MECH152-L25 - 1

Tool Design
 MECH152-L25 - 2

Types of Tools
• Material Cutting Tools
• Workholding Devices
• Pressworking Tools
• Bending, Forming and Drawing Dies
http://www.youtube.com/watch?v=gkHbRVUvFgw&feature=channel_page

• Tool Design for Inspection and Gaging

http://www.youtube.com/watch?v=z4D76vMqwD4&feature=channel_page

• Tool Design for Joining Process

• Tooling for Casting
http://www.youtube.com/watch?v=3ciyG_hidhE&feature=channel_page

http://www.youtube.com/watch?v=4Pw_tcgIiTQ&feature=channel_page
 MECH152-L25 - 3

General Considerations
• Safety and Ergonomics
• Tool Materials
• Heat Treatment
• Surface Roughness and Finish
• Tolerances and Fits
• Tooling Economics
• Material Handling
 MECH152-L25 - 4

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
 MECH152-L25 - 5

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
 MECH152-L25 - 6

Tool Materials (I)

• Tool steels (principal materials)
– Tool and Die Steel (typical hardness RC40~60)
• 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_steels/tool.cfm)

• Cast Iron
• Stainless Steel
 MECH152-L25 - 7

Tool Materials (II)

• Non-ferrous materials - limited
productions only (Aluminum,
Magnesium, Zinc, Lead, Beryllium,
Bismuth)
• Composite materials – soft tools for
limited run
 MECH152-L25 - 8

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.
 MECH152-L25 - 9

Fixture & Jig

Fixture:
- Hold and accurately position a
workpiece http://www.youtube.com/watch?v=ujKyRrf-Z1M&feature=channel_page
Jig:
- Also be used to hold and position a
workpiece.
- Provides some means for guiding
the cutting tool
http://www.youtube.com/watch?v=2ikkuZe0zQU&feature=channel_page
 MECH152-L25 - 10

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
 MECH152-L25 - 11

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
 MECH152-L25 - 12

Examples III
Automatic
Reversible Cam
Action Workholding
Assemblies

http://www.youtube.com/watch?v=vrrjLYn-6WY
 Methods of Location
MECH152-L25 - 13

3-2-1 Principle
http://www.youtube.com/watch?v=wTs_IaD0JWU&feature=PlayList&p=3AFB507B668AF162&index=35

- 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
 MECH152-L25 - 14

Methods of Location I

12 degrees of
freedom

3 pins arrest
5 dof
 MECH152-L25 - 15

Methods of Location II
5 pins arrest
8 dof
Horizontal
workpiece

6 pins arrest
9 dof
Vertical
workpiece
 MECH152-L25 - 16

Methods of Location III

Radical location
with internal pins
or plug

Radical location
by external pins
 MECH152-L25 - 17

Methods of Location IV
7 dof
arrested by
V locator
with stop
pin

Workholder with
multiple V locators
 MECH152-L25 - 18

Tool Forces I

Pin-type drill
fixture resisting Tapping
torque and thrust fixture
resisting
torque and
thrust
 MECH152-L25 - 19

Tool Forces II
Workholder for
broaching operation

Cutting
Forces
resisted by
solid jaw
of vise
Cutting force resisted
only by friction
 MECH152-L25 - 20

Tool Forces III

Mechanical
methods of
transmitting and
multiplying force
(A) Screw
(B) Cam
(C) Wedge
(D) Toggle link
(E) Lever
(F) Combined
screw and wedge
 MECH152-L25 - 21

Clamping Forces I

Fixture
components
 MECH152-L25 - 22

Clamping and Support

http://www.youtube.com/watch?v=l-V4mplHjZ8

Clamping and
support of large
workpiece
 MECH152-L25 - 23

Fixture Components
 MECH152-L25 - 24

Fixture Components

Toggle clamp
http://www.youtube.com/watch?v=H4r8hUyZMUY
http://www.youtube.com/watch?v=ZefYGTMKRUw
http://www.youtube.com/watch?v=nheuik2YHkI

Quick-acting
screw
 Jigs and Fixture Design MECH152-L25 - 25

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?v=ujKyRrf-Z1M&feature=channel
 Fixture for Rectangular MECH152-L25 - 26

Components
Clamping action

• Location and holding for flat surface

• Base plate - reference surface for setup
• Clamp – quick action cam-based clamp
 Fixture for Rectangular MECH152-L25 - 27

Components

• Hydraulic clamp for larger clamping force

• Swing clamp http://www.youtube.com/watch?v=1RMqoQlZ-2c
http://www.youtube.com/watch?v=jkAINXgZaCk
 Fixture for Rectangular MECH152-L25 - 28

Components

Magnetic chuck
http://www.youtube.com/watch?v=WzawhEUBLL8&feature=PlayList&p=CAC636741CCDCCB0&playnext=1&playnext_from=PL&index=4
http://www.youtube.com/watch?v=S-xKCAHpU-4&feature=PlayList&p=CAC636741CCDCCB0&playnext=1&playnext_from=PL&index=6
http://www.youtube.com/watch?v=8pabjZp4D2Y

Vacuum
chuck
http://www.youtube.com/watch?v=xr3lfAvQuJs&feature=related
http://www.youtube.com/watch?v=2jcQZ5W4ED4
 Fixture for Rectangular MECH152-L25 - 29

Components

Electrostatic chuck

Vacuum chuck
 Fixture for Circular MECH152-L25 - 30

Components

Round workpiece
held with strap clamp
and T bolts

Fixture for straddle

milling connecting rod
Fixture for Circular MECH152-L25 - 31

Components
Workpiece held in a
4-jaw chuck for a
boring operation
http://www.youtube.com/watch?v=npJfKhkS0QE

Nut arbor
 Fixture for Circular MECH152-L25 - 32

Components

Drill jig – V block, quick-

acting clamp, and drill
V block bushing combination
http://www.youtube.com/watch?v=QFH2kUorn88
Fixture for Circular MECH152-L25 - 33

Components
Internal and
endwise
chucking

Between centers
and combination
with chucking
 Fixture for Circular MECH152-L25 - 34

Components

Solid mandrel Roll lock type

expanding mandrel
 Fixture for Circular MECH152-L25 - 35

Components
Axial location
by collet
Split busing and
split collet

Collet with stopper

http://www.youtube.com/watch?v=bJIIeN4rg3E
Fixture for Circular MECH152-L25 - 36

Components
Collet with immediate
bushing to eliminate
axial shift

Collet for internal chucking

 MECH152-L25 - 37

Rigid and Elastic Workholding

Rigid workholding

Elastic and spring workholding Rigid/hydraulic workholding

 MECH152-L25 - 38

Accuracy of Work Location

Accuracy of work location Concentricity of workpiece

by collet
Workholders for Irregular
MECH152-L25 - 39

Workpiece

Pump-type jigs
 MECH152-L25 - 40

Workholding Selection

Workpiece rotation Tool rotation

 MECH152-L25 - 41

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?v=2o74aR0JL1k
 MECH152-L25 - 42

Cutter Setup
 MECH152-L25 - 43

Box-Type Drill Jigs

 MECH152-L25 - 44

Milling Fixture
 MECH152-L25 - 45

Milling Fixture
 MECH152-L25 - 46

Milling Fixture

Indexing fixture
http://www.youtube.com/watch?v=JkftVHaMQSs

Key slot milling

 MECH152-L25 - 47

Milling Fixture