On the opposite side of the impression no respective mark is visible but another design is impressed. If coining is one sided (opposite side flat) it is known as embossing. Typical application of coining making coins.

Semi piercing
This operation is similar to embossing. The difference is that opposite as the impression we fird projecttions. It is used for forming reinforcing ribs, welding projections to permit assembly by resistance welding.

Deep drawing
Deep drawing techique permits to produc semless hollow containers of regular and irregular shapes.
The metal is drawn by the punch and die. Blank holder pressure is applied to control the material flow. If the blakholder pressure is required it is know as form drawing.

Crimping
Crimping is a sort of bending. It is appli3ed to assemble electrical wire to sheet metal (brass, copper)

CURLING
Curling means rolling one-edge of a flat sheet metal blank, curled components are very rigid. Sometimes two curled parts are assembled to form a lid and a can. The assembly is not leak proof.

FORMING
Forming as such is difficult to define since it is general expression. It has become a bit the collective term for as unusual, indefinable forming operations as long as a pad is used.

COLLAR DRAWING
This is actually not cutting operation. It is scrapples and the material is torn and formed. The punch is bullet shaped. Although we call it “Collar-Drawing” it is not a typical drawing operation. We can easily identify application for collar drawn openings id to offer extended length for holes which are to be tapped. Sometimes this operation is known as “hole flanging” provided a hole is pierced before.

SUMARY OF CUTTING OPERATIONS
Operations to Produce Blanks
- Shearing
- Blanking
- Cropping (Cut – Off)
- Parting
- Shaving (secondary operation)

Operations To Cut Holes
- Piercing
- Hole Flanging (pre–cut collar drawing)
- Shaving (secondary operation)

Scapless Operations
- Shearing
- Cropping
- Lanzing
- Semi-notching
- Collar drawing

OPERATION SUITABLE FOR PROGRESIVE WORK
Cuting Operation
- Pierching
- Blanking
- Nothing
- Parting
- Cropping
- Lanzing
- Semi-Notching
- Shaving
- Trimming

Non Cutting Operations
- Bending
- Flanging
- Coining
- Embossing
- Semi- Piercing
- Deep Drawing (limited)
- Crimping
- Curling

TERMS FOR PRESS TOOL PARTS
Punch: The male part of a press tool, is fixed either with the top or bottom plate. It determines the dimensions of openings. Material : Preferably High Cromium High Carbon Steel, Hardened and tempered 60-62 HRC.

Die : is the female counter part of the punch and therefore fixed on the opposite appropriate plate. The die opening determines the dimensions of the outer shape of components. Material : Same as punch, hardened 60-62 HRC.

Bottom Plate (die shoe)
Supports usually the die (Except for inverted or compound tools) and locates guide pillars. Migh be graded cost Iron or Mild Steel (40 kg/mm2)

Top Plate (Punch Shoe)
Support normally the punches or punch holder plate (Except for inverted or compound tools), accommodates guide-bushes, shank. Material : Graded Cast Iron or Mild Steel (40/mm2).

Guide Pillar, Guide Bush
Are assembled as a matching pair to locate top plate and bottom plate accurately. Material : Carbon Steel Hardened.

Shedder
Use in compound or inverted dies to eject the blank, medium alloyed steel, hardened.

Punch Holder Plate
Holds smaller punches and is fixed and located with the top plate, Mild Steel.

Pressure Plate (Thrust Plate)
Is mounted at the back of the punch holder plate to take the punching pressure, medium alloyed steel, hardened.

Stripper
Strips coil (fixed or spring loaded) and pierced components (spring loaded) from the punch medium alloyed steel, hardened. Fixed stripper serves as punch guide in case of absence of guide pillars.

HOW TO GET NICE MUSCLE TONE AND BUILD AN ATTRACTIVE MUSCULAR BODY

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Most people know that they need to lift weight build muscles. However many just want to have nice muscle tone and an attractive but not too muscular body as they do not want big muscles. So they just lift light weights with high repetitions. Well, it is not going to work. To have nice muscle tone, you will have to build some muscles right? So you will have to lift heavy to force your muscles to grow. Once you are satisfied with the size of your muscles, you will then need to cut your body fats for your muscles to show up well and that means nice muscle tone.

You need to have a solid commitment and knowledge to get nice muscle tone and build an attractive muscular body. Here are some muscle building tips. Before you commence weight training, remember to warm up and as well as doing some

Because of this, it is important that every time you train hard, you give your body time to recover as it has suffered strains and actually sustained many small scarring. Contrary to popular belief, your muscles grow when you rest, especially when you sleep and not in the gim. So sleep at least 8 hours a day. Also, do not train everyday or work the same muscle group more than once or twice a week. If your training was vigorous enough, do no more than an hour per session.

Try not to do cardio work on the same day as your weight lifting work. In fact, during the muscle building phase, you should do less cardio work as aerobic exercises burn muscles. You can increase your cardio work at cutting body fat phase, so as to lose body fat in order for your muscle tone to show up nicely.

•Technique And Form

This is the most neglected fundamental of bodybuilding. Everywhere, everyday, you will see people using wrong forms and techniques. This not only compromises your growth, it will also make you susceptible to injuries... sometimes even permanently putting you out of the gym.

Wrong form occurs usually when people try to lift weights that are too heavy, whether out of vanity or ignorance. As a guide, always lift with strict focus on the muscle you intend to build for that ecercise. Feel it contract and extend. Lift the weights deliberately and slowly. Never ever swing your weights up especially when doing bicep curls or the military press.

•To Build Muscles Fast You Must Perform Lower Body Exercises!

This is what most people don't realize. Your lower body makes up 60-70% of your musculature. If you don't train them, not only will you look spider-legged, your entire body will not grow as quickly and as large. Don't think that you can hide those skinny limbs in pants! Most people do not train their legs because squats, dead lifts and lunges can be very grueling exercises. But it is precisely because of such intensity that you will produce more growth hormones when you sleep and overall muscular development is stimulated. Your body shape will also be more balanced and therefore more attractive.

Do read up more to understand how your muscles work and then work on it so that in no time you will be a proud owner of a well tone attractive muscular body.