Tool and die design for beginnners; a practical handbook for the beginner in the fields of tool design, die making, and metal stamping, with typical problems carefully analyzed

[Virtual Presenter] Welcome to our training video on tool design, die making, and metal stamping. Today, we will be reviewing a handbook written by mechanical engineer and general manager, Frank E. Shailor in 1917. This handbook is a valuable resource for beginners, as it provides a practical guide and analysis of common problems in these fields. Titled 'Tool and Die Design for Beginners: A Practical Handbook for the Beginner in the Fields of Tool Design, Die Making, and Metal Stamping, with Typical Problems Carefully Analyzed', it was published by the American Technical Society in Chicago and has been a trusted source of information for over a century. Throughout this training, we will cover various topics and provide examples of common problems and their solutions. By the end, you will have a better understanding of these areas and be able to apply this knowledge in your own work. Let's dive into the first chapter of this handbook and begin our journey into the world of tool and die design. It is essential to have a strong foundation in these fields, and with this handbook, you will be on your way to success. We hope you find this training informative and beneficial. Let's get started!.

[Audio] Today, we will be discussing a handbook written by mechanical engineer and general manager Frank E. Shailor in 1917. This handbook is aimed at beginners in the fields of tool design, die making, and metal stamping. It contains a comprehensive analysis of common problems in these industries. The focus of our presentation will be on the copyright information, which can be found on slide number 2. The text states that the handbook is copyrighted by the American Technical Society in 1917 and also copyrighted in Great Britain. This means that the content is protected and cannot be used without permission. The last line of this text includes a copyright number, which is a unique identifier for this specific edition of the handbook. This is important as it helps to differentiate between different versions of the same text. Our presentation will now dive deeper into the content and lessons of the handbook. Let's continue to the next slide..

[Audio] This presentation will focus on the text "A Handbook for Tool Design, Die Making, and Metal Stamping" written by Frank E. Shailor in 1917. Tooling up is an essential aspect of modern shop practice and has greatly influenced the development of this industry. In the past, projects were completed one at a time, but with the implementation of multiple processes, devices are now assembled in tens or hundreds. Designing a large-scale project involves careful planning and multiple changes before a final design is approved. Once finalized, an expert tool designer is responsible for finding the most economical way to produce the device in large quantities. This includes studying the drawings and creating jigs, dies, and fixtures for different processes. The author, Frank E. Shailor, has extensive experience in this field and provides a detailed and comprehensive approach in this text. His expertise makes this book a valuable resource for beginners..

[Audio] Slide number 4 focuses on the use of a rotary surface grinder for grinding high-carbon steel gears. This tool was first introduced in a handbook by Frank E. Shailor, a mechanical engineer and general manager, in 1917. It is targeted towards beginners in the fields of tool design, die making, and metal stamping. The rotary surface grinder is a highly specialized tool that is used for precision grinding of various materials, including high-carbon steel. It utilizes a rotating abrasive wheel to remove thin layers of material from the gear's surface, resulting in a smooth and precise finish. Careful and precise handling is necessary when working with high-carbon steel gears, as they are known for their strength and toughness, but also pose a challenge due to their high hardness. However, the rotary surface grinder allows for a perfect blend of strength and precision in the gears. We can see an example of a rotary surface grinder in action in this slide. The machine shown is from Jleald Machine Company in Worcester, Massachusetts, a company renowned for its high-quality machine tools for various industries. The expertise of this company is evident in the impeccable finish of the gears shown in the image. It is important to note that the use of a rotary surface grinder requires proper training and safety precautions. As with any machinery, it is crucial to follow all safety guidelines and wear appropriate protective gear to avoid accidents and injuries. The use of a rotary surface grinder allows for high precision and quality in grinding high-carbon steel gears, making it a valuable tool for professionals in the fields of tool design, die making, and metal stamping. This concludes our discussion on slide number 4, and there is more valuable information to come in the following slides of this presentation..

[Audio] Slide number 5 out of 50 of our training on tool design, die making and metal stamping focuses on the selection of tool types. Various types of tools are discussed, such as those for flatiron production, drilling, and turning. The section also covers the methods for finishing a flatiron base and the essentials of a good designer. The next topic is punches and dies, which are crucial tools in metal stamping. Understanding their functions is essential for successful tool design. This section covers different types of dies, including piercing-and-blanking dies, sub-press dies, and combination dies. Jigs and fixtures, which serve as guides and supports for the workpiece, are also important in the tool design process. In this section, we will discuss their purposes, proper relation to operations, and essentials in their design. Different devices for rapid operation, such as drilling fixtures and boring and milling jigs, are also covered. The author stresses the importance of understanding design essentials for creating effective and efficient tools. As we conclude this slide, keep in mind the crucial role of proper tool design in metal stamping. The information in this handbook will provide the necessary knowledge and skills to excel in this field. Let's continue to slide number 6 and explore more topics in this comprehensive guide..

[Audio] In this training, we will be discussing tool design, die making, and metal stamping. We will specifically focus on the contents of the handbook written by mechanical engineer and general manager Frank E. Shailor in 1917, which is designed for beginners in this field. This handbook includes valuable analysis of common problems that may be encountered in the industry. In the upcoming slides, we will delve into the topic of gages, their classification, and how to use them effectively. We will also cover the use of a bench micrometer for precision measurements. Moving on, we will shift our focus to successful designing and address the problem of the sequence of operations, the best method for holding work, and how to machine for maximum accuracy. We will also discuss key considerations in the design process, such as collaboration and observation. Part II of this training will focus on dies and sheet-metal stamping. We will explore types of blanking and shearing, as well as how to make a simple punch and die. Additionally, we will cover the size factor, the sequence of operations, and the importance of selecting the right steel for the project. Next, we will explore the preparation of a die block and the process of laying out a die. This will include discussions on shaping, hardening, and finishing a die, as well as the components of a punch. We will also touch on the use of a die shoe and sub-press dies, and their typical features. We will then move on to the creation of a press body, a plunger, and small parts. We will also discuss the use of special cutters and how to fit piercing punches and dies. This section will also cover the placement of round holes and the assembly of parts. Lastly, we will discuss the advantages of sectional dies and their assembly, as well as the importance of precision in creating these types of dies. We hope this training on tool design, die making, and metal stamping will be helpful to you in your journey to become a successful and efficient tool designer..

