DEBRE BERHAN UNIVERSITY

College of Engineering
Department of Mechanical Engineering
Tool and Die Design
Individual assignment

Name Abebe Beyene

Id no 2587/11
submitted to Ins. Asrat A.

Submission date 22/09/2015 E.C

06/04/2023 1
Tooling: refers to the hardware necessary to produce a particular component and
consists of a vast type of cutting devices, forming devices etc.

Types of tooling
1. Press Tools :provides Sheet metal press working dies for all types of sheet
metal fabrication.
2. Dies for casting :consists of die for die castings, dies for plastic molding,
dies for permanent molding etc.
3. Cutting tools: includes single point cutting tool and Multi point cutting tools
4. Such as forging dies, rolling dies, extrusion dies, and drawing dies.
5. Jigs and fixtures :for guiding the tool and holding the work piece.
6. Gauges (measuring instruments) :Such as slip gauges

Tool and die design

Tool design is the process of creating and developing methods, shapes and techniques

for tooling (tools and dies) . e.g. Design of cutting tools

Tool and Die Design objectives

The main objective of tool design is to produce products with lower manufacturing

cost ,increase quality and production rates.

Qualities of Tool and Die Design Engineer

a. Detail drawing of each part of tool designer must be clear, complete, exact, and

easily understood.

b. Sub assembly drawing

c. Assembly drawing Must be inventive (creative) and be able to incorporate his

ideas in design layout.

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 At the end of designing and manufacture tools and dies, tools
and dies should satisfy:
(i) It should be easier to load and unload the tool
(ii) All sharp edges on the tool should be chamfered
(iii) All controls and clamps should be located within easy reach
of the operator
(iv) Chip guards should be provided to protection, if there is
(v) Clamping devices should not loosen during tool operation
(vi) Body should be rigid enough to resist all cutting forces
(vii) Should easy to assembling and disassembling (avoid
physical injury while assembling).
The Design Procedure:
Introduction
Brief introduction about the project topic.
Statement of the problem
The second step in the design procedure is to define the problem in
a clear and simple statement.
The designer receive information about:
 which tool is needed andcapabilities of the tool,
 the type of machine on which tool must be used,
 number of parts to be produced and other necessary
information concerning the part.
After this detail is received, the problem statement is prepared in one
or two paragraphs with short sentences.
The need analysis
The needs analysis are pinpoints that defines the problem in terms of
functional need.

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In this part information and data based on the needs analysis are gathered ,such as;
 the dimensions of the part to be held or produced,
 the kind of material from which the part is made,
 the tolerances of the part,
After collecting data we should make research and idea generation.
Ideas that would apply to the particular situations should be sketched on paper for
future reference .
Tentative Design Solution
The research and sketches should be combined into one or two tentative design
solutions.
Which may consist of rough working drawings.
The finished design
After tentative design finished designing should be performed.
Every thing should be design before going to manufacture and Conventional
design techniques are followed.
Tool Failure
Three Modes of Tool Failure
 Fracture failure
Cutting force becomes excessive and/or dynamic, leading to brittle fracture
 Temperature failure
Cutting temperature is too high for the tool material
 Gradual wear
Gradual wear is preferred because it leads to the longest possible use of the tool
Gradual wear occurs at two locations on a tool:
 Crater wear – occurs on top rake face
 Flank wear – occurs on flank (side of tool)

