A vise is a mechanical screw apparatus used for holding or clamping a work piece to allow work to be performed on it with tools

such as planes, saws and sandpapers. Vises usually have one fixed and another parallel jaw which is moved towards or away from the fixed jaw by the screw. A bench vise is used in mechanical work applications. The jaws are made of soft or hard metal. The vise is bolted onto the top surface of the bench with the face of the fixed jaws just forward of the front edge of the bench. The bench height should be such that the top of the vise jaws is at or just below the elbow height of the user when standing upright. The vise may include other features such as a small anvil on the back of its body.

The nut in which the screw turns may be split so that, by means of a lever, it can be removed from the screw and the screw and moveable jaw quickly slid into a suitable position at which point the nut is again closed onto the screw. The disadvantage to this system is lower precision, as compared to a solid screw system. Vise screws are usually either of an Acme thread form or a buttress thread. Those with a quick-release nut use a buttress thread. Some vises have a hydraulic or pneumatic screw, making setup not only faster, but more accurate as human error is reduced. There are two main types of jaws on engineer's vises: hard and soft. Hard jaws are available with either a coarse gripping surface or are ground flat and smooth to increase accuracy. The latter relies on pressure for gripping, instead of a rough surface. An unskilled operator has the tendency to over-tighten jaws, leading to part deformation and error in the finished work piece. Soft jaws are usually made from a soft metal (usually aluminum), plastic, or wood. They are used to either hold delicate work pieces or cut to hold specifically shaped work pieces. These specifically cut jaws are often used in place of fixtures and most commonly used in gang operations. They are also used for rapid change-over type set-ups since they can be easily engraved with the part number, the job number, or other information relevant to the job being run. Soft jaws are considered a consumable item, because they are discarded or recycled after multiple uses.

There also many types of vises in the world. There are hand vises, machine vises, compound slide vises, cross vises, off-center vises, sine vises, rotary, diemaker's vise, pin vises, and others vises.

How take care of the vise

1. Don't hammer on the handle, no matter how tempting it is. Don't put a big cheater on it
either. This greatly increases backlash and slop in the vise. And it can break it. 2. Be careful when bending material from a vertical position. Realize that the laws of physics are placing HUGE demands on the vise when you do this. 3. A vise is not a press. You can press-fit things within reason, but it is a mechanical screw clamp, not a hydraulic ram. 4. Never use your vise as a spreader. Vises are very strong in the direction they are meant to be used in. They are not that strong backwards. 5. When the vise was manufactured, the handle was made a certain length for a reason. The engineers did calculations, and came up with a handle length that would allow the vise to be used within a certain factor of design. Keep that in mind.

Bench vise parts In the bench vise, when we separated the components of the vises they are about 13 components overall. They are :1. Base 2. Sliding jaw 3. Jaw plate 4. FL HD Screw 5. Vise screw 6. Handle rod 7. Handle ball 8. slide plate 9. Taper pin 10. Collar 11. Set screw 12. Special key

All of the components are important in vise. If one of the components are missing, the vise will considered broken because it cannot be use anymore.

The material There are many materials used for built a vise. This is because each part are using different material to make the vise useful and can stand long lasting.

Part

Material

Manufacturing Operation

Machine used

Base Sliding jaw Jaw plate Vise screw Collar

Grey Cast Iron Grey Cast Iron Steel AISI 3140 Steel AISI 3140 Steel AISI 1020(Colddrawn)

Sand casting Sand casting Ceramic casting Continuous casting Cold extrusion Extruder machine

Special key

Steel AISI 1020(colddrawn)

Lost-wax casting

Neutec/USA Lost wax machine

Handle rod Handle ball

Cold Rolled Steel Steel AISI 1020(Colddrawn)

Hot extrusion Skew rolling

Extruder machine Skew rolling piercer machine

Slide plate

Steel AISI 1020(Colddrawn)

Lost-wax casting

Neutec/USA Lost wax machine

Set screw

Steel AISI 1016

Thread rolling

ENKOroll thread rolling machine, type TA01

FL HD Screw

Steel AISI 1016

Male threading

Screw threading maching

Taper pin

Steel AISI 1020(Colddrawn)

