NAME =Takele Ewunetu

Id =2654/11

CHAPTER 1 - TOOL-DESIGN METHODS

Definition of TOOLING: refers to the hardware

necessary to produce a particular component.
 The common classification of types
of tooling is as follows
1. Cutting tools

 such as

(a) single point cutting tools

(b) Multi point cutting tools

2. Press Tools

 Such as Sheet metal press working dies for all types of

sheet metal fabrication

3. Dies for casting

4. forming dies

5. Jigs and fixtures

6. Gauges (measuring instruments)

1.2 TOOL and DIE DESIGN
Tool design is the process of creating and developing methods,

shapes and techniques for tooling (tools and dies)

 1.6 THE DESIGN PROCEDURE

i. Introduction
ii. Statement of the problem
iii. The need analysis
iv. Research and Idea generation
v. Tentative Design Solution
vi. The finished design
 Chapter-two

Design of Single Point Cutting tool

2.1. Tool Failure
 Three Modes of Tool Failure
i. Fracture failure
ii. Temperature failure
iii. Gradual wear
Investigation of Tool Life in Production
1. Complete failure of cutting edge
2. Visual inspection of flank wear (or crater wear) by the machine operator
3. Fingernail test across cutting edge
4. Changes in sound emitted from operation
5. Chips become ribbony, stringy, and difficult to dispose
6. Degradation of surface finish
7. Workpiece count
8. Cumulative cutting time
 2.2. Tool Materials

The important properties that a tool material should possess:

 Wear Resistance
 Hot Hardness
 Toughness
• Coefficient of Thermal Expansion
 Hardness
 Thermal Conductivity
The most common cutting tool material are:
1. High Carbon Steel
2. High speed steel
3. Cemented carbides
4. Coated carbides
5. Ceramics
6. Cermets
7. Diamond
 Six angles of single point cutting tool

o Back Rake Angle

o Side Rake Angle
o Relief Angle
o Side Cutting Edge Angle
o End Cutting Edge Angle
o Nose Radius
 Chapter-Three
DESIGN OF DRILL JIGS AND FIXTURES

 A Jig is defined as the device which holds and positions the

workpiece, locates and guides the CUTTING TOOL related
to the workpiece.
 Fixture is a WORK HOLDING device used to locate
accurately and hold securely one or more WORK PIECES.
Advantages of jigs and fixtures
 They are used to accurately manufacture
duplicate interchangeable parts.
Finally using jigs and fixtures result in INCREASES MANUFACTURING
EFFICENCY AND REDUCTION IN THE COST OF WORK PIECES.
 Disadvantages of Jigs & fixtures

It needs high skilled designer

Long initial development time.
Elements of Jigs and Fixtures
1. Locating elements
2. Clamping Elements
3. Tool Guiding and Setting Elements
• Types of Drill Jigs
Depending upon their construction and method of
operation,
Drill jigs can be broadly classified as follows:
1. Plate Jig
2. Channel Jig
3.Template Jig
4. Angle plate jig
5. Leaf or latch jig
6. Indexing jig
 Chapter Four
Design of sheet metal dies
 Press working may be defined as a chip less manufacturing
process by which various components are made from sheet
metal.
 This process is also termed as stamping.

 Press working process is the application of large force for a

short period which results in the cutting (shearing) or
deforming the work material.
The commonly Used press work operations are as follows:
Blanking: In this operation the cut out part from the
material strip is the required component.
Piercing: In this operation the cut out part from the
material strip is waste, hole left in the strip being required
part.
 Analysis of blanking and piercing

 Process parameters in sheet-metal cutting are clearance between

punch and die, stock thickness, type of metal and its strength, and
length of the cut.
 The clearance in a shearing operation is the distance between the
punch and die
 Typical clearances in conventional press working range between
4% and 8% of the sheet-metal thickness t.
 The effect of improper clearances is illustrated in Figure below.
Types of stamping dies
By type of construction of the dies stamping dies can
be classified:
 Compound die
 Combination die
 Progressive die
 Major die components

1. upper and lower die shoe with guide post

2. Die block
3. Punch plates
4. Backup plate
5. Guide rails/ gauges
7. Punch
9. Pilots
11. Strippers
Strip Layout
 The layout of scrap strip is most important for economical
stock utilization.
 Evaluation of economical aspects of such an arrangement
consists of comparing an area of the blank to the total area
of the strip needed for production of such a part.
 The goal should be at least 75 per cent utilization.
 Chapter six
Molding Die Design
 Plastic Injection Molding

 Plastic Injection Molding is a manufacturing technique for making

parts from thermoplastic and thermoset materials
 Molten plastic is injected at high pressure into a mold, which is the
inverse of the desired shape.
 The mold is made from metal, usually either steel or aluminium
THE PROCESS:
 The plastic material is received by the molder in granular
form
 It is placed in the hopper of an injection-molding machine,
from which it is fed to a heated cylinder.
 Mold defines final shape as material cools and solidifies
 As the granules heat in the cylinder, they melt, or plasticize
*

Schematic of thermoplastic Injection molding machine

 process parameters
1.Material Parameters
2.Geometry Parameters
3.Manufacturing Parameters

Injection Unit
 Purpose: to liquefy the plastic materials and then
inject the liquid into mold
 Resin is introduced through hopper
 Some machines can have several hoppers (to fed filler,
colorants, other additives)-Injection molding act as mixer
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