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Unit One The Die and Mold Materials and Heat Treatment1

1.1 Abstract1

1.2 Die and Mold Materials1

1.2.1 Carbon Steels1

1.2.2 Alloy Steels2

1.2.3 Die and Mold Steels3

1.2.4 Selection of Typical Mold Steels4

1.3 Heat Treatment of Die and Mold Materials5

1.3.1 The Purposes of Heat Treatment5

1.3.2 Types of Heat Treatment5

New Words and Expressions7

Glossary of Terms9

Notes11

Questions11

Unit Two Die Design13

2.1 Abstract13

2.2 Sheet Metal Forming13

2.2.1 Deformation Modes in Sheet Forming13

2.2.2 Characteristics of Sheet-Metal Forming Processes15

2.3 Piercing Die16

2.3.1 Piercing Die Processes16

2.3.2 Piercing Die Design16

2.4 Blanking Die Design18

2.4.1 Shearing Action in Die Cutting Operations18

2.4.2 Center of Pressure19

2.4.3 Clearances19

2.4.4 Blanking Die Design20

2.4.5 Definition of Various Shearing Operations21

2.5 Bending Die Design22

2.6 Drawing Die Design25

2.6.1 Drawing Die25

2.6.2 Drawing Die Design27

2.7 Compound Die Design29

New Words and Expressions31

Glossary of Terms35

Notes38

Questions40

Unit Three The Plastic Mold Design41

3.1 Abstract41

3.2 Plastics41

3.2.1 Classification of Plastics42

3.2.2 Properties of Plastics42

3.2.3 Filler of Plastics43

3.3 Plastic Material Molding43

3.3.1 Compression Molding44

3.3.2 Transfer Molding45

3.3.3 Injection Molding45

3.4 Thermoplastic Mold Design47

3.5 Thermosetting Mold Design48

New Words and Expressions49

Glossary of Terms53

Notes55

Questions58

Unit Four The Parts for Dies and Molds59

4.1 Abstract59

4.2 Die Parts59

4.2.1 Stock Stops59

4.2.2 Pilots61

4.2.3 Strippers63

4.2.4 Knockout Bars64

4.2.5 Standard Die Base64

4.3 Plastic Injection Mold Parts65

4.3.1 Plastic Injection Mold Parts65

4.3.2 Design Guides for the Part to Be Molded67

4.4 Pressure Die-Casting Die Parts68

4.4.1 The Assembly of Pressure Die-Casting Dies68

4.4.2 The Die Insert68

4.5 Trouble-shooting Guide for Thermoplastic Part Defects71

4.5.1 Sink Marks71

4.5.2 Burnt Streaks/Brown Marks/Silver Streaks72

4.5.3 Weld Line/Meld Lines72

4.5.4 Jetting73

4.5.5 Air Streaks/Air Hooks74

4.6 Trouble-shooting Guide for Thermosetting Part Defects75

4.6.1 Blisters75

4.6.2 Cracks77

4.6.3 White Marks79

4.6.4 Porosity79

4.6.5 Orange Rind81

New Words and Expressions82

Glossary of Terms85

Notes87

Questions88

Unit Five The Forming and Molding Equipment90

5.1 Abstract90

5.2 The Forming Equipment90

5.2.1 Press Types91

5.2.2 Main Components of a Press94

5.3 The Molding Equipment94

5.3.1 The Injection-molding Machine94

5.3.2 Components of Injection-molding Machine97

5.3.3 Types of Injection-molding100

5.3.4 The Injection-molding Products&i1

5.3.5 The Economics of Injection-molding Products102

5.4 The Specification of Equipment103

5.4.1 The Specifications of Press103

5.4.2 The Specifications of Injection-molding Machine105

New Words and Expressions107

Glossary of Terms111

Notes116

Questions117

Unit Six CNC Manufacturing and Programming119

6.1 Abstract119

6.2 Applications of CNC Machines119

6.2.1 Definition of NC/CNC Machines119

6.2.2 Classification of CNC Machines120

6.2.3 The Applications of NC/CNC120

6.2.4 Types of CNC Equipment121

6.2.5 Control System for Controlling Tool Feed122

6.2.6 Type of System Control for Tool Movements123

6.3 CNC Machining Centers124

6.4 The Advantages and Disadvantages of CNC Machines125

6.4.1 The Advantages of CNC Machines125

6.4.2 The Disadvantages of CNC Machines125

6.5 The Operation Panel of CNC Machines125

6.6 Coordinate System of CNC Machines131

6.7 The Components of CNC Machines135

6.7.1 The Construction of CNC Machines135

6.7.2 The Components of CNC Machines136

6.8 NC Programming138

6.8.1 Basic Requirement of NC Machine Control138

6.8.2 Setup Procedure140

6.8.3 Debugging the Program141

6.8.4 Manual Part Programming142

6.8.5 Computer-aided Part Programming145

6.9 Main Specification of CNC Machining Centers146

6.10 Electrochemical Machines149

6.11 Electro-discharge Machines150

New Words and Expressions152

Glossary of Terms156

Notes161

Questions164

Unit Seven CAD/CAM/CAE/CAPP166

7.1 Abstract166

7.2 Historical Development of CAD/CAM166

7.3 CAD/CAM167

7.4 The Applications of CAD/CAM171

7.4.1 The Application in Computer-aided Die Design171

7.4.2 The Application of CAD/CAM in Injection Mold173

7.4.3 Animation and CAD/CAM173

7.4.4 Computer Integrated Manufacturing173

7.4.5 CIM in Making Mold174

7.4.6 Process Planning and CIM175

7.4.7 Computer-Aided Process Planning(CAPP)175

7.4.8 Manufacturing Resources Planning(MRPⅡ)and CIM176

7.4.9 Computer-aided Manufacturing178

7.4.10 Computer-aided NC Part Programming178

7.5 CAD/CAM Hardware179

7.6 CAD/CAM Software182

7.7 CAD System ExampIes183

7.7.1 Pro/Engineering184

7.7.2 AutoCAD185

7.8 CAD/CAM Selection Criteria186

7.9 CAE187

7.9.1 CAE for Polymer Processing188

7.9.2 The Applications of CAE190

New Words and Expressions193

Glossary of Terms197

Notes199

Questions201

Unit Eight Advanced Manufacturing Technology202

8.1 Abstract202

8.2 Rapid Prototyping and Manufacturing202

8.2.1 The Application Areas of RP and M203

8.2.2 Characteristics of Rapid Prototyping Technologies204

8.2.3 Subtractive Processes206

8.2.4 Additive Processes206

8.2.5 Virtual Prototyping208

8.3 Manufacturing Technology for Special-purposes208

8.3.1 Ultrasonic Machining Installations208

8.3.2 Laser Cutting Machines209

8.3.3 Electron-beam Cutting Installations209

8.3.4 Traveling-wire EDM209

8.4 Group Technology210

8.5 Flexible Manufacturing Systems211

8.6 Robotics Technology212

New Words and Expressions213

Glossary of Terms216

Notes217

Questions219

Appendix A Glossary of Terms and Abbreviations220

Appendix B Vocabulary246

参考文献272