[Audio] In this segment, we will be discussing various types of dies and their construction. A die is a specialized tool used in metalworking to shape and cut materials. In the sixth section of this handbook, we will explore the contents and construction requirements of different types of dies. First, we will look at shaping dies, which have specific requirements for proper functionality. Next is the making of dies, where we will delve into the steps involved in creating a die from scratch. We will also cover the process of attaching piercing punches and creating a blanking punch for cutting. Moving on to gang dies used for mass production, we will discuss the approved method of making them and achieving precision in their production. Shearing dies, used for cutting metal sheets, require a two-punch principle for efficiency and we will also explore the making of lower and upper punches as well as the process of drawing and forming. In the next section, we will look at drawing dies and the importance of determining the size of the blank before creating the die. We will also discuss different types of drawing dies and the making of combination type dies. Forming dies are used for shaping materials and we will discuss the method for making them. Embossing dies are used for creating raised designs on metal surfaces and we will touch upon the method of die sinking for intricate designs. In addition, we will explore the usage and operation of fluid dies and their substitute processes. Moving on, we will discuss the process of forming a die and the importance of cutting designs for efficient operation. Drop-forging dies and methods for saving material during their production will also be covered. Finally, we will talk about the shaping of die blocks and the process of recessing the d..

[Audio] Today, we will be discussing slide number 8, which features the INGERSOLL 72-INCH FOUR-HEAD MILLING MACHINE. This machine, provided by the Ingersoll Milling Machine Company, is located in Rockford, Illinois. The machine is used for milling heavy castings, utilizing various tools and techniques to shape and manipulate metal materials. This is a common practice in fields such as tool design, die making, and metal stamping. The INGERSOLL 72-INCH FOUR-HEAD MILLING MACHINE is a powerful tool that can help achieve desired results. However, as with any tool, there may be common problems that may arise while using it. This is why we have a handbook written by mechanical engineer and general manager, Frank E. Shailor, in 1917. This provides valuable analysis of common issues and solutions to overcome them. As beginners, it is crucial to be familiar with this machine and its capabilities. By understanding its uses and potential challenges, we can effectively use it in our work. The INGERSOLL 72-INCH FOUR-HEAD MILLING MACHINE is just one of the many tools at your disposal. Keep learning and exploring, and you will become an expert in no time. That's all for slide number 8..

[Audio] This presentation will discuss tools design, die making, and metal stamping, with a focus on the salient features of modern tool designs for jigs, fixtures, punches, and dies. The main objective of these tools is to ensure accurate and efficient production of various products, though the methods and accuracy requirements may vary depending on the specific product. For instance, the tools used for manufacturing harvesting machinery will differ from those used for watches. Therefore, it is crucial for designers and engineers to thoroughly study the designs and reasons for using specific tools for certain operations in order to select the most appropriate tool for the intended product. It is important to understand the differences between jigs and punches and dies when selecting specific tools. For example, in the production of an electric flatiron, we would require tools such as blanking dies, drawing dies, forming dies, drill jigs, tapping fixtures, and milling fixtures. The decision on which tools to use is based on the production basis, which refers to the number of products that need to be manufactured per year. This production basis significantly influences the design of the tools. For instance, a production basis of 150000 units will result in more expensive but more efficient and economical tools. In conclusion, this presentation serves as a useful handbook for those new to tool design, providing insights on the various types of tools and their purposes. Written by mechanical engineer and general manager Frank E. Shailor in 1917, it will offer valuable insights on the proper selection and design of tools for successful manufacturing. Thank you for watching..

[Audio] Today we will discuss four methods of tool design for beginners: turning, planing, grinding, and milling. Each method has its own advantages and qualifications. Turning involves using a lathe to turn surfaces, but can be slow and produce poor surface quality, making it costly. Planing requires creating two fixtures for holding bases and reloading one while the other cuts, but is not commonly found in manufacturing departments and may not produce desired surface quality. Grinding, like turning, also involves waiting for the cut to be completed and requires multiple cuts, increasing the risk of breakage. Milling, on the other hand, offers multiple cutting points and the ability to set and lock the cutter to a specific depth, ensuring all bases are made to the same specifications. It is the most efficient and effective method for tool design. In conclusion, milling is the ideal method for tool design as it saves time and produces the best results. Thank you for joining our discussion on tool design methods..

[Audio] Slide number 11 of our training video focuses on milling fixtures and their various types. Deciding on the type and size of the milling cutter is crucial in determining the necessary fixture. For a plain milling machine, we recommend using two fixtures—one for loading and unloading, and another for milling the bases. This allows for a speedy and efficient process. For a milling machine with a circular milling attachment, the ideal method is to use a fixture shown in Figure 3's upper view. This fixture can be easily attached and detached, resulting in a smoother and more efficient operation. One benefit of using milling fixtures is maintaining a consistent material thickness, resulting in a smoother base surface. It's important to consider your milling machine type when designing a fixture. Do thorough research and choose the most suitable option for an efficient and effective process. Thank you for learning about milling fixtures. We hope this information will aid in your tool design and metal stamping process. Next, we will discuss more aspects of tool design..

[Audio] Today, we will be discussing the important topic of tool design. In 1917, mechanical engineer and general manager, Frank E. Shailor, wrote a handbook for beginners in these fields, with an analysis of common problems. This resource is valuable for anyone entering the world of tool design. Let's take a closer look at the circular fixture in the image. This fixture constantly revolves, just like the milling cutter. It is designed to easily remove the finished base and insert a rough casting without stopping the machine. The lower illustration in Fig. 3 shows the jigs used by the Becker Milling Machine Company, highlighting the importance of efficient and seamless tool design in the production process. Efficient and well-designed tools are crucial in manufacturing for continuous operation and efficient material handling. By following the guidelines outlined in this handbook and paying attention to details such as fixture design and tool placement, a smoother and more efficient production process can be achieved. Thank you for joining us for this discussion on tool design. Stay tuned for our next slide as we continue to explore important concepts in the world of tool design, die making, and metal stamping..