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 Taylor tool life
Each combination of work piece and tool materials and each
cutting condition have their own n and C
values,
Both of which are determined experimentally.
Note that the magnitude of C is the cutting speed at T = 1
min.
VT^n=C
Note that the smaller the n value, the faster the tool life
Tool life decreases with increasing cutting speed.
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
Tool Materials
The important properties that a tool material should possess:
 Wear Resistance
Wear resistance refers to the ability of tool material to retain
its sharpness and shape for longer duration while 5
machining is continued.
Hot Hardness
It is the measure of the ability of tool material to resist the penetration,
scratching, abrasion or cutting at high temperature.
Toughness
It is the ability of material to absorb energy and deform plastically
before failure and fracture.
Coefficient of Thermal Expansion
Coefficient of thermal expansion determines the influence of thermal
stresses and thermal shocks on a material.
 tool does not get distorted after heat treatment.
Hardness
It is the ability of material to resist the penetration, scratching, abrasion
or cutting and high possible.
 Thermal Conductivity
It should be as high as possible with a view to remove the heat quickly
from chip-tool interface.
The most common cutting tool material are:
1. High Carbon Steel
 usually plain carbon steel containing 0.6 to 1.5 % C.
 Method of fabrication is forging,
 hot hardness temperature of about 250°C.
 maximum cutting velocity is about 5 m/min and cheapes tool materials
also soft materials e.g Al,cu
2. High Speed Steel (HSS)
 HSS capable of maintaining hot hardness at elevated temperatures
better than high carbon steels and higher speed than HCS
 Hot hardness temperature is about 600°C
 Cutting velocity of HSS is 40-60 m/min.
 Application complicated tool geometries, such as drills, taps, milling
cutters, and broaches
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o Two basic types (AISI)
1. Tungsten type, designated T‑ grades
2. Molybdenum type, designated M‑grades
o Tungsten is added to increase hardness.
o Chromium is added to increase hot hardness.
o Vanadium is added to increase wear resistance.
o Method of fabrication for HSS is forging.
3. Cemented Carbides
 Cemented carbides are tungsten carbide 85-95% tungsten carbide and 5-15%
cobalt.
 Fabrication for carbide is carried out by employing powder metallurgical
techniques.
 Two basic types:
1. Non‑steel cutting grades - only WC‑Co
2. Steel cutting grades - Tic and TaC added to WC‑Co
 Non‑steel cutting carbide grades are used for machining of nonferrous
metals and gray cast iron
 Steel cutting carbide grades are used for machining low carbon, stainless, and
other alloy steels.
4. Coated Carbides
 Cemented carbide insert coated with one or more thin layers of wear resistant
materials, such as TiC, Tin, and/orAl2O3
 Applications are machining cast irons and steels in turning and milling
operations
 Best applied at high speeds where dynamic force and thermal shock are
minimal
5. Ceramics
 Primarily fine-grained Al2O3, pressed and sintered at high pressures and
temperatures into insert form with no binder.
 These are also called as cemented oxide.
 major constituent is aluminium oxide ,better resistance and low cofficient of
friction.

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 6. Cermets

This is combination of ceramic and metal.

It is substitute for full ceramics material.
The method employed for fabrication of cermet is also powder
metallurgical technique.
Cermet gives better toughness than ceramic.
It gives very good wear resistance
7. Diamonds
• Diamond possesses all the desirable characteristics
• But has very high cost.
• Diamond is made by graphitization technique.
• Its hardness is higher than any other material.
• It has high thermal conductivity.
• Diamond is not used for machining of ferrous material because diamond is
basically pure carbon.
Six angles of single point cutting tool
Side Cutting Edge Angle
 The angle between side cutting edge and side of the tool shank is called side
cutting edge angle.
End Cutting Edge Angle
 The angle between the end cutting edge and a line perpendicular to the
shank of tool is called end cutting edge angle.
Side Relief Angle
 The angle between the portion of the side flank immediately below the side
cutting edge and line perpendicular to the base of tool measured at right
angles to the side flank is known as side relief angle.
End Relief Angle
 End relief angle is the angle between the portion of the end flank
immediately below the end cutting edge and the line perpendicular to the
base of tool, measured at right angles to end flank.
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 Back Rake Angle
The angle between face of the tool and a line parallel with the base of the tool, measured in a
perpendicular plane through the side cutting edge is called back rake angle.
Side Rake Angle
The angle between the face of the tool and a line parallel with the base of the tool, measured in a
plane perpendicular to the base and side cutting edge is called side rake angle.
Tool signature also describes how the tool is positioned in relation to the workpiece.
Influence of Various Angles on Tool Design
Back Rake Angle
oThe rake angle of single point cutting tool is useful in determining the direction of
chip flow across the fac
oNegative back rake angle is preferable for carbide tool.
oPositive back rake angle is used for machining low tensile strength and non ferrous
materials.
oNegative back rake angles are used for machining high tensile strength material.
Side Rake Angle
oMostly side rake angle should be positive.
oThe significance of side rake angle is that it is used to avoid rubbing action
between tool and workpiece.
Relief Angle
The main significance of relief angle is that it prevents rubbing action below
cutting edge
Side Cutting Edge Angle
It may vary from 0 to 90°.
On increasing side cutting edge angle, the full length of cutting edge is not in
contact with workpiece when the tool enters the cut
End Cutting Edge Angle
End cutting edge angle prevents rubbing between the end of the tool and the
workpiece.
If end cutting edge angle is less, it will cause vibration because of end excessive
tool contact with workpiece

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 Nose Radius
 Nose radius is provided to increase strength of tip of the tool.
 It is also affects the surface finish.
Jigs and fixtures
o A Jig is defined as the device which holds and positions the work-
piece, locates and guides the cutting tool related to the workpiece.
o It is usually lighter in construction and weight
o It is only used for drilling, taping, boring operation
Fixture
• Fixture is a work holding device used to locate accurately and hold
securely one or more work pieces.
• It is usually heavily construction .
Advantages of jigs and fixtures
 They are used to accurately manufacture duplicate inter-
changeable parts.
 Enables heavy and complex shaped parts to be machined by
being held rigidly to the machine.
 There is reduction in scrap, easy assembly and savings in la-
bour costs.
 Finally using jigs and fixtures result in increases manufacturing
efficency and reduction in the cost of work pieces.
Disadvantages of Jigs & fixtures
 Jig/fixture may become obsolete if there is any change of product
design.
 It needs high skilled designer
 Long initial development time.

