Production Engineering

Production Engineering

Jig and Tool Design

8th Edition - January 1, 1972

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  • Authors: E. J. H. Jones, H. C. Town
  • eBook ISBN: 9781483140773

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Description

Production Engineering: Jig and Tool Design focuses on jig and tool design as part of production engineering and covers topics ranging from inspection and gauging to multiple and consecutive tooling, tool calculation and development of form tools, deep-hole boring, and grinding-wheel form-crushing. Air and oil operated fixtures, negative rake machining, and the economics of jig and fixture practice are also discussed. This text is comprised of 22 chapters; the first of which provides an overview of the function and organization of the jig and tool department. Attention then turns to the subject of cutting tool materials, with emphasis on the science of surface technology and the effects on the economics of tooling. A chapter on diamond tools offers insights into boring and turning operations, and examples of the features of preset tooling are presented. The chapter on air or oil operated fixtures contains examples from actual practice, some of the pneumatic examples being applicable to holding small units where the machining time is in seconds, and the rapid insertion and removal of work is essential. The reader is also introduced to the methods of truing grinding wheels, including surface grinding, and diamond honing. The book concludes by highlighting the problem of small batch manufacture in transfer machining and group technology. This book is intended not only for the experienced jig and tool designers but also for the production engineering students and the technical college lecturers.

Table of Contents


  • 1 Function and Organization of the Jig and Tool Department

    Surface Technology

    Designing for Ease of Production

    Economics of Tooling

    Copy Turning

    Economics of Jig and Fixture Practice

    2 Inspection and Gauging

    Factory and Line Inspection

    Limits and Fits

    Design of Limit Gauges

    Principles of Precision Measurement

    Slip Gauges

    Comparators

    Optical, Pneumatic and Electrical Types

    Measuring Machines

    Sine Bar and Angular Measurement

    3 Cutting-Tool Materials

    Carbon Tool Steel

    High-speed Steel

    Tungsten Carbide

    Ceramic Cutting Tools

    Diamond Tool and Machining Operations

    4 Small Tools

    Drills

    Rifle Drills

    Core Drills

    Spade Drills Reamers and Taps

    Thread Milling

    Grinding and Rolling

    5 Milling Cutters

    Types of Cutters

    End Mills

    Form Relieved Cutters

    Face Milling Cutters

    Throw-away Tips

    High Rake Cutters

    Down-cut Milling

    Vibration Problems

    Pendulum Milling

    6 Milling Fixtures

    Fixtures for Milling Slots and Jaws

    Edge Clamping

    Sighting Plates

    Fixtures for Quantities

    Fluid Clamping

    Gang Milling

    Indexing Fixtures

    7 Multiple and Consecutive Tooling

    Multiple Drilling Machine

    Consecutive Tooling

    Depth of Counterbores Pre-set Tooling

    Automatic Operating Cycles

    8 Tool Calculation and Development of Form Tools

    Examples of Calculation

    Calculating Correction on Form Tools

    Development of Form Tools

    Hardening of Form Tools

    Circular Form Tool Calculations

    Form Relief

    9 The Underlying Principles of Jig and Fixture Design

    Reduction of Idle Time

    Clearance between Jig and Component

    Sighting Faces

    Coolant to Cutting Edges

    Lugs or Bosses

    Clamps and Adjustments

    Inserts

    Loose Parts

    Foolproofing

    10 Jig and Fixture Details

    Guide Bushes

    Ejector Devices

    Locating Principles

    Clamps

    Cam Clamps

    Pressure Equalizing Clamps

    Indexing Plungers

    Jacks and Supporting Pins

    11 Drill Jigs

    Marking-off Templates

    Built-up Jigs

    Box Jigs

    Jigs for Large Components

    Trunnion and Indexing Jigs

    12 Multi-spindle Drill Heads

    Mounting and Designing Multi-heads

    Eight-spindle Drill Head

    Swiveling Drill Head

    Head with Adjustable Centers

    Three-spindle Head

    Unit Construction

    13 Broaches

    Material for Broaches

    Design of Broaches

    Determination of Pitch, Chip Clearance, Pulling Load, etc.

    Allowance for Broaching

    Types of Broaches

    Surface Broaching

    Heavy Broaching Developments

    14 Broaching Fixtures

    Keyway Broaching

    Keyways in Taper Bores

    Spline Broaching

    Outrigger Supports for Horizontal Machine

    Push Broaching

    Surface Broaching

    Broach

    Pullers

    15 Grinding Fixtures

    Cylindrical Grinding

    Mandrels

    Internal Grinding

    Surface Grinding

    Beeswax Fixture

    Vacuum Chucks

    16 Grinding-Wheel Truing Devices and Generating Systems

    Radius Forming

    Forming Angles

    Spline Grinding

    Blending Radii

    Truing Irregular Forms

    Truing on Surface Grinders

    Generating a Spherical Surface

    Spherical Grinding

    17 Grinding-Wheel Form-Crushing

    The Grinding Wheel

    Electrical Cut-out Device

    The Crushing Roller

    Dressing Blocks

    18 Boring Bars and Fixtures

    Locating and Clamping

    Boring Tools

    Tool Setting

    Boring Bar Problems

    Elimination of Vibration by Damping

    Honing Operations

    Diamond Honing

    Fixtures for Boring and Facing

    Multiple Boring Operations

    19 Deep-Hole Boring

    Trepan Boring

    The Trepanning Head

    The Machine

    Requirements for Successful High-speed Trepan Boring

    Production Data

    Cutting Tool for Trepan Boring

    'Pressure' and 'Sizing' Pads

    High-pressure Oil Supply

    Pierce Boring

    20 Air and Oil Operated Fixtures

    Air Cylinders and Controls

    Safety Features

    Swarf Clearance

    Pneumatic Jigs and Fixtures

    Hydraulic Operation

    Design Features

    Accumulator System

    High Pressure Units

    21 Negative Rake Machining

    Face-milling Cutters

    Cutting Rakes

    Bevel Angle and Corner Radius

    Types of Cutter Blanks

    Turning Tools

    Cutter Design

    22 Transfer Machining and Group Technology

    Flow Production

    Automatic Work Handling

    Advantages of Transfer Machining

    Machine Design

    The Table

    Work Holding

    Transfer Mechanism

    Swarf Removal

    Sequence of Operation

    A Semi-automatic Installation

    Factors Influencing the Choice of Installation

    he Platen

    Layout of the Line

    Machine Design

    Transfer Mechanism

    Operation Sequence

    The First Operations

    The Transfer Line

    Machining the Angular Holes

    Final Stages

    Group Technology

    Cell System

    Index


Product details

  • No. of pages: 300
  • Language: English
  • Copyright: © Newnes 1972
  • Published: January 1, 1972
  • Imprint: Newnes
  • eBook ISBN: 9781483140773

About the Authors

E. J. H. Jones

H. C. Town

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