[Audio] This training video is aimed at beginners in the areas of tool design, die making, and metal stamping. Today's focus will be on the significance of speed and accuracy in tool design, as well as the use and design of milling fixtures and drill jigs. Slide 13 out of 50 is the topic of our presentation, titled "Tool Design: A Beginner's Handbook" by Frank E. Shailor, a mechanical engineer and general manager, published in 1917. As a designer, it is crucial to prioritize speed and accuracy throughout the design process, particularly when selecting bases and holding devices. Using continuous reasoning, we can ensure maximum efficiency and productivity. These methods are applicable to most flat work that requires surfacing, regardless of the type of surface. Moving on, the next step is to drill two holes after milling the top and bottom of the base. To achieve this efficiently, a drill jig will be used. In the subsequent section on Jigs and Fixtures, we will explore various types of jigs. The most practical choice is the open box jig, depicted in figure 64. This can be used with a multiple-spindle drill press, allowing for faster operation without the need for clamps or screws. To further enhance productivity, the base is placed on round cross-rods to prevent chip interference and eliminate the need for constant cleaning and adjustments. In the next section, we will discuss different designs of milling fixtures and their uses. To achieve successful tool design, it is essential to balance speed and accuracy in all aspects. Thank you for watching and I will see you in the next slide..

[Audio] In this session, we will focus on beginner tool design, specifically in the areas of die making and metal stamping. We will analyze a text from 1917 by mechanical engineer and general manager Frank E. Shailor, which addresses common problems in this field. Our emphasis will be on slide 14 out of 50, which introduces the concept of tool design and its ability to eliminate the need for cleaning after each drilling operation. This method is not possible with other types of jigs. It is important to note that this type of jig is only effective when all holes are drilled at the same time, preventing the work from shifting. However, there may be a slight variation of 0.002 inch between the holes and the edge of the work, resulting in less accuracy. If this level of accuracy is not necessary for a particular project, it may be more cost-effective to use V-spots in the pattern and drill the castings from those spots, eliminating the need for jigs. This should be the preferred method whenever possible. Moving on to the pressure plate, labeled "b" in Fig. 2, we see that it is machine drilled using the same jigs and fixtures as the base. If necessary, we may need to design and make additional holding fixtures and stops for successful machining. Next, we have the special bolt, labeled "e" in Fig. 2. This bolt requires special attention and design for manufacturing. It can be made on an automatic or hand-screw machine, starting with a hex rod turned to the size of the screw (inch in this case) from the end as shown at "a" in Fig. 4. It is important to avoid using a crossbar tool (b in Fig. 4), as the corners of the hex rod may cause it to jump and result in inconsistent diameters. This is also why it is difficult to maintain uniform diameters when using a crossbar tool, as the rod may spring during machining. Lastly, we have the flatiron handle bracket, labeled "d" in Fig. 2. This part is made from sheet steel and before the use of jigs and fixtures, it was difficult to achieve precise measurements..

[Audio] Today's topic is tool design and die making, specifically focusing on the different types of dies and their applications. Our presentation will cover various types of dies and their pros and cons in producing the bracket shown on slide 6. Slide 15 features five different types of dies that could be utilized to produce the bracket. The first type, the plain blanking die shown in slide 16, only produces a blank as seen on slide 5 and would require a separate process for piercing holes. This can be time-consuming and may lead to errors in the final product. Slide 18 showcases the punch and die, also known as a follow die, which has the ability to both pierce and blank the holes in one stroke, as seen on slide 5. However, there is a possibility of errors as the holes may not be accurately located due to the strip stock not lying level on the die's surface. The subpress die shown in slide 21 is the most precise and produces high-quality products, but it comes with a higher initial cost. Finally, we have the punch and die shown in slide 22, which is our recommended choice for producing the bracket. This type of die allows for the formation of the L-shaped bracket with a rib between the two holes, as seen in slide 2. It also has the advantage of punching away the surrounding stock, leaving the blank on the strip as shown in slides 6 and 23. In conclusion, for accurate and efficient production of the bracket shown on slide 6, we recommend using the punch and die shown in slide 22 due to its ability to produce high-quality products and reduce the risk of errors. Thank you for joining me in this discussion on tool design and die making..

[Audio] The sixteenth slide of our training video on tool design, die making, and metal stamping focuses on the important topic of tool design. We will first examine the plain blanking punch and die, shown in Figure 16, which should be avoided due to the need for multiple operations and presses, resulting in time and cost inefficiency. The combination tool, shown in Figure 18, and the subpress, shown in Figure 21, should also be avoided as they can lead to difficulties in maintaining proper center distance between holes and require additional operations and presses. Instead, we recommend using the punch and die shown in Figures 22 and 23, which only require one operator and one press and can produce a complete bracket with each stroke. However, it is important to note that this tool is only suitable for slight variations of 0.005 to 0.010 inches. Then, we discuss the process of pressing a flatiron top, illustrated in Figure 2 as sheet steel, which involves multiple dies such as blanking, drawing, redrawing, trimming, and forming dies. It is a challenging task, but with proper techniques and tools, it can be successfully accomplished. For more detailed information, refer to the handbook written by mechanical engineer and general manager, Frank E. Shailor in 1917. This concludes our discussion on tool design. Next, we will cover die making. Thank you for your attention..

[Audio] This slide delves into the process of finding the blank in tool design, as explained in Frank E. Shailor's handbook for beginners in this field. It is necessary for the designer to collaborate with the tool-makers in order to determine the appropriate blank for the drawing dies, also known as the "shop expression". This involves cutting two steel pieces into a specific shape, labeled A and A, and testing them in the drawing punches and dies. If the resulting blank is not satisfactory, the process is repeated with new blanks labeled B and B until the desired shape is achieved. The chosen blank then becomes the blanking die. This trial and error approach allows the designer to accurately determine the shape and thickness of the blank needed for the final product. Another important step in the tool design process is the use of a trimming die to refine the edges of the cup after it has been partially drawn. By continuously working with the tool-makers and utilizing trial and error methods, the designer can successfully produce high-quality products. Stay tuned for more valuable information in the remaining slides..

