Tools, Jigs and Die Design

Addisalem Adefris & Belay Taye (M.sc)

Lecturer; Mechanical Engineering
Manufacturing Engineering Chair
School of Mechanical and Automotive Engineering
Dilla university, odeya’a campus, Dilla Ethiopia
E-mail:-Addis2198@gmail.com; Office No: B-613, 2nd floor Staff room -6,
 Chapter – 2
2. Tools classification and design of tools

 Tool can be categorized in to five groups based on the types of operation to be

performed.

1. Cutting Tools

2. Bending Tools

3. Forming Tools

4. Drawing Tools

5. Pressing Tools
a) Single tool

b) Compound tool

c) Combination tool

d) Progressive tool 2
• Cutting tools: From the raw material to finished product many operations
should be conducted on material. Cutting tools used in metal cutting
processes like lathe machine, drilling machine and milling machine etc.
to remove unwanted material from raw material.

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• Cutting tools may be classified according to the number of major cutting
edges (points) involved as follows:
1. Single-Point Tools

– One cutting edge

– Turning uses single point tools

– Point is usually rounded to form a nose radius

• e.g., turning tools, shaping, planning and slotting tools and boring tools

2. Multi-point cutting tools

– More than one cutting edge

– Motion relative to work usually achieved by rotating

– Drilling and milling use rotating multiple cutting edge tools.

• e.g., milling cutters, broaching tools, hobs, gear shaping cutters etc.
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 Single point cutting tool
Basic features of single point tool.

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Elements of tool signature or nomenclature of
single point tool

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• Single point cutting : Removal of the metal from the workpiece by means of
cutting tools which have one major cutting edge.

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 Nomenclature Single Point Tool
 Back rake angle:- It is the angle between the face of the tool and a line parallel
with base of the tool measured in a perpendicular plane through the side cutting
edge.

• This angle helps in removing the chips away from the work piece.

• Rake angle is provided for ease of chip flow and overall machining. Rake angle
may be positive, or negative or even zero as shown in Figure

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The rake angle for a tool depends on the following
factors
1. Type of the material being cut: A harder material like cast iron may be
machined by smaller rake angle than that required by soft material like
mild steel or aluminum.
2. Type of tool material. Tool material like cemented carbide permits
turning at high speed. At high speeds rake angle has little influence on
cutting pressure. Under such condition the rake angle can minimum or
even negative rake angle is provided to increase the tool strength.
3. Depth of cut: In rough turning, high depth of cut is given to remove the
maximum amount of the material. This means that the tool has to
withstand severe cutting pressure. So the rake angle should be decreased
to increase the lip angle that provides the strength of the cutting edge.
4. Rigidity of tool holder and machine: an importantly supported tool on
old or worn out machine cannot take up high cutting pressure. So while
machining under above
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 Side rake angle:- It is the angle by which the face of tool is inclined side ways.

• This angle of tool determines the thickness of the tool behind the cutting edge.

 End relief angle:- It is defined as the angle between the portion of the end flank
immediately below the cutting edge and a line perpendicular to the base of the
tool, measured at right angles to the flank.

• It is the angle that allows the tool to cut without rubbing on the work- piece.

 Side relief angle:- It is the angle between the portion of the side flank
immediately below the side edge and a line perpendicular to the base of the tool
measured at right angles to the side.

• It is incorporated on the tool to provide relief between its flank and the work
piece surface.

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 End cutting edge angle:- It is the angle between the end cutting edge and a
line perpendicular to the shank of the tool.

• It provides clearance between tool cutting edge and work piece.

 Side cutting edge angle:- It is the angle between straight cutting edge on the
side of tool and the side of the shank. It is also known as lead angle.

• It is responsible for turning the chip away from the finished surface.

 Nose radius:- It is the nose point connecting the side cutting edge and end
cutting edge.

• If the radius is more, the surface finish will be good. But due to too
large nose radius, contact between tool and workpiece increases, which
in turn increase friction. Thus, power consumption increases, along with
increase in vibration and chatter occurs.
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 Tool Signature
• Convenient way to specify tool angles by use of a standardized abbreviated
system is known as tool signature or tool nomenclature.
• This will always be true as long as the tool shank is mounted at right angles to
the work-piece axis.
• The seven elements that comprise the signature of a single point cutting
tool can be stated in the following order:
• Tool signature 0-7-6-8-15-16-0.8
1. Back rake angle (0°)
2. Side rake angle (7°)
3. End relief angle (6°)
4. Side relief angle (8°)
5. End cutting edge angle (15°)
6. Side cutting edge angle (16°)
7. Nose radius (0.8 mm)
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• Multi-point cutting tools: Removal of the metal from the workpiece
by means of cutting tools which have more than one major cutting edge.

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15
Nomenclature of the twist drill bits

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 Bending Tools
• Bending is a metal forming
process in which a force is
applied to a piece of sheet
metal, causing it to bend at an
angle and form the desired
shape.

 Beyond yield strength but below the

ultimate tensile strength.
 For bending operation the bending
where A = bend angle
IR = inside radius of bend (in mm). allowance can be calculated as:
K = constant for neutral axis location
(0.33 for IR < 2t and 0.50 for IR > 2t).
t = metal thickness (in mm).
Bending types
Two common bending methods are:
 V-Bending

 Edge bending

 V-Bending: The sheet metal

blank is bent between a V-shaped
punch and die.

