Production Engineering

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.

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