[Audio] This slide discusses the process of trimming and redrawing cups using specially designed punches and dies. These tools are similar to a plain blanking punch and die, but are specifically made for this operation. Figures 8 and 9 show how the punch and die securely hold the cup in place during trimming. The punch is attached to the die shoe, which is then fixed onto the bolster on the press bed. This allows for accurate trimming and shaping of the cup. The punch's top section acts as a locator, ensuring consistent and precise trimming. The locator is detachable, making it easier to grind the punch's top face. After trimming, the edges of the cup are squared and the margin is uniform, resulting in a cleaner and more precise finished product. The cup then moves to the redrawing die, shown in Figure 10, which creates a final cup with straight and parallel edges. During the upward stroke, the punch is held in place by cap screws, preventing the blank from getting stuck on the corners and potentially damaging the tools. In conclusion, successful trimming and redrawing of cups requires well-designed punches and dies, ensuring a high-quality finished product. Thank you for watching and stay tuned for the next slide..

[Audio] This training video covers slide number 19 out of 50, which focuses on extruding in tool design. When designing drawing dies for producing portions bulged from the central part of a cup, it is important to design a preparatory drawing die. This die will push out a surplus amount of stock in an easy-to-draw shape, as shown in section a, Fig. 11. This helps prevent tearing due to stretching and sharp corners during extrusion. The extruded metal in the center of a sheet causes stretching, so it is necessary to have a sufficient or surplus amount of stock pushed out. The final shape can then be achieved using the forming punch and die, seen in Fig. 12. This also helps smooth out any wrinkles or surplus stock caused during the preparatory bulging or drawing of the cup. The die in Fig. 12 is made in the desired shape, with the punch in the same shape but smaller. The metal to be formed needs to be between the punch and die. The extruded portion g, Fig. 2, must also be pierced with a small hole before its final drawing, as shown in a, Fig. 13. To streamline the process, the piercing die can be incorporated into the same die used to finish the part, as in Fig. 12. It is important to note that if the extruded portion g, Fig. 2, is pierced while the top of the cup is flat, there is a higher risk of cracks when drawn to the final shape, as seen in b, Fig. 13. Be sure to stay tuned for the next slide in our presentation..

[Audio] In this slide, we will discuss the importance of using a sizing punch and die in the final drawing operation on a flatiron top. This punch and die, shown in Fig. 14, allows for the simultaneous piercing of two holes with uniform center distances. A jig may seem like a tempting option for this operation, however, using a piercing die has several advantages. Using a piercing die ensures precise center distances between holes that may not be achievable with drilling each hole individually. It also avoids the problem of irregular holes when drilling thin stock, as the drill point may break through the sheet before fully piercing through. With a piercing die, there is also no risk of burrs protruding from the bottom edge of the hole, as can occur with drilling. Additionally, using a punching die allows for greater control over the size and shape of the hole, as opposed to the potential variation when drilling with different sized bushings or jigs. Therefore, utilizing a sizing punch and die for the final operation on the flatiron top guarantees precision and uniformity, and avoids common problems that may arise when drilling thin stock. Next, we will discuss the benefits of using a piercing die for the final operation. Thank you for listening..

[Audio] We are now on slide number 21 where we will be discussing the different types of tools and the requisites of a designer. As a designer, it is important to carefully consider the advantages of various tools before making a decision on which one to use for a specific operation. In some cases, a less commonly used tool may be the best choice for a certain type of work. The designer must also have extensive knowledge of various tool designs and the ability to create original tools for specific operations. Moving on to our next topic, we will discuss punches and dies. One type of die that we will focus on is the blanking die, used to punch out initial plain blanks from sheet stock. The piercing-and-blanking die, also known as cut and follow or combination die, is suitable for certain operations. As a designer, it is important to have a thorough understanding of all types of tools and the ability to come up with original designs for specific operations. This concludes our discussion for slide number 21. We will now move on to the next slide.".

[Audio] We will now discuss the causes of inaccuracy in tool design, die making, and metal stamping, and how to improve accuracy in our designs and productions. Let's examine Fig. 16, which displays a typical blanking die. The curvature of the sheet can lead to varying distances between pierced holes, and the use of pilots for positioning can also cause variations in direction. When straightening curved or kinked stock, the blanking punch can result in distorted and uneven holes. This type of die is best for work that does not require high accuracy, with a precision of 0.005 inch. Moving on to Fig. 19, we see the same die design with a spring stripper attached to the punch plate. While this helps to straighten the stock, accuracy is still limited to around 0.003 inch. For blanks over 2 inches long, it is recommended to use hardened bushings as shown in Fig. 20, which utilize hardened and tool steel for the blanking section while maintaining the pierce section. In the upcoming slide, we will discuss the use of hardened inserts for even greater accuracy in our die designs..

[Audio] In this lesson, we will be discussing the benefits of using hardened steel and bushed holes in tool design, specifically focusing on slide number 23 of our presentation. Tool design is an essential skill for those working in the fields of die making and metal stamping, as emphasized by mechanical engineer and general manager Frank E. Shailor in 1917. The use of hardened steel and bushed holes in tool design offers several advantages, such as cost-effectiveness and consistent center distances. Additionally, bushings can be easily changed without the need for annealing, saving time and allowing for quick adjustment of hole sizes. It is recommended to have bushed holes in all piercing-die holes, regardless of the type of steel being used. When designing piercing punches, including heads allows for easier creation and prevents them from being pushed or pulled out of position. In conclusion, incorporating hardened steel and bushed holes in tool design can greatly improve efficiency and precision in the toolmaking process. As you continue your studies in tool design, remember these important points..

