Tool Design

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Tool Design
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Types of Tools

• Material Cutting Tools
• Workholding Devices
• Pressworking Tools
• Bending, Forming and Drawing Dies
• Tool Design for Inspection and Gaging
• Tool Design for Joining Process
• Tooling for Casting

http//www.youtube.com/watch?vgkHbRVUvFgwfeature
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http//www.youtube.com/watch?vz4D76vMqwD4feature
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http//www.youtube.com/watch?v3ciyG_hidhEfeature
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http//www.youtube.com/watch?v4Pw_tcgIiTQfeature
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General Considerations

• Safety and Ergonomics
• Tool Materials
• Heat Treatment
• Surface Roughness and Finish
• Tolerances and Fits
• Tooling Economics
• Material Handling

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Safety and Ergonomics (I)

• Safety should be built into the design with due
  respect to legal requirements
• Sufficient clamping and rigidity of the tool
  design is necessary
• Guards should be introduced to movable parts of
  the machine
• Limit switches to protect workers and product
  against moving parts
• Electrical equipment should be properly grounded

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Safety and Ergonomics (II)

• Exhaust system for air polluting system
• All adjustments and clamping should be easily
  accessible
• Quick release or emergency braking mechanism may
  be needed for special cases
• Prevent severe burns or eye injury for welding or
  thermal process
• Provision for handling pressurized and toxic
  equipment

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Tool Materials (I)

• Tool steels (principal materials)
• Tool and Die Steel (typical hardness RC4060)
• W, Water-Hardening Tool-Steels
• O, Oil-Hardening Tool-Steels
• A, Air-Hardening Medium Alloy Die-Steels
• D, High-Carbon High-Chromium Die Steels
• S, Shock-Resisting Tool-Steels
• H, Hot-Work Die Steels
• P, Low-Carbon Mold Steels
• T and M, Tungsten and Molydenum High-Speed Steels
• L, Low-Alloy Tool-Steels
• F, Carbon-Tungsten Finishing Steels
• (http//www.efunda.com/materials/alloys/tool_steel
  s/tool.cfm)
• Cast Iron
• Stainless Steel

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Tool Materials (II)

• Non-ferrous materials - limited productions only
  (Aluminum, Magnesium, Zinc, Lead, Beryllium,
  Bismuth)
• Composite materials soft tools for limited run

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Workholding Devices

• Workholding Devices All devices that hold,
  grip, or chuck a workpiece in a prescribed manner
  of firmness and location, to perform on it a
  manufacturing operation.

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Fixture Jig

• Fixture
• - Hold and accurately position a workpiece
• Jig
• - Also be used to hold and position a workpiece.
• - Provides some means for guiding the cutting
  tool

http//www.youtube.com/watch?vujKyRrf-Z1Mfeature
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http//www.youtube.com/watch?v2ikkuZe0zQUfeature
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Examples - I

• High Rise Clamps

http//www.carrlane.com/Catalog/index.cfm
High-Rise Clamps can be stacked on Narrow Riser
Blocks and Spacer Blocks to reach tall workpieces
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Examples II
http//www.steelsmith.com/

• Swing Clamp

Please refer to the price list also!
ARM MODULAR IRON PER ASTM A536 GRADE 65-45-12,
ZINC PLATED CLEAR CHROMATE ALL OTHER PARTS MILD
STEEL, BLACK OXIDE FINISH
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Examples III

• Automatic Reversible Cam Action Workholding
  Assemblies

http//www.youtube.com/watch?vvrrjLYn-6WY
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Methods of Location3-2-1 Principle
http//www.youtube.com/watch?vwTs_IaD0JWUfeature
PlayListp3AFB507B668AF162index35

• A workpiece will be completely confined when
  banked against
• 3 points in one plane
• 2 points in another plane
• 1 point in a third plane
• If the planes are perpendicular to each other
• Buttons should be as far apart as possible
• Greater spread, Less alignment error

