TOOL DESIGN (18ME825)

TOOL DESIGN

Course Code: 18ME825 
CIE Marks 40
Teaching Hours /Week (L:T:P) 3:0:0 
SEE Marks 60
Credits 03 
Exam Hours 03

Course Learning Objectives:

• To develop capability to design and select single point and multipoint cutting tools for various
• machining operations.
• Exposure to variety of locating and clamping methods available.
• To enable the students to design jigs and fixtures for simple components.
• To expose the students to the design/selection procedure of press tools and die casting dies.

Module-1

Introduction to tool design: Tooling, requirements of a tool designer, general tool design procedure, tool
engineering functions and its importance to enhance productivity and quality. Review of cutting tool materials. Tool angles and signature, Carbide inserts grades - ISO designation and applications, tool holders for turning-ISO designation. Solid type tool, brazed tip tool, throwaway indexable insert types, coated carbides and chip breakers. Design of single point cutting tools: Design of shank dimensions using strength and rigidity considerations for rectangular, square and round cross section and selection of tool geometry.

Module-2

Design of Multi Point Cutting Tools: Types of drills, Drill bit design - elements like back taper, web thickness, land width, margin, flute length and cross section and selection of tool geometry. Re-sharpening of drill bit. Tool holders for milling, different tapers used for mounting tool holders in milling, ISO designation. Tool mounting systems. Design of milling cutters: Design of elements like number of teeth and height, circular pitch, body thickness, chamfer width, fillet radius and selection of tool geometry. Profile sharpened and form relieved milling cutters. Re-sharpening of side and face milling cutter and end mill.

Module-3

Jigs and Fixtures: Functions and differences between jigs and fixtures, advantages in mass production, design principles, economics of jigs and fixtures. Location: 3-2-1 Principle of location, different types of locating elements. Clamping: Principles of clamping, types of clamping devices, and power clamping. Drill bushes; Drill jigs: Different types, exercises of designing jigs for simple components.
Fixture Design: Turning fixtures, milling fixtures, grinding fixtures, fixturing for CNC machining centers, and modular fixtures. Design exercises on fixtures for turning and milling for simple components

Module-4

Press tools: Classification and working of power presses. Concept and calculations of press tonnage and shut height of a press, components of a simple die, press tool operation, die accessories, shearing action in punch & die, clearance, shear on punch and die, Centre of pressure, and strip layout. Simple, progressive, compound, combination and inverted dies. Design problems on blanking and piercing dies for simple components. Bending dies – Introduction, bend allowance, spring back, edge bending die design.

Module-5

Drawing dies – Single action, double action and triple action dies, factors affecting drawing and drawing die design. Design of drawing dies for simple components. Die casting: Die casting alloys, terminology- core, cavity, sprue, slug, fixed and movable cores, finger cams, draft, ejector pins and plates, gate, goose nozzle, over-flow, platten, plunger, runner, vent, water-line etc. Types of Dies: Single cavity, multi cavity dies, combination dies, unit dies, advantages and disadvantages of types of dies; finishing, trimming and inspection of die casting components, safety, and modern trends in die casting dies.

Assignment:

Course work includes a ToolDesign project. Tool design project should enable the students to design a tooling like Jig or a fixture for a simple component, fixture for a simple component on CNC machining centers, design of a simple blanking and piercing die, progressive die, drawing die etc. Any one of these exercises should be given as an assignment. A group of students (maximum number in a group should be 4) should submit assembly drawing and part drawings, completely dimensioned, indicating the necessary manufacturing tolerances, surface finish symbols and geometric tolerances wherever necessary. Tool design project must be completed using appropriate solid modeling software. Computer generated drawings must be submitted. Design calculations must be hand written and should be included in the report. Tool design project should be given due credit in internal assessment.

Course Outcomes: At the end of the course, the student will be able to:

CO1: Select appropriate cutting tools required for producing a component.
CO2: Understand and interpret cutting tool and tool holder designation systems.
CO3: Select suitable locating and clamping devices for a given component for various operations.
CO4: Analyze and design a jig/fixture for a given simple component.
CO5: Understand various press tools and press tool operations.
CO6: Classify and explain various die casting and injection moulding dies.

Question paper pattern:

• The question paper will have ten full questions carrying equal marks.
• Each full question will be for 20 marks.
• There will be two full questions (with a maximum of four sub- questions) from each module.
• Each full question will have sub- question covering all the topics under a module.
• The students will have to answer five full questions, selecting one full question from each module.

Textbook

1 Tool Design Cyril Donaldson, George H. Lecain, V.C.Goold, Mc Graw Hill Education 5th edition, 2017
2 Manufacturing technology P.N.Rao, Mc Graw Hill Education 4th edition, 2013

Reference Books

1 Jigs and Fixtures P.H.Joshi Mc Graw Hill Education 3rd edition, 2010
2 Fundamentals of Tool Design John.G. Nee, William Dufraine, John W. Evans, Mark Hill Society of Manufacturing Engineers 2010
3 Fundamentals of Tool Design Frank W.Wilson PHI publications
4 An introduction to Jig and Tool design Kempester M.H.A VIVA Books Pvt.Ltd. 2004
5 Metal cutting and Tool Design RanganathB.J Vikas publishing house
6 Metal cutting theory and practice V. Arshinov& G. Alekseev MIR publishers, Moscow
7 Design and production of metal cutting tools Rodin Beekman publishers
8 Production Technology HMT TataMc Graw Hill 2013.