[Audio] We are currently on slide number 24 out of 50 in our presentation on tool design, die making, and metal stamping. This slide will focus on the use of subpress dies. A subpress die, illustrated in Fig. 21, is the most accurate type of die in the blanking category. It is crucial to note that this type of die should only be used for tasks that require extreme precision. The designer should also consider the use of bushings, shown in Fig. 20, which can save significant costs in expensive steel when designing a subpress die. It is essential to avoid using a subpress die for tasks that do not require extreme accuracy, as well as avoiding a piercing-and-blanking die when precision in the blank is necessary. Mechanical engineer and general manager, Frank E. Shailor, highlights the importance of carefully selecting the appropriate die for each specific job in his 1917 handbook for beginners in this field. So, remember, when it comes to subpress dies, accuracy is key. Thank you for listening and stay tuned for the rest of our presentation..

[Audio] In this section, we will be discussing important considerations for designing subpress dies. It is crucial to ensure that the die has necessary rigidity in all its components, particularly the guide pins. If a significant amount of work will be done with subpress dies, it is recommended to use a casting pattern for the bodies and base. Three commonly used styles of subpress dies are shown in Figs. 380, 381, and 382 in Tool-Making, Part III. Moving on to a unique type of die known as a combination die, which is composed of multiple punches rather than a single die, as seen in Fig. 22. Unlike other dies, this die punches away the stock and leaves the blank on the strip, making it easier to handle for subsequent operations. Fig. 23 elaborates on this die, showing how it can produce a blank's profile, pierce holes, cut the blank, and final-form it to an L-shape in one press stroke. However, it is crucial to secure the strip in place with a suitable method for this process to work successfully. Next, we will discuss the importance of proper die maintenance for optimal performance. Stay tuned for slide number 26..

[Audio] This slide discusses the topic of tool design, a crucial aspect in the fields of tool design, die making, and metal stamping. In 1917, mechanical engineer and general manager Frank E. Shailor published a comprehensive handbook for beginners. The image on the slide shows a combination die, with the upper member responsible for bending and the lower member guiding the die shoe. The cut-off punch separates the material into the desired shape, followed by the forming punch to shape it into its final form. The blanking punch removes excess material, and the final forming punch gives the material its finishing touches. The side view of the lower member shows the progressive steps in forming the finished blank, highlighting the precision and accuracy involved in the tool design process. Understanding the different components and steps involved is crucial in creating high-quality tools for various industries. The next slide will further discuss this topic..

[Audio] Today we will be discussing slide number 27 which focuses on the topic of drawing and forming in tool design, die making, and metal stamping. Designing drawing dies offers endless possibilities, with the potential for cross-slides for bending and even a tapping fixture for additional operations. The tapping fixture, powered by gears driven by a rack attached to the punch plate, allows for multiple operations to be completed in one press stroke. Slide number 28 showcases a specific design of a tapping fixture for punching and die operations, with a vertical shaft containing a long key that rotates the tap shaft driven by a bevel gear. Let's now move on to discussing the various types of drawing dies. A simple drawing die, also known as a shallow cup die, is specifically designed for producing shallow cups as shown in slide number 29. The main difference between this type of punch and die and a plain blanking die is the size of the punch, which is smaller by twice the thickness of the stock to be drawn, and has sharp corners to assist in the drawing operation. Stay tuned for our next segment on advanced drawing die designs and join us on slide number 30..

[Audio] This training video focuses on tool design, die making, and metal stamping. We will discuss the different types of cups formed by drawing dies and design considerations for these dies. Slide number 28 shows a drawing die in Fig. 28 that enables the stock to transition from a flat state to a cup shape without scratching the blank. However, it is important to note that this design requires another die to punch out the blanks, as shown in Fig. 27. This type of die is not efficient for producing large quantities of cups and should only be used for small quantities. Fig. 29 introduces another type of drawing die, as shown in its simplest form in Fig. 30, which also requires pre-punched blanks. It is important to keep in mind that this type of die should not be used for rapid production or high-quality results. Next, we will discuss combination blanking and drawing dies, which combine two types of dies. As a designer, you must consider the limitations of the presses in use. Fig. 31 shows a die designed for a specific press, emphasizing the importance of understanding press function and limitations when designing these dies. This concludes the section on drawing dies. I hope this information has been useful and aids in your own designs. We will continue with further in-depth discussions on tool design in the next section..

[Audio] In this presentation on tool design, die making, and metal stamping, we will be focusing on the single-action press, also known as the crank press, and how it is used in the metal stamping process. The single-action press was first discussed in the early 1900s by mechanical engineer and general manager Frank E. Shailor in his handbook for beginners in this field. This handbook has been a valuable resource for those in the industry. Let's examine the single-action press further. It has only one crank on the drive shaft with a driving rod that activates the ram, resulting in only one action. Moving on, in Fig. 31, we can see a drawing die with a spring stripper. This die can produce various cups and has the advantage of being able to punch out its own blank and draw it to a cup with every press stroke. However, this die is more complex and may require a greater level of skill and knowledge to operate and maintain. And that concludes our discussion on the single-action press and the drawing die. Thank you for watching and continue learning in the rest of our presentation. See you on slide number 30!.

[Audio] Welcome back to our training video on tool design, die making, and metal stamping. In this lesson, we will be discussing the design and operation of a specific type of die known as a blanking and drawing die. This type of die is typically used when working with a single-action punch press, in order to achieve rapid production. The design of the die is crucial in ensuring efficient and effective operation. During operation, the blanking punch cuts out the blank while the lower stripper pinches the blank between its angular faces and the blanking punch. As the punch continues to descend, the lower stripper also descends and the forming punch pushes the blank up into the drawing die, which is a recess in the blanking punch. The stroke of the ram is carefully adjusted so that at the extreme point of the downward stroke, the forming punch presses the blank firmly against the face of the upper stripper, while the back face of the stripper presses firmly against the bottom of the recess. As the ram ascends, the lower stripper moves along with the blanking punch, thanks to the heavy springs that actuate it. This allows for a smooth and efficient operation of the forming punch and the cup against the upper stripper. Thank you for watching this lesson on blanking and drawing dies. Stay tuned for more information on other types of dies and their design and operation. See you in the next lesson!.

