MFG 403 - Basic Die Making Lab

1. Examine shop safety
   1. Identify common shop hazards
   2. Demonstrate safety as it applies to common shop equipment
2. Maintain all tooling and equipment (student or school property) in accordance with each individual manufacturer
   1. Perform required daily maintenance
   2. Demonstrate appropriate care and use of machines
   3. Demonstrate proper care of all inspection equipment
3. Machine Die components
   1. Saw proper materials to dimension
   2. Machine die components using mills, lathes, & grinders
   3. Drill and/or tap necessary holes in tool steel materials
4. Examine the safety concerns related to heat treating steel
   1. Explain how parts heated to1750 degrees Fahrenheit are handle safely
   2. Demonstrate the safe use of stainless steel wrap
   3. Demonstrate the safe use of a heat treating oven
5. Harden tool steel components
   1. Heat treat die components to proper hardened state as required by the die design
   2. Temper die components to relieve stress
6. Assess proper steels according to die application
   1. Determine proper steel types from blueprints
   2. Harden and temper steel according to application
   3. Test hardened components for correct Rockwell hardness
7. Critique shop work
   1. Evaluate workload and determine best time management according to machine availability
   2. Determine best method of processing die components
8. Manufacture the following single station basic dies
   1. Build a blank and shallow draw die (ashtray die)
   2. Build a pierce die (round die)
   3. Build a compound die (washer die)
   4. Build a bend die (U-bend die)
   5. Build a blank-thru die (rectangular die)
9. Assemble die components
   1. Grind die components after heat treat
   2. Lap dowel holes for doweling purposes
   3. Select proper die springs according to pressure requirements
   4. Select proper fasteners to mount die components
   5. Align punch and die contours to establish proper cutting clearance
   6. Transfer screw and dowel holes
   7. Fit punch(es) into punch plates(s)
   8. Sharpen die components
   9. Mount die members to die set
10. Assess stock strip material
    1. Locate proper sheet metal according to piece part requirements
    2. Shear sheet metal to proper width
11. Evaluate a punch press
    1. List safety rules as applied to dies and presses
    2. Identify all punch press controls and safety features
    3. Mount die into a punch press
    4. Set press shut height and knock-out system
    5. Create piece part samples from a die
    6. Trouble-shoot die(s) as required
12. Evaluate a press brake
    1. List safety rules as applied to dies and presses
    2. Identify all brake press controls and safety features
    3. Mount die into a break press
    4. Set press shut height
    5. Create piece part samples from die
    6. Trouble-shoot die(s) as required