Introduction

to Tool
Design

Lecture Video
Tujuan Tool
● Reduce overall cost to manufacture a
product
● Increase production rate
● Maintain/improve quality
● Reduce cost of tooling (cost effective)
○ Remember: Cheap tools might not reduce cost
● Design safe and easy to use tools
 Prerequisites:
Lingkup pengetahuan... CAD, Statics, Strengths of Materials &
Manufacturing Processes

● Cutting tools, tool holders, cutting fluids

● Machine tools
● Jigs and fixtures
● Gages and measuring instruments
● Dies for sheet-metal cutting and forming
● Dies for forging, upsetting, cold finishing, and extrusion
● Molds for plastics manufacturing
● Fixtures and accessories for welding, riveting, and
mechanical fastening
The Design Process
● Statement of the problem
○ Scope (apa yang dapat diubah?)
○ Assumptions
● Analysis of requirements (constraints [tolerance, environment])
● Development of initial ideas - Informed Creativity
● Evaluate design alternatives
● Development & Finalization of design ideas
○ Iteration & finalization
● Implement
● Evaluate
Requirements
● Functions
● Precision
● Environment
● Costs
● Lead time
● Safety
● Adaptability, compatibility, standardization
● Working life
Economics of Design
● Berpikir ramping (simple, mudah)
● Menggabungkan berbagai operasi
● Membandingkan berbagai biaya proses
○ Break even point (1-1)
○ Total unit cost for a particular method (1-2a)
○ Break even point, W&S method (1-3)
○ Economic Lot Size (1-4)
Total Unit Cost
Break Even Point
 Economic Lot Size

What about SMED, Lean techniques?

Economic Lot Size (simplified)
 Cutting tools

http://www.heinemannsaw.com/assets/pdf/US3576200.pdf
 Typical Tooling Example
Press tooling
Molds
Workholding & Inspection Tools
Toolmaker’s tools

1-2-3 setup and tri blocks

Sine plates & vises
Spin & index fixtures
Planer gages See Suburban Tool’s
product listing for reference
Bench centers
Measuring instruments
Tooling Drawings
Tooling Drawings
Tooling Drawings
● Do not crowd views
● Analyze each cut
● Use standard values
● Use only the views necessary to define the part
● Realistic, thoughtful tolerances
● Shaft easier to change than hole
● Use stock sizes if possible
● Notes may be necessary
Tooling Layout
● Lay out the part (separate by layer)
● Lay out cutting tools and holders
● Indicate locating requirements
● 3-2-1 locating planes
● Indicate clamping requirements
● Use full scale if possible
● Indicate standard fixture parts
● Identify each item with balloons and leaders
Tolerances
Is this part exactly
One half inch in
diameter?
Tooling Precision (See Dwg)
NX Progressive Die Wizard
NX Injection Mold Wizard
Safety
● Design out hazards if possible
● Always break sharp edges
● Rigidity
● Make drill jigs large enough to hold without spinning
● Use guards if possible
● Punch Presses
● Limit Switches, Shear Pins
● Feed Mechanisms
● Electrical Equipment
● Lockout provisions
● Other Provisions