[Audio] Today's discussion will focus on tool design for beginners in the fields of tool design, die making, and metal stamping. The handbook, written by mechanical engineer and general manager Frank E. Shailor in 1917, offers valuable analysis of common problems. Our attention will now turn to slide number 31, which delves into the design of blanking-and-drawing dies for a single-action press. The diagram illustrates how the blanking punch and forming punch work together to form a cup shape from a flat sheet of material. In this design, the lower stripper serves a dual purpose by stripping the cup from the forming punch and pressing the stock against the angular face of the blanking punch to prevent wrinkling. This is a crucial step, as without pressure on the flat blank, it would wrinkle during the transition to the cup shape. Therefore, the designer must incorporate powerful springs to maintain pressure on the stock and prevent wrinkling. As the ram reaches the end, the spring pressure is crucial in maintaining the desired cup shape..

[Audio] Slide number 32 of our presentation on tool design, die making, and metal stamping will focus on the importance of selecting the right type of press for production needs. The double-action press, as shown in Fig. 34, has two strokes and three cranks or eccentrics. The two end cranks are connected to the large ram, while the central crank is connected to the smaller ram, allowing for simultaneous blanking and drawing of cups. The shape of the drawing punch determines the shape of the cup's bottom, and plans should include notes for polished corners on the drawing die and sides of the drawing punch. This coordination between the designer and toolmakers is crucial for efficient and effective production. By understanding the different types of presses and their impact on production, the designer can select and fit the die to the press for the most rapid production. In the next slide, we will continue our discussion on tool design and the importance of communication between the designer and toolmakers..

[Audio] We are now on slide 33 where we will be discussing tool design. Tool design is a crucial aspect in the fields of tool design, die making, and metal stamping. This slide will focus on the punch and die design for producing the cups shown in Fig. 27. The ideal die for this task is the one shown in Fig. 34, as it is simple, fast, and allows for the blanks to be pushed all the way through, as shown in Fig. 33. However, the double-action type of die may not offer any significant advantages for this specific cup design compared to a single-action press, as seen in Fig. 31. It is important to carefully analyze the task and choose the appropriate die design for optimal results, as the efficiency and effectiveness of punch and die designs can vary depending on the specific task. This text, written by mechanical engineer and general manager Frank E. Shailor in 1917, provides a comprehensive overview and analysis of common problems in tool design for beginners. Our discussion on this topic will continue on the next slide..

[Audio] Slide number 34 of our training video on the basics of tool design, die making, and metal stamping discusses the concept of deep drawing dies and its necessary components for success. The information is taken from a 1917 handbook written by mechanical engineer and general manager Frank E. Shailor. The diagram in this slide shows a deeper cup produced in a deep drawing die, which is used for creating long shells or deep cups. This type of die is also known as a redrawing die because the shell in Figure 37 cannot be produced in one single operation. This is due to the diameter of the drawing punch being too small compared to the size of the cup, which would cause the punch to push through the blank. In simpler terms, the force required to transform a large blank into a long, slender tube in one stroke is more than what is needed to push the punch through the stock. To produce the desired shell, a series of redrawing dies, such as the one shown in Figure 38, is necessary. This is best understood by looking at the successive drawing operations indicated in Figure 39. As a cup goes through multiple drawing operations, the stock inside the cup becomes very hard and therefore, the cups must be annealed (heat-treated) before further drawing. The deeper the cup, the more draws and annealing operations will be required. This is why it is crucial to design the dies for these successive operations, as shown by the dotted lines in Figure 39. In addition, the dies should also have a plunger that is actuated by a powerful spring to ensure the cup is forced from the die, and a close-fitting stripper surrounding the punch to properly remove the cup from the die and minimize any potential issues. This informative segment on deep drawing dies has given a better understanding of the process and the necessary components for successful production. Stay tuned for the next slide where we will be discussing another important aspect of tool design..

[Audio] This section discusses the tool design for a double-action press and the importance of a proper stripper for the punch. The stripper for the punch should be positioned high enough from the die to allow for easy removal of the blank. This is necessary for efficient and smooth operation of the press, as well as to prevent damage to the tools. A double-action press from Waterbury-Farrel Foundry and Machine Company is shown in Fig. 35, demonstrating the importance of a proper stripper. Without the correct height, the blank would not be able to be removed easily, resulting in production delays and potential damage to the tools. In addition, the thickness of the stock being punched also has an impact on the final product. Thicker stock can result in ragged edges on the blank and in the hole. To avoid this, careful consideration of the type of die and the materials and thickness of the stock is essential. This will ensure clean and precise cuts, leading to a high-quality final product. In summary, the correct stripper design is crucial for efficient and high-quality production in tool design, die making, and metal stamping. Thank you for your attention and we will proceed to the next slide..

[Audio] In this video, we will discuss the world of tool design, die making, and metal stamping with a focus on common problems and solutions. We will be covering the importance of precision in punching and finishing blanks on slide 36 out of 50. As mentioned before, when working with small parts like cams, levers, eccentrics, or components for typewriters, adding machines, and cash registers, precision is crucial. These parts must have smooth and accurate actions, requiring a clean and precise edge. To achieve this, we use a shaving die, seen in its simplest form in figure 42. This die is designed to finish the blank and leave a smooth edge with a tolerance of a few thousandths. This precision is crucial, as seen with the eccentric washer in figure 43, where the outer edge must be perfectly smooth for proper functioning. When working with deep drawing blanks, precision is equally important. The blanks, as shown in figure 37, are often tapered and irregular in shape after being punched. To achieve the desired size and shape, we use a series of redrawing dies, as seen in figure 38. These dies gradually reshape the blank to its final shape and size. To sum it up, precision is essential in punching and finishing blanks to achieve smooth and accurate parts. By using techniques like shaving and redrawing dies, we can ensure the proper functioning of small parts. Thank you for watching and we will continue our exploration of tool design, die making, and metal stamping in the upcoming slides..

[Audio] Today, we will be discussing slide number 37 in our presentation "A Handbook for Beginners in Tool Design, Die Making, and Metal Stamping". This slide focuses on tool design and the importance of using a subpress die for consistently producing blanks. As seen in Fig. 21, a subpress die is specifically designed to ensure proper alignment between the punch and die. Unlike blanking dies, shaving dies do not require clearance and should have a close fit between the two components. It is recommended to use subpress construction for shaving dies in order to achieve this close fit. In addition, these dies can be equipped with a close-fitting spring stripper (shown in Fig. 42) or the blanks can be pushed through the die. When creating a shaving die, it is crucial to maintain a depth of 1 inch and ensure adequate lubrication to prevent any issues. Thank you for tuning in, I hope this information was beneficial to you..