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Methods of Location I
12 degrees of freedom
3 pins arrest 5 dof
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Methods of Location II
5 pins arrest 8 dof
Horizontal workpiece
Vertical workpiece
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Methods of Location III
Radical location with internal pins or plug
Radical location by external pins
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Methods of Location IV
7 dof arrested by V locator with stop pin
Workholder with multiple V locators
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Tool Forces I
Pin-type drill fixture resisting torque and thrust
Tapping fixture resisting torque and thrust
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Tool Forces II
Workholder for broaching operation
Cutting Forces resisted by solid jaw of vise
Cutting force resisted only by friction
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Tool Forces III

• Mechanical methods of transmitting and
  multiplying force
• Screw
• Cam
• Wedge
• Toggle link
• Lever
• Combined screw and wedge

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Clamping Forces I
Fixture components
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Clamping and Support
http//www.youtube.com/watch?vl-V4mplHjZ8
Clamping and support of large workpiece
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Fixture Components
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Fixture Components
Toggle clamp
http//www.youtube.com/watch?vH4r8hUyZMUY
http//www.youtube.com/watch?vZefYGTMKRUw
http//www.youtube.com/watch?vnheuik2YHkI
Quick-acting screw
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Jigs and Fixture Design Principles

• Review the workpiece to determine the
  manufacturing processes
• Decide on the number of setups
• Determine for each setup
• Reference surface
• Workpiece location
• Workpiece clamping and rigidity
• Ergonomics and safety

http//www.youtube.com/watch?vujKyRrf-Z1Mfeature
channel
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Fixture for Rectangular Components

• Location and holding for flat surface
• Base plate - reference surface for setup
• Clamp quick action cam-based clamp

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Fixture for Rectangular Components

• Hydraulic clamp for larger clamping force
• Swing clamp

http//www.youtube.com/watch?v1RMqoQlZ-2c
http//www.youtube.com/watch?vjkAINXgZaCk
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Fixture for Rectangular Components
Magnetic chuck
http//www.youtube.com/watch?vWzawhEUBLL8feature
PlayListpCAC636741CCDCCB0playnext1playnext_f
romPLindex4
http//www.youtube.com/watch?vS-xKCAHpU-4feature
PlayListpCAC636741CCDCCB0playnext1playnext_f
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http//www.youtube.com/watch?v8pabjZp4D2Y
Vacuum chuck
http//www.youtube.com/watch?vxr3lfAvQuJsfeature
related
http//www.youtube.com/watch?v2jcQZ5W4ED4
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Fixture for Rectangular Components
Electrostatic chuck
Vacuum chuck
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Fixture for Circular Components
Round workpiece held with strap clamp and T bolts
Fixture for straddle milling connecting rod
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Fixture for Circular Components
Workpiece held in a 4-jaw chuck for a boring
operation
http//www.youtube.com/watch?vnpJfKhkS0QE
Nut arbor
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Fixture for Circular Components
Drill jig V block, quick-acting clamp, and
drill bushing combination
V block
http//www.youtube.com/watch?vQFH2kUorn88
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Fixture for Circular Components
Internal and endwise chucking
Between centers and combination with chucking
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Fixture for Circular Components
Solid mandrel
Roll lock type expanding mandrel
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Fixture for Circular Components
Axial location by collet
Split busing and split collet
Collet with stopper
http//www.youtube.com/watch?vbJIIeN4rg3E
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Fixture for Circular Components
Collet with immediate bushing to eliminate axial
shift
Collet for internal chucking
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Rigid and Elastic Workholding
Rigid workholding
Elastic and spring workholding
Rigid/hydraulic workholding
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Accuracy of Work Location
Concentricity of workpiece by collet
Accuracy of work location
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Workholders for Irregular Workpiece
Pump-type jigs
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Workholding Selection
Workpiece rotation
Tool rotation
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Workholding Selection
Steady to reduce workpiece vibration
Minimizing cutting force by applying holding
force close to point of tool application
http//www.youtube.com/watch?v2o74aR0JL1k
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Cutter Setup
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Box-Type Drill Jigs
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Milling Fixture
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Milling Fixture
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Milling Fixture
Indexing fixture
http//www.youtube.com/watch?vJkftVHaMQSs
Key slot milling
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Milling Fixture