Overview of Tool Design 1
Content
• The Design Process
• Cutting Tools
• Locating and Clamping Methods
• Limit Gauges
• Metal Forming Dies
• Selection of Tooling Materials
• Heat Treatment
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The Design Process
Comprises the planning, designing, developing, and
analysis of tools, methods and procedures
necessary to increase efficiency and productivity.
Statement and analysis of the problem
Analysis of the requirements
Development of initial ideas
Development of possible design alternatives
Finalization of design ideas
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1. Statement and analysis of the problem
The first step in the design of any tool is to define the
problem or objective as it exists without tooling.
2. Analysis of the requirements
Perform specific functions
Meet certain minimum precision requirements
Keep costs to a minimum
Be available when the production schedule requires it
Be operated safely
Meet various other requirements such as adaptability to
the machine
Have an acceptable working life
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3. Development of initial ideas
Initial design ideas are normally conceived after an
examination of the preliminary data.
In many cases, the designer and planner (responsible for tool
request) work together in a team environment to develop
the initial design parameters.
4. Development of possible design alternatives
During the initial concept phase of design, many ideas will
occur to the designer and/or the team. There are always
several ways to do any job.
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5. Finalization of design ideas
Once the initial design ideas and alternatives are determined,
the tool designer must analyze each element to determine
the best way to proceed toward the final tool design.
Rarely is one tool alternative a clear favourite. The tool
designer must evaluate the strong points of each alternative
and weigh them against the weak points of the design.
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Cutting Tools
Feature to be machined
Work material and material condition
Tool material and coatings
Cutting tool/insert geometry
Tool/insert holder (size/shape)
Use of cutting fluids
Inspection of rotating tools (Runout)
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Locating and Clamping
Locating the work piece - The dimensional and positional
relationship between the work piece and the cutting tool
used on the machine.
Generally, 9 out of 12 degrees of freedom need to be
restricted using locators.
3 degrees of freedom (+X, +Y & +Z) are free to load the
component on the machine table.
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Clamping the work piece - During machining operation,
clamping is a way to counter the cutting forces and keep the
workpiece in the located position.
After loading the component, remaining degrees of
freedom are going to be arrested using clamps.
Manual work setting
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Jigs & Fixtures are designed based on the locating &
clamping principles.
If rightly designed they ensure faster loading and ensures
produce the parts at high production rate with high
precision & accuracy.
JIG Fixture
JIGs – Ensures the drilling (position) of the hole at right
place by guiding the drill bit.
FIXTUREs – Means for holding and locating the workpiece
during machining operation.
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Limit Gages
Gauge (Go/No-Go) are inspection tools of rigid design, without a
scale, which used to check the maximum and minimum material
limits of the manufactured components (accept/reject).
Gauge is not recommended if the tolerances on the components
are less than 20 µm, as the tolerances become so close on the
gauges (10% of work tolerances), and difficult to manufacture
and use them because of alignment and wear related issues.
Gauges are designed based on Taylor’s principles and prime
objective is a gauge should not accept the part which is
manufactured outside its limits.
Limits on the No-Go gauge are critical as the part rejected will
be scrapped as it checks the minimum material limit.
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Sheet Metal Forming Dies
A die is a specialized tool used in manufacturing industries
to cut or shape material mostly using a press.
A stamping die, one-of-a-kind precision tool that cuts and
forms sheet metal into a desired shape or profile.
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Tooling Materials and Heat Treatment
It is important to consider proper selection of materials and
heat treatment at the design stage itself.
Material selection
Heat treatment
Hardness requirement
Distortion control
Material for a tool is determined by the mechanical & other
properties necessary for that tool’s proper operation, i.e.,
elastic modulus, wear resistance and dimensional stability.
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Tooling Materials and Heat Treatment
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Tooling Materials and Heat Treatment
The principal materials used for tools can be divided into
three major categories:
Ferrous metals, Nonferrous metals, Non-metallic materials
For most applications, more than one type of material will be
satisfactory, and a final choice normally will be governed by
material availability and economic considerations.
Heat Treatment
Tool steels are high in alloying elements, not only helps in
attaining required material properties (hardness, strength,
toughness etc.), also allows air quenching during heat
treatment, helps in avoiding distortions.
Next Topic: 3. Introduction to Jigs & Fixtures 15