[Audio] In this section, we will be discussing different types of dies and their uses in the manufacturing process. One commonly used die is the shaving die, which produces a highly polished edge on a blank. It is important to keep the shaving die in mind when designing a tool. Another type of die is the embossing die, used to create designs on metal. It is best to use a drop press for heavier embossing, or a stripper design on a punch press to prevent damage. In some cases, a punch press may be necessary for embossing, but there is a risk of springing the shaft. In these situations, it is better to use a die design instead of a direct blow. The last type of die is the extruding die, which forces metal through a small opening to create a longer and thinner shape. This is similar to pushing a lead pencil through a cartridge filled with butter. We hope this information on different types of dies will be useful to you in your future tool design and manufacturing endeavors..

[Audio] We will now discuss the various types of extruding dies and their operations. These dies are commonly used for making small eyelets, hollow rivets, and thin tubes. Figures 46 and 47 demonstrate how these dies are designed to allow for one-directional metal flow, requiring slow press movement. Hydraulic presses are often used for this type of work. Using a punch press at high speeds can cause the press's shaft to break. Figure 46 shows another type of extrusion work for creating tapped holes in thin stock. This is commonly paired with a forming die, shown in figure 46b. We also have the shaving die, seen in figure 42, and the forming die, shown in figure 48. The forming die can be incorporated into other dies for piercing, cutting, and straight edges, as shown in figure 49a. This allows for easily creating desired shapes with purchased stock. Finally, figure 44 demonstrates the process of embossing, used to create raised or recessed designs on metal surfaces. Thank you for watching this segment on extruding dies and we hope it was informative for your tool design understanding. Please continue watching for the remaining slides..

[Audio] We are now on slide number 40 out of 50 in our presentation on the handbook for beginners in tool design, die making, and metal stamping by Frank E. Shailor. On this slide, we will be discussing a common problem in tool design, specifically, the design of extruding dies. Extruding dies are used to create long, continuous shapes by forcing a material through a smaller hole or opening. This process is commonly used in the manufacturing of pipes, tubes, and other hollow shapes. The design of an extruding die is a complex task that requires consideration of various factors, such as the material being used, the desired shape and size of the final product, and the available machinery and equipment. One important factor to consider is the angle of the die's opening, as it determines the flow of the material and shape of the final product. The material used for the die must also be strong and able to withstand high pressure, heat, and wear. It is important to note that there is no one-size-fits-all approach to designing an extruding die, as different industries may have different materials and processes. Each project must be carefully evaluated and a customized design must be created for the best results. In conclusion, extruding die design greatly impacts the final product and requires careful consideration. As we move on to our next slide, we will continue to explore common problems and solutions in tool design.".

[Audio] Slide number 41 focuses on the different types of dies and their operations. The first type is the washer, which uses extruding dies to form a hole in the center. Next, we have simple forming dies which can be used for various shaping and cutting processes. Lastly, there is the combination of piercing and forming dies, which allows for both punching and shaping of the material. Understanding these types of dies and their operations is essential for those in the fields of tool design, die making, and metal stamping. Having a proper understanding of these processes will result in more efficient and effective work. Finally, let's quickly review the topics covered in our final few slides..

[Audio] Today, we will be discussing the use of liquid forming in tool design for die making and metal stamping. Tool design is crucial for achieving precise and efficient results in manufacturing, as mentioned in previous slides. In slide 42, we will focus on the use of water forming in die design. This technique utilizes water to shape metal and is often used for intricate and complex designs. As seen in Fig. 51, the design for a water forming die is simple, with a stationary half and a sliding half controlled by a locked lever. This allows for easy removal of formed blanks. The process involves filling a cup, as shown in Fig. 52, with water and inserting it into the die. As the hammer falls, the punch strikes the water, forcing the metal to take the shape of the die. This method ensures that the metal is pressed into all parts of the die, resulting in detailed and precise forms. Designers can enhance this basic design by using water to create more intricate forms. In summary, liquid forming is a highly effective technique in tool design, giving designers the ability to create complex and precise forms. With proper design and execution, this method can greatly improve the quality and efficiency of the manufacturing process. We will continue to explore different tool design techniques in the upcoming slides..

[Audio] In our discussion on tool design, we will now turn our attention to slide number 43. Here, we will be discussing the crucial role of jigs and fixtures in the tool design process. These components are necessary for accurately holding and guiding the material being machined. Jigs can be used for various types of machining, including grinding, boring, turning, planing, milling, and drilling. However, when it comes to drilling fixtures, it is important to note that extreme accuracy may be difficult to achieve due to the difference between the bushing hole and the drill diameter. This difference can lead to inaccuracies in the work being performed. The simplest form of a drilling jig is shown on the slide for reference. As a tool designer, it is important to keep in mind the significance of creating foolproof jigs and fixtures. This involves incorporating precise locating points for proper positioning of the work, as well as locking devices to hold the material in place. These elements are critical in achieving accuracy and avoiding errors in the machining process. With this knowledge, we will now move on to our next topic on slide number 44, where we will discuss the advantages of utilizing jigs and fixtures in tool design..

[Audio] In this presentation, we will be discussing the importance of carefully designing jigs to minimize the personal element. Jigs are essential tools in the manufacturing process and are used to guide and hold a piece of work in position. However, if a jig relies too much on the operator's skill and attention, it can result in errors and ruined pieces. This is especially true for unskilled operators who may not have the same level of care and interest as more experienced workers. To prevent these issues, it is crucial to design jigs in a way that reduces the personal element. One effective design is the V-type jig, which features a V-shaped portion that centrally locates a round piece of work. To overcome the issue of chips sticking to the angular sides when using a lubricant, the V can be relieved as seen at point a in Figure 54. Additionally, an improved design in Figure 55 incorporates a mechanical method of locating and holding the work, eliminating the need for complicated locking or adjusting mechanisms. When designing jigs, it is important to prioritize simplicity and reliability to ensure consistently accurate results. Our exploration of tool design continues in the next slide, thank you for your attention..

