MECH152-L25 - 1

Tool Design
 MECH152-L25 - 2

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

• T lD
Tool Design
i ffor JJoining i i P Process
• Tooling
g for Casting g
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
• T li E
Tooling Economics
i
• Material Handling
g
 MECH152-L25 - 4

Safety
y and Ergonomics
g ((I))
• Safety should be built into the design
with
ith d
due respectt tto legal
l l requirements
i t
• Sufficient clamping
p g and rigidity
g y 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
y and Ergonomics
g ((II))
• Exhaust system for air polluting system
• All adjustments and clamping should be
y accessible
easily
• 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
f handling pressurized and
toxic equipment
 MECH152-L25 - 6

Tool Materials (I)

()
• Tool steels (principal materials)
– Tool
T l and
d Di
Die St
Steell (t
(typical
i lh hardness
d RC40
RC40~60)
60)
• W, Water-Hardening Tool-Steels
• O, Oil
Oil-Hardening
Hardening Tool-Steels
Tool Steels
• A, Air-Hardening Medium Alloy Die-Steels
• D, High-Carbon High-Chromium Die Steels
• S Sh
S, Shock-Resisting
k R i ti T Tool-Steels
l St l
• 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
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,
g
Magnesium, , Zinc,, Lead,, Beryllium,
y ,
Bismuth)
• Composite materials – soft tools for
limited run
 MECH152-L25 - 8

Workholding
g Devices
Workholding Devices – All devices that
hold, grip, or chuck a workpiece in a
prescribed manner of firmness and
p
location, to perform on it a
manufacturing operation
operation.
 MECH152-L25 - 9

Fixture & Jig

g
Fixture:
- Hold and accurately position a
workpiece http://www.youtube.com/watch?v=ujKyRrf-Z1M&feature=channel_page
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
th cutting
the tti tool
t l
http://www.youtube.com/watch?v=2ikkuZe0zQU&feature=channel_page
 MECH152-L25 - 10

Examples
p -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
p II
http://www.steelsmith.com/

• Swing Clamp

Please refer to the

price list also!

ARM: MODULAR IRON PER ASTM

A536 GRADE 65-45-12,
65 45 12 ZINC PLATED
CLEAR CHROMATE
ALL OTHER PARTS: MILD STEEL,
BLACK OXIDE FINISH
 MECH152-L25 - 12

Examples
p III
Automatic
Reversible Cam
Action Workholding
Assemblies

http://www.youtube.com/watch?v=vrrjLYn-6WY
 MECH152-L25 - 13
Methods of Location
3 2 1 Principle
3-2-1
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
i t iin a thi
third
d plane
l
- If the planes are perpendicular to each
other
- Buttons should be as far apart
p as
possible
- Greater spread,
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 ppins arrest
9 dof
Vertical
Ve c
workpiece
 MECH152-L25 - 16

Methods of Location III

Radical location
with
i h internal
i l pins
i
or plug

Radical location
by external pins
 MECH152-L25 - 17

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

Workholder with
multiple
l i l V locators
l
 MECH152-L25 - 18

Tool Forces I

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

Tool Forces II
Workholder for
b
broaching
hi operation
i

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

Tool Forces III

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

Clamping
p g Forces I

Fixture
components
p
 MECH152-L25 - 22

Clamping
p g and Support
pp
http://www.youtube.com/watch?v=l-V4mplHjZ8

Clamping and
support of large
workpiece
k i
 MECH152-L25 - 23

Fixture Components
p
 MECH152-L25 - 24

Fixture Components
p

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
p 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
Cl
Clamping
i action
ti

• 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

• H
Hydraulic
d li clamp
l ffor llarger clamping l i fforce
• Swing
g clampp http://www.youtube.com/watch?v
http://www youtube com/watch?v=1RMqoQlZ-2c
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
http://www.youtube.com/watch?v=8pabjZp4D2Y

V cuu
Vacuum
chuck
htt //
http://www.youtube.com/watch?v=xr3lfAvQuJs&feature=related
t b / t h? 3lfA Q J &f t l t d
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
W k i held
h ld in
i a 4-
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
IInternal
t l andd
endwise
chucking

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

Components

S lid mandrel
Solid d l Roll lock type
expanding mandrel
 Fixture for Circular MECH152-L25 - 35

Components
Axial location
by collet
Split
p busing g and
split collet

Collet with stopper

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

Components
Collet
C ll t with
ith immediate
i di t
bushing to eliminate
axial shift

Collet for internal chucking

 MECH152-L25 - 37

Rigid
g and Elastic Workholding
g

Rigid workholding

Elastic and spring workholding Rigid/hydraulic workholding

 MECH152-L25 - 38

Accuracy
y of Work Location

A
Accuracy off work
k llocation
ti Concentricity of workpiece
by collet
Workholders for Irregular
MECH152-L25 - 39

Workpiece

Pump type jigs

Pump-type
 MECH152-L25 - 40

Workholding
g Selection

Workpiece rotation Tool rotation

 MECH152-L25 - 41

Workholding
g Selection
Steady to
reduce
workpiece
p
vibration

Minimizing cutting
force by applying
holding force close to
ppoint of tool application
pp

http://www.youtube.com/watch?v=2o74aR0JL1k
 MECH152-L25 - 42

Cutter Setup
p
 MECH152-L25 - 43

Box-Type
yp Drill Jigs
g
 MECH152-L25 - 44

Milling
g Fixture
 MECH152-L25 - 45

Milling
g Fixture
 MECH152-L25 - 46

Milling
g Fixture

I d i fixture
Indexing fi t
http://www.youtube.com/watch?v=JkftVHaMQSs

Key slot milling

 MECH152-L25 - 47

Milling
g Fixture