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Elements of Jigs and Fixtures
Generally all the jigs and fixtures consist of:

1. Locating element ::These position the workpiece accurately with respect to the tool guid-

ing. 2.clamping element:CThese hold the workpiece se-

curely in the located position during operation.

3.Tool Guide and setting : guiding or setting of the tools in correct position with respect to

the workpiece.
Principle of Location
The Location, refers to the dimensional and positional relationship between the work piece and
the cutting tool used on the machine.
For a fixture designer, the major portion of time spent is deciding how to locate the work piece
in the fixture.
You know that any free body has a total of twelve degrees of freedom.
TYPES OF LOCATORS
PLANE SURFACE :Includes Adjustable locator,Spring loaded pad.
PROFILE SURFACE :Includes Six point locator, Profile location by pins Eccentric locator
Nest & cavity locator.
CYLINDRICAL SURFACE :Includes, Conical locator,Female locator etc.
VEE LOCATOR
Vee locators are a specialized form of locating element. They are used mainly for round or
cylindrical work pieces.
Six Principles of Location
1. The workpiece should be prevented from moving along and rotating around the X,Y and Z
axes.
2. It is preferable to use a more accurately machined surface than a less accurate surface for loca-
tion.
3. Location must be related to the dimensional requirements stated on the component/work piece
drawing.
4. Location system should facilitate easy and quick loading and unloading of the workpiece.
5. Redundant locators must be avoided.

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 Principle of Clamping
While designing the clamps following factors essentially need to be considered :
 clamping need to be strong and rigid enough to hold the blank(W/P) firmly dur-
ing machining
 clamping should be easy, and quick.
 clamping should be such that it is not affected by vibration, chatter or heavy
pressure.
TYPES OF CLAMPS
1. Strap clamps
 The clamping end of the strap is pressed against a spring which enables quick
unclamping.
2. Clamping by swing plates
 are simple and relatively quick in operation and suitable for jobs of relatively
smaller size, simpler shape and requiring lesser clamping forces.
3. Cam action clamping
 Quick clamping by cam is very effective and very simple in operation.
4. Latch clamp
The Latch Clamp is employed to clamp a job by a Latch.
The leaf is closed on the job and is kept in position by the Latch.
construction is limited to relatively light work and difficult to secure rigid clamp-
ing.
Tool guiding Elements
Drill bushing
The cutter is set relative to the work in a fixture by adjusting the machine or by
using the cutter setting block.
 Bushes may be : Without head,With head,With a flange ann screw.

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o These are convenient for applications when multiple operations are performed in same hole.
o The both Slip Renewable bush is installed and the hole is drilled.
o The drill bush is removed and side allows rapid change over
Extended Drill Bush:
Types of drill gig
1. Plate jigs:
 The plate jig is so named because a plate containing bushing forms the main structural mem-
ber.
 It is open construction, which facilitates for loading and unloading, chip removal, and clamp-
ing.
 The disadvantages of plate jig are that only one surface can be drilled at one loading.
2. Channel drill jig
• To simplify location and clamping, jigs are made of Channel shape
• They can be used only with parts having fairly simple shapes.
3. Template jigs
Template Jigs are simplest and most basic types
These Jigs are made without clamps.
This type of Jig fits over, on, or into the work.
Like prototyping and Cost is less.
4. Angle-plate jigs
 Angle-plate jigs are used to hold parts that are machined at right angles to their mounting lo-
cators as shown in figure below.
5. Leaf jigs
• Leaf jigs are small box jigs with a hinged leaf to allow for easier loading and unloading.
6. Indexing Jig
 Indexing jigs are used for circular hole patterns in which the part is indexed successively to
the different positions under a single bushing.

 Press working defined as a chip less manufacturing process by which various components are
made from sheet metal and 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.

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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.
 If the clearance is too small, then the fracture lines tend to pass each other, causing a
double burnishing and larger cutting forces.
 If the clearance is too large, the metal becomes pinched between the cutting edges and
an excessive burr results.