[Audio] In this slide, we will be discussing the design of tools and jigs. The design of these tools is crucial for efficient and accurate production. One important aspect to consider is "foolproof" design, which minimizes room for error. When designing jigs, it's essential to keep this in mind as mistakes can result in costly errors. Another important element is the initial locating of a casting for drilling, milling, or machining. Castings can vary greatly in size and shape, making it difficult to create a universal tool. However, the spring-pump locator, shown in Fig. 56, is able to centrally locate various workpieces, providing a more adaptable solution. As shown in Figs. 57 and 58, this tool has been effective in accommodating for burrs, unequal shrinkage, and other foundry causes that can affect accuracy. The use of the spring-pump locator allows for flexible and precise designs. This concludes our discussion on tool design, but please continue to watch our presentation for more on tool design and metal stamping..

[Audio] We previously discussed the importance of designing tools in a way that ensures the proper sequence of operations for success in tool design. Now, let's take a closer look at the proper relation of operations. The first step is to ensure that the tools are designed to complete the first and most crucial operation first. For example, in a carburetor casting, the large hole is drilled and bored in the first operation and the four holes in the lugs are drilled in the second operation. This can lead to variations in castings, as seen in Figure 60. To avoid this issue, the first-operation jig should be used to drill the four holes in the lugs and locate the body. In the second operation, the jig for boring the large hole should have four pins to enter the holes in the lugs, ensuring the large core hole is central with the four holes after drilling and the four holes are central with the outside lugs. As a designer, it is crucial to prioritize designing the first operations and using the same holes as locating points in successive operations for accuracy and efficiency. With this knowledge, you are prepared to address common problems in tool design. In the remaining slides, we will discuss additional tips and best practices for beginners in the field. Let's move on to the next slide and continue learning..

[Audio] Students, today we will discuss key points to keep in mind when designing drilling jigs. These include simple operation, rounded ends for preventing chip buildup, and avoiding corners for accumulation. It is also important to use small feet at the bottom instead of a broad surface for easier clean-up. Consider the number of parts when deciding the level of complexity in the design. We will also explore devices for quick operation, such as those in Figs. 61-70, with locking mechanisms and holding methods for speed in boring, milling, and grinding fixtures. You may also encounter hinged or swinging-cover jigs, as shown in Figs. 61-62, but note that they are not suitable for precise work. We hope this lesson on designing drilling jigs has been helpful for your future projects..

[Audio] In this section, we will discuss tool design, essential for those involved in fields such as die making and metal stamping. A handbook by Frank E. Shailor, published in 1917, contains an analysis of common problems. Slide 48 will cover various types of jigs, beginning with the screw-bushing jig, shown in Fig. 63, which holds and guides the drill but can be inaccurate due to the free fit of threads on the screw bushing. Next is the hinged-cover box-drill jig, shown in Fig. 61, used for drilling holes in a box-shaped workpiece. The multi-spindle jig, shown in Fig. 64, is designed for a multi-spindle drill press and reduces the need for clamping devices. Lastly, Fig. 65 features the drilling-and-reaming jig, which allows for both drilling and reaming in one jig, increasing efficiency and accuracy. It is important to use a clearance hole or soft bushing when using a reamer to prevent wear. I hope this presentation has provided a better understanding of common types of jigs used in tool design. Good luck in your future endeavors." We will now discuss tool design, which is essential for those involved in fields such as die making and metal stamping. To provide insight into common problems, mechanical engineer and general manager Frank E. Shailor published a handbook for beginners in these fields in 1917. Slide 48 will cover different types of jigs commonly used in tool design. The first type is the screw-bushing jig, shown in Fig. 63, which acts as a guide for the drill but can be inaccurate due to the free fit of threads. Moving on to Fig. 61, we have the hinged-cover box-drill jig, used for drilling holes in a box-shaped workpiece. The multi-spindle jig, shown in Fig. 64, is designed for use with a multi-spindle drill press and reduces the need for clamping devices as all drills cut simultaneously. Lastly, Fig. 65 features the drilling-and-reaming jig, which allows for both drilling and reaming without removing the drill bushing, increasing efficiency and accuracy. It is important to note that when using a reamer, a clearance hole or soft bushing should be used to prevent wear on the hardened bushing. I hope this presentation has provided a better understanding of commonly used jigs in tool design. Good luck in your future endeavors..

[Audio] This training video will cover tool design, die making, and metal stamping with a focus on indexing techniques. Slide number 49 discusses the indexing jig shown in Figure 66, which is used to accurately drill multiple holes in circular patterns. This method is more precise than the alternative shown in Figure 67. By using an indexing plate with a larger diameter, any discrepancies in the notches on the edge will be reduced to a 1:6 ratio, making them negligible. To better understand this concept, think of the difference in travel between the rim and the hub of a wagon wheel. Moving on to Figure 63, we see a drill jig with a screw bushing. It's important to note that there are not the only designs that can be used. As a beginner, it's crucial to become familiar with the principles of jig design, including locking devices and locating methods. Incorporating multiple principles in a jig design can lead to greater efficiency. One example of this is using slip bushings, shown in Figure 69, for reaming, counterboring, or tapping operations without removing the work from the jig. This concludes our discussion on indexing and jig design. We hope this has been helpful in navigating the world of tool design and metal stamping. Stay tuned for a final slide on jig design principles..

[Audio] We have reached the conclusion of our presentation and we hope you have gained a comprehensive understanding of tool design, die making, and metal stamping, as well as the common challenges that may arise in these areas. As demonstrated in the previous slides, there are various types of jigs and fixtures that can be utilized, each with their own benefits and specific uses. It is crucial to carefully consider the design and arrangement of these tools to achieve maximum efficiency and precision in your production process. Thank you for taking the time to watch this training video. We trust that the knowledge and techniques shared in this presentation will be valuable to you in your role as a tool designer, die maker, or metal stamper. Thank you again for your attention and we wish you success in your future endeavors. Best of luck!.