Taper turning

Lathe machine

THE VISE MAKING PROCESS

Sand Casting Process Sand Casting also known as Green Sand molding process utilizes a cope (top half) and drag ( bottom half ) flask set-up. The mold consists of sand, ( usually silica ), clay and water. When the water is added it develops the bonding characteristics of the clay, which binds the sand grains together. When applying pressure to the mold material it can be compacted around a pattern, which is either made of metal or wood, to produce a mold having sufficient rigidity to enable metal to be poured into it to produce a casting. The process also uses coring to create cavities inside the casting. After the casting is poured and has cooled the core is removed. The material costs for the process are low and the sand casting process is exceptionally flexible. A number of metals can be used for castings in sizes from ounces to many thousand pounds. The mold material is reclaimable, with between 90 and 95% of the sand being recycled, although new sand and additions are required to make up for the discarded loss. These features, combined with the relative ease of mold production, have ensured that the green sand molding process has remained as the principal method by which castings are produced. The sand used for green sand molding is critical and determines the favorable or unfavorable outcome of the casting. It controls the tolerances, surface finish and the repeatability while in production. Remembering that the tolerances on sand castings are usually wider than the other casting methods. The sand must exhibit the following characteristics: 1. Flowability: The ability to pack tightly around the pattern. 2. Plastic deformation: Have the ability to deform slightly without cracking so that the pattern can be withdrawn. 3. Green strength: Have the ability to support its own weight when stripped from the pattern, and also withstand pressure of molten metal when the mold is cast. 4. Permeability: This allows the gases and steam to escape from the mold during casting.

The process of cast casting

Ceramic Casting Process The first step in manufacture by ceramic mold casting is to combine the material for the mold. A mixture of fine grain zircon (ZrSiO4), aluminum oxide, fused silica, bonding agents, and water creates a ceramic slurry . This slurry is poured over the casting pattern and let set. The pattern is then removed and the mold is left to dry. The mold is then fired. The firing will burn off any unwanted material and make the mold hardened and rigid. The mold may also need to be baked in a furnace as well. The firing of the mold produces a network of microscopic cracks in the mold material. These cracks give the ceramic mold both good permeability and collapsibility for the casting process. Once prepared, the two halves of the mold are assembled for the pouring of the casting. The two halves,(cope and drag section), may be backed up with fireclay material for additional mold strength. Often in manufacturing industry the ceramic mold will be preheated prior to pouring the molten metal. The metal casting is poured, and let solidify. In ceramic mold casting, like in other expendable mold processes the ceramic mold is destroyed in the removal of the metal casting.

Continuous casting process Molten metal is tapped into the ladle from furnaces. After undergoing any ladle treatments, such as alloying and degassing, and arriving at the correct temperature, the ladle is transported to the top of the casting machine. Usually the ladle sits in a slot on a rotating turret at the casting machine. One ladle is in the 'on-cast' position, the other is made ready in the 'off-cast' position, and is switched to the casting position when the first ladle is empty. From the ladle, the hot metal is transferred via a refractory shroud to a holding bath called a tundish. The tundish allows a reservoir of metal to feed the casting machine while ladles are switched, thus acting as a buffer of hot metal, as well as smoothing out flow, regulating metal feed to the molds and cleaning the metal. Metal is drained from the tundish through another shroud into the top of an open-base copper mold. The depth of the mold can range from 0.5 to 2 metres , depending on the casting speed and section size. The mold is water-cooled to solidify the hot metal directly in contact with it; this is the primary cooling process. It also oscillates vertically or in a near vertical curved path to prevent the metal sticking to the mold walls. A lubricant can also be added to the metal in the mold to prevent sticking, and to trap any slag particles that may be present in the metal and bring them to the top of the pool to form a floating layer of slag. Often, the shroud is set so the hot metal exits it below the surface of the slag layer in the mold and is thus called a submerged entry nozzle (SEN). In the mold, a thin shell of metal next to the mold walls solidifies before the middle section, now called a strand, exits the base of the mold into a spray chamber. The bulk of metal within the walls of the strand is still molten. The strand is immediately supported by closely spaced, water-cooled rollers which support the walls of the strand against the ferrostatic pressure (compare hydrostatic pressure) of the still-solidifying liquid within the strand. To increase the rate of solidification, the strand is sprayed with large amounts of water as it passes through the spray-chamber; this is the secondary cooling process. Final solidification of the strand may take place after the strand has exited the spray-chamber. It is here that the design of continuous casting machines may vary. This describes a 'curved apron' casting machine; vertical configurations are also used. In a curved apron casting machine, the strand exits the mold vertically or on a near vertical curved path and as it travels through the spray-chamber, the rollers gradually curve the strand towards the horizontal. In a vertical casting machine, the strand stays vertical as it passes through the spray-chamber. Molds in a curved apron casting machine can be straight or curved, depending on the basic design of the machine. In a true horizontal casting machine, the mold axis is horizontal and the flow of steel is horizontal from liquid to thin shell to solid. In this type of machine, either strand or mold oscillation is used to prevent sticking in the mold. After exiting the spray-chamber, the strand passes through straightening rolls (if cast on other than a vertical machine) and withdrawal rolls. There may be a hot rolling stand after withdrawal to take advantage of the metal's hot condition to pre-shape the final strand. Finally,

the strand is cut into predetermined lengths by mechanical shears or by travelling oxyacetylene torches, is marked for identification, and is taken either to a stockpile or to the next forming process.

