
Production Engineering
Jig and Tool Design
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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