• Air bending: If the punch does

not force the sheet to the bottom
of the die cavity, leaving space or
air underneath, it is called "air
bending“. 18
 • Edge or Wipe Bending:
Wipe bending requires the sheet to
be held against the wipe die by a
pressure pad. The punch then
presses against the edge of the
sheet that extends beyond the die
 Force required for V-Bending die
and pad. The sheet will bend
against the radius of the edge of
the wipe die.
where L = length of bend part (in mm)
S = ultimate tensile strength (in N/mm2)
t = thickness of blank (in mm)
W = width between contact points on the die 19
  Force required for
Where, L = length of bend (in mm) V-Bending die
T = Thickness of stock (mm)
kYLT 2
P
K = die opening factor W
where
S = ultimate tensile strength
k = 0.3 for wiping die,
(in N/ mm2) k = 0.7 for a U - die,
W = width of die opening (in mm). k =1.3 for a V - die
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 FORMING Tool
• Forming operation is done along a curved axis rather than a straight

axis. Due to the complexity of shapes, general formulae are not

developed for determining forming forces.

• Types of Forming dies:
1. Solid form dies

2. Curling dies

3. Embossing dies

4. Coining dies

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 Solid form dies

 Solid form dies:

These are similar to
bending die, except
that these are of
complex shapes like
pipeline clamps. This
is explained in Fig.
Fig. Solid Forming Die
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 Curling dies

 Curling dies: Curling is done at

the edges of the drawn
component. Many of the
stainless steel utensils have
curled edges. This is explained
in Fig.

Fig.: Curling Die

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 Embossing dies

 Embossing dies: Here there is

no change in thickness of the
metal, as the component takes
the shape of the male punch.
 Here, one side has protrusions,
whereas the other side has
Fig.: Embossing Die depressions. The same is
explained in Fig.

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 Coining dies

 Coining dies: In this process, the

metal is squeezed by the compressive
force of the punch and the die, as well
as edge restraining discs.
 It changes the thickness of the
material as explained in Fig. 2.20.
This process is carried out generally in
drop hammers and hydraulic presses,
Fig. : Coining Die due to the heavy force needed to
squeeze the metal to desired surface
projections.
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Deep Drawing Tools
• Deep drawing is a metal
forming process in which
sheet metal is stretched
into the desired shape.
• A tool pushes downward
on the sheet metal, forcing
it into a die cavity in the
shape of the desired part.

Fig.: Deep drawing 26

Deep Drawing Die

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Deep Drawing Sequence

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  Maximum load required for drawing of a cup
 D  
Fmax  D pT UTS o   0 .7 
 D p 
 

Figure: (a) Schematic illustration of the deep-drawing process on a circular sheet-metal blank. The stripper ring
facilitates the removal of the formed cup from the punch. (b) Process variables in deep drawing. Except for the punch
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force, F, all the parameters indicated on the figure are independent variables.
 Press tools
 Press Tools:- A press tool is a device that enables any one of the
operations such as blanking, piercing, bending, and drawing to be
performed repeatedly in mass-scale in a press.
 In some other occasions, operations like blanking and bending, blanking
and drawing or piercing and blanking can be carried out in tandem,
calling for specialized press tools.
 Since the punch or a die are the two major components in a press tool,
which are subjected to severe loads and hence wear and tear, they are
quite often designed based on the quires condition.

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A press tool (Die Set) consists of the following components
 Die Shoe, which holds the die by means of a set of screws and dowels. They
are designed to withstand the severe impact loads transmitted to the die. They
have flanges protruding on the two ends, to facilitate fastening the die set to
the bolster plate of the press.
 Punch holding plate, which moves up and down the guiding pins and which
carries the punch.
 Shank, is a member in the die set to which the punch plate is fitted. This is
also fastened to the ram of the press and is a transmitting member of the
reciprocating motion down to the component.
• Guiding pins, having bushes are vertical pins about which the punch holder
plate and hence the punch, moves vertically. These are fitted to the die shoe.
Guiding pins can be two, three or four in number, depending on the
application. 31
Blanking
• A piece of sheet
metal is removed
from a larger piece
of stock.
• This removed piece
is not scrap, it is the
useful part.

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Punching Operations

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Blanking & Punching example

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Blank and Punch Die

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Press Tools (Dies) Classifications According to
Number of Stations
1. Simple die
2. Compound die
3. Combination die
4. Progressive die

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Simple Die
• Simple dies or single
action dies perform
single operation for
each stroke of the
press slide.
• The operation may be
one of the cutting or
forming operations.

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  The construction of a single drop-
through die is shown in Fig. 6.9.
It includes all basic elements like
die punch, die block, upper and
lower die shoes, the guide posts,
stripper plate, container and
some other auxiliary components
for safety requirements.

Limitations:
i. Single operation die is used when only blanking or piercing operation is to be done.
ii. If larger diameter blank is to be produced, this may result in a defect called dishing.
This defect involves slackening of the blank in the middle and the obtained blank
becomes curved, and not flat.
 Compound Die
 Compound Dies: Several
operations on the same strip
may be performed in one
stroke with a compound die in
one station.
 The compound die is used to
perform two or more operations
simultaneously in a single stage. It
has a more complicated
construction than single drop-
through die.

Limitation
• It can perform only cutting operations not shaping or bending operations.

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Combination Die
 In this die also , more than one
operation may be performed at
one station.
 The combination die is used to
perform both cutting (i.e.,
blanking) and shaping (i. e.
bending, drawing) operations.
 It is different from compound
die in that in this die, a cutting
operation is combined with a
bending or drawing operation,
due to that it is called
combination die.
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Progressive Die

 Progressive Dies: Parts requiring

multiple operations, such as
punching, blanking and notching
are made at high production rates
in progressive dies. The sheet
metal is fed through a coil strip
and a different operation is
performed at the same station with
each stroke of a series of punches.
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Progressive Die

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