1. Ladle 2. Turdish 3. Mold 4. Plasma torch 5. Stopper 6. Straight zone

Cold Extrusion Extrusion is the process by which a billet of metal is reduced in cross section by forcing it to flow through a die orifice under high pressure. Extrusion is used to produce cylindrical bars or hollow tubes. The reaction of the extrusion billet with the container and die results in high compression stresses which are effective in reducing cracking of material during primary breakdown from the ingot. Cold extrusion process The process done at the room temperature or slightly elevated temperature. This process can be used for most materials-subject to designing robust enough tooling that can withstand the stresses created by extrusion. The advantages are no oxidation takes place, good mechanical properties due to severe cold working as long as the temperature created are below the recrystallization temperature.

Lost-wax casting process Casts can be made of the wax model itself, the direct method; or of a wax copy of a model that need not be of wax, the indirect method. These are the steps for the indirect process: 1. Model-making. An artist or mold-maker creates an original model from wax, clay, or another material. Wax and oil-based clay are often preferred because these materials retain their softness. 2. Moldmaking. A mold is made of the original model or sculpture. The rigid outer molds contain the softer inner mold, which is the exact negative of the original model. Inner molds are usually made of latex, polyurethane rubber or silicone, which is supported by the outer mold. The outer mold can be made from plaster, but can also be made of fiberglass or other materials. Most molds are at least two pieces, and a shim with keys is placed between the two halves during construction so that the mold can be put back together accurately. In case there are long, thin pieces sticking out of the model, these are often cut off of the original and molded separately. Sometimes many molds are needed to recreate the original model, especially for large models. 3. Wax. Once the mold is finished, molten wax is poured into it and swished around until an even coating, usually about 18 inch (3 mm) thick, covers the inner surface of the mold. This is repeated until the desired thickness is reached. Another method is filling the entire mold with molten wax, and letting it cool, until a desired thickness has set on the surface of the mold. After this the rest of the wax is poured out again, the mold is turned upside down and the wax layer is left to cool and harden. With this method it is more difficult to control the overall thickness of the wax layer. 4. Removal of wax. This hollow wax copy of the original model is removed from the mold. The model-maker may reuse the mold to make multiple copies, limited only by the durability of the mold. 5. Chasing. Each hollow wax copy is then "chased": a heated metal tool is used to rub out the marks that show the parting line or flashing where the pieces of the mold came together. The wax is dressed to hide any imperfections. The wax now looks like the finished piece. Wax pieces that were molded separately can be heated and attached; foundries often use registration marks to indicate exactly where they go.

6. Spruing. The wax copy is sprued with a treelike structure of wax that will eventually provide paths for molten casting material to flow and air to escape. The carefully planned spruing usually begins at the top with a wax "cup," which is attached by wax cylinders to various points on the wax copy. This spruing doesn't have to be hollow, as it will be melted out later in the process. 7. Slurry. A sprued wax copy is dipped into a slurry of silica, then into a sand-like stucco, or dry crystalline silica of a controlled grain size. The slurry and grit combination is called ceramic shell mold material, although it is not literally made of ceramic. This shell is allowed to dry, and the process is repeated until at least a half-inch coating covers the entire piece. The bigger the piece, the thicker the shell needs to be. Only the inside of the cup is not coated, and the cup's flat top serves as the base upon which the piece stands during this process. 8. Burnout. The ceramic shell-coated piece is placed cup-down in a kiln, whose heat hardens the silica coatings into a shell, and the wax melts and runs out. The melted wax can be recovered and reused, although often it is simply burned up. Now all that remains of the original artwork is the negative space, formerly occupied by the wax, inside the hardened ceramic shell. The feeder and vent tubes and cup are also hollow. 9. Testing. The ceramic shell is allowed to cool, then is tested to see if water will flow through the feeder and vent tubes as necessary. Cracks or leaks can be patched with thick refractory paste. To test the thickness, holes can be drilled into the shell, then patched. 10. Pouring. The shell is reheated in the kiln to harden the patches and remove all traces of moisture, then placed cup-upwards into a tub filled with sand. Metal is melted in a crucible in a furnace, then poured carefully into the shell. If the shell were not hot, the temperature difference would shatter it. The filled shells are allowed to cool. 11. Release. The shell is hammered or sand-blasted away, releasing the rough casting. The sprues, which are also faithfully recreated in metal, are cut off, to be reused in another casting.

