Standard

 

MCA 224 – Die Construction II

Course Description

Provides practical application of theory and competencies in MCA 223. Topics include: application of related formulas, calculations and manufacture of bends, draw die manufacture, manufacture of fasteners, spring selection, and safety.

 

Competency Areas

Hours

 

Application of Related Formulas

Class

2

Calculation and Manufacture of Bends

D. Lab

2

Draw Die Manufacture

P. Lab/O.B.I.

6

Manufacture of Fasteners

Credit

5

Spring Selection

 

 

Safety

 

 

 

 

 

Prerequisite/Corequisite:

MCA 223

 

Course Guide

 

Competency

After completing this section, the student will:

Hours

Class

D.Lab

P.Lab/

O.B.I.

APPLICATION OF RELATED FORMULAS       

 

 

 

Die diameter formulas

Discuss the minimum and maximum die diameter formulas and demonstrate how they are used.

 

 

 

 

Explain the formula for finding blank sizes, height of drawn shells, drawing pressures, cubic content of drawn shells, bend allowances, and spring back allowances.

 

 

 

Bend formulas

Demonstrate bend formulas and explain how the degree of the bend and the thickness of the workpiece affect the calculations.

 

 

 

CALCULATION AND MANUFACTURE OF BENDS

                                                                       

 

 

 

Bend theory

Discuss charts for finding inside radius of 90 degree bends.

 

 

 

 

Explain formulas for computing material allowances for multiple bends, and how to calculate bend allowances for angles smaller or greater than 90 degrees.

 

 

 

 

Define drawing edge and how the radius affects the drawing of a shell with various thicknesses of metals.

 

 

 

Bend processes

Describe problems with both shallow and deep drawing processes.

 

 

 

 

Select the proper size blank and process that could be used to produce the shell for examples of drawing bends.

 

 

 

 

Discuss machinery and dies that are used to produce bends in different products.

 

 

 

DRAW DIE MANUFACTURE                   

 

 

 

Die theory

Define drawing of metal parts, alligator skin, vents, pressure pads, shell, annealing, grain growth, hard rolled stock, half hard stock, soft stock, dead soft stock, special dead stock, inverted drawing, deep drawing, drawing rings, and wrinkles.

 

 

 

 

Discuss the types of products that are drawn, problems found in drawn shells, and the causes of the problems.

 

 

 

 

Describe methods of die construction that are used to eject parts.

 

 

 

 

Discuss methods of lubricating drawing dies.

 

 

 

Die design

Design simple excursions to test drawing dies, identify problems, and suggest corrections for the problems found.

 

 

 

SPRING SELECTION                                 

 

 

 

Spring definitions

Define the following: multi-spring and toggle-lever, deflecting springs, coil springs, spring pressure pads, conical springs, flattened conical springs, and spring fingers.

 

 

 

 

Explain the role of springs in die manufacturing.

 

 

 

 

Describe how spring dimensions and wire size affect spring pressure.

 

 

 

Spring selection

Select the type of spring necessary for every phase of die manufacturing.

 

 

 

MANUFACTURING OF FASTENERS                 

 

 

 

Fastener types

Describe the following types of fasteners: socket cap screw, dowels, socket button-head screws, socket flat-head screws, socket set screws, stripper bolts, allen screws, hexagonal bolts and nuts, studs, washers, and lock washers, rivets, and clips.

 

 

 

 

Discuss how and when each type of fastener would be selected, its purpose, the spacing of fasteners, and the advantages and disadvantages of each.

 

 

 

Fastener manufacture

Describe the processes that are available in industry to manufacture the various fasteners.

 

 

 

 

Explain the types of materials used and the heat treatment of metal fasteners.

 

 

 

SAFETY

 

 

 

 

 

 

 

 

 

Suggested Resources

 

Books

 

American Society of Tool and Manufacturing Engineers Staff. (Ed.). (1965). ASTME die design handbook. New York: McGraw-Hill.

Jones, F. D. (1951). Die design and diemaking practice. New York: Industrial Press.

Keyes, K. A. (1982). Innovation in die design. Dearborn, MI: Society of Manufacturing Engineers.

Paquin, J. R., & Crowley, R. E. (1987). Die design fundamentals (2nd ed.). New York: Industrial Press.

Smith, D. (1990). Die design handbook. Dearborn, MI: Society of Manufacturing Engineers.

Society of Manufacturing Engineers Staff. (Ed.). (1971). Die design and construction. Ann Arbor, MI: Prakken.

Society of Manufacturing Engineers Staff. (Ed.). (1978). Manual of instruction for die design. Ann Arbor, MI: Prakken.