12. Metal-chasing. Just as the wax copies were chased, the casting is worked until the telltale signs of the casting process are removed, and the casting now looks like the original model. Pits left by air bubbles in the casting, and the stubs of spruing are filed down and polished.

Hot extrusion process 1. Preparation The solid round bars are machined (peeled) to remove any surface imperfections. 2. Cutting Bars are cut into shorter lengths called billets based on profile weight per foot and desired extruded length. Radius machined on one end to facilitate the extrusion.

3. Heating Induction furnaces and controlled atmosphere heating of billets to a temperature appropriate to the quality of the steel. 4. Extrusion A modern horizontal hydraulic press were used with complex sections, solid or hollow, designed within a maximum diameter of 7.87 inches. 5. Finishing To ensure dimensional accuracy, all products require straightening, twisting, and punch straightening. Surface cleaned by blasting and/or pickling. Final product then cut to customer specified length, inspected, bundled, and packaged for overseas transportation.

Skew Rolling Process A round wire or rod is fed into the roll gap and roughly spherical blanks are formed continuously by the action of the rotating rolls.

Thread rolling process Thread Rolling is a chip-less Cold-Forging Process. A plain cylindrical blank, with a diameter part way between the major and minor diameters of the finished thread, is rotated and squeezed between cylindrical type hardened steel dies whose working surfaces are the reverse of the thread form to be produced. The threads of the die penetrate the surface of the black as it rolls between them, displacing material to form the roods of the threads, and forcing the displayed material radially outward to form the crests. Unlike other threading processes, no material is wasted. Most threads are rolled by the in-feed method in which the entire thread length is formed simultaneously without axial movement of the part. Threads that are too long to be produced by the in-feed method can, however, be rolled by a thru-feed method on these machines.

Thread making process When we make the male thread, generally we use a die tool. When we make the female thread, we use a tap tool. If we do not have the suitable tools, we can also make the thread using a lathe.

Tap and die

The Altenate Process to manufact a vise Mild steel is used throughout, except for the brass inserts.

Accurately aligning the angle plate on the mill table. See Article Number 28 for additional information on the angle plate.

Precisely squaring the body edges. A precision trysquare was used to set the right angle. Fine adjustments were made with taps of a small hammer After milling, the workpiece was checked to assure that it did not shift during machining.

Cutting the first side guide slot. The overall width is 10 mm and the depth 15 mm. Cuts progressed in 0.5 mm steps using a roughing end mill. After completing the first slot, turn the workpiece over without changing the setup to retain symmetry. Second slot cuts also progressed in 0.5 mm steps.

Unfortunately, a locking screw of the mill loosened and led to running off track. The ruined piece was saved for another project and a new piece was selected for a fresh start.

Marking out the side holes after machining the two guide slots.

Drilling the holes, 50 mm deep -- a key process in making this vise calling for precise drilling -- the holes must be straight and positioned accurately. The hole positions were indexed using a dial indicator. The marking out lines served for double-checking to avoid careless errors.

The holes were drilled to 7.8 mm and reamed to 8 mm. Since hole accuracy is critical for smooth operation of this vise, each hole was inspected using a mandrel and trysquare. All holes passed.

Cutting the slot in the underside of the base. The slot depth extends to the centerline of the cross-drilled holes. The end mill 12 mm.

Completion of the underside slot cutting.

A slot has been cut through from the underside of the base. A 12 mm end mill was used, with depth increments of 0.5 mm.

Initially the fixed jaw was mounted with robust machine screws set into counterbored holes. Eventually two tight-fitting dowels were added to fix the jaw and provide additional rigidity. The dowels were set with Loctite, high strength.

Machining the moving jaw while held in a drill press vise. The drill press's lack of precision makes it difficult to machine parallel surfaces on the mill. As shown, shims were added as packing under the vise.

Drilling the hole for the vise's tightening screw, starting with a center-drill.

Machining slot for tightening screw.

The clearance space in the moving jaw is made as shown in the figure. The white area is the clearance space.

Reaming the cross-hole in the moving jaw to a diameter of 12 mm.

This is the tightening system.

Drilling a brass jaw plate while held in partially finished vise.

All the finished parts.

View of the underside of the vise.

It is complete. The jaw plates are made of brass.

References 1. http://wiki.answers.com/Q/What_material_is_a_vise_made_of#ixzz1uBg6wsjc 2. www.custompartnet.com 3. www.hswalsh.com/waxcasting.aspx 4. www.metalcastimg.com 5. www.matweb.com 6. www.cadtutor.net/forum 7. . Serope Kalpakjian, Steven R. Schmid, Manufacturing Engineering and Technology., 6th Ed.,Prentice hall, 2010