Types of stamping dies

1.Compound Dies
 Compound dies perform two or more operations at a single position of the metal strip.
 These dies consist of a single station where the part is blanked out, formed, pierced
and so on.
 Compound dies ensure more accurate positional relationship between the various
elements of the job.
2.Combination dies.
By this die at least two operations during each stroke of the press can be performed.
3. Progressive Dies
 Progressive dies are a mixture of various single dies operating as different stations and
grouped into the same die shoe.
 Usually, the die sequence is arranged side by side, or horizontally.
 Progressive dies perform one operation at a time at a station.

Major die components

1. upper and lower die shoe with guide post

 Both machined to be parallel

 The upper die shoe is sometimes provided with a shank, by

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which the whole tool is clamped to the ram of the press.
2. Die block
It is firmly attached to the lower die shoe.

It is made of tool steel, hardened after machining.

The die block is usually a block of steel, either solid or sectioned, into which the openings are
machined.

3. Punch plates
 The punch plate is mounted to the upper shoe in much the same manner as the die block.

 It holds all punches, pilots, spring pads, and other components of the punch.

4. Backup plate
 Both the die block and the punch plate are often separated from the die shoe by back-up plates.

5. Guide rails/ gauges

 The sheet-metal strip is fed over the die block’s upper surface, and it is usually secured between
guide rails or gauges.and two types of gauges: side gauges, for guiding the sheet through the
die, and end gauges.

6. Punch
• If the size of the punch is small it should have a shouldered structure, either if the punch is very
large it can be anchored directly to the back plate using screws.

7. Pilots
In construction, pilots are similar to punches, with the only difference being in their
smooth, radiused end.
Pilots are always longer than any punches, to assure their contact with the strip prior
to the occurrence of any cutting.

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8. Strippers
• The strip is covered up, either whole or its portions, which provides for stripping of the
pierced material off the punch.
a. stationary stripper it is attached to the die block and it can be used the same screws and
dowel pins necessary for attaching the die block to the die shoe.
b. Spring strippers : they are attached to the punch plate, which makes them slide along with
the movements of the ram or punch plate.
Strip Layout
• The layout of scrap strip is most important for economical stock utilization.
• The goal should be at least 75 per cent utilization.

Plastic injection mold

 Plastic Injection Molding is a manufacturing technique for making parts from thermoplastic
and thermoset materials.
 The injection machine is constructed injection unit, mold unit and clamping device that
opens and closes the mold tool.
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.
 process parameters:
1. Material Parameters
 Pressure, Shrinkage, Flow properties
2. Geometry Parameters
 Wall Thickness of Part, Number of Gates, Gate Location
3. Manufacturing Parameters
 Fill Time, Packing Pressure Level, Mold Temperature

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Injection Unit
Purpose: to liquefy the plastic materials and then inject the liquid into mold.

Two types of system used in injection molding;

 Reciprocating screw- similar to extruder screw but with unique recipro-
cating action
 Ram injector Important measure of the size of an injection molding is
weight of resin that can be injected per one shot siImo.
Ram Injection Molding Machine
 The molten resin is collect in a pool in a barrel celled injection chamber
 The molten resin is then push forward by the action of plunger (ram or piston)
Molds
 Mold Parts – mold is placed in between stationary plate and the moveable
plate.
 Secondary runner channel are used for multicavity molds
Gates
 The end of runner and the entry path into the cavity
 The gate shape can also affect the filling of the cavity and dimension.
 Submarine Gate: starts from the edge of the runner, and goes into the cavity
edge at an angle
 The advantage is separation of the parts and the runner is automatic.
 Disadvantage is gate cannot be used for some resins of high shear.
Types of gates
 Tab Gate: By connecting the runner directly into the cavity with no reduction
in runner cross-section.
 Fan Gate: Made by reducing the thickness and not the diameter of the runner
channel as it goes into the cavity.

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Ring Gate: Used to make hollow cylinder parts
The ring gate covers the entire top of the cylinder part
Cavities

Are actual molding locations

Resin enter the cavities through gate, fills the cavities, and cools to form the solid.
Cavities are the heart of the molding process, and must be precisely prepared.
Blow Molding

Blow molding processes represent the most popular way of producing hollow products
such as bottles, drums, and other vessels.
Process Operation
The process begins with applications of heat and pressure to create the “melt.”
Types of blow moldng
parison production which refers to most blow molding operations; .
cooling phases in the mold.
ejection from the mold.

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 Extrusion Blow Moulding
 extrusion of parison
 parison is pinched at the top and sealed at the bottom around a
metal blow pin as the two halves of the mold come together
 the tube is inflated at the bottom so that it takes the shape of the
mold cavity
 mold is opened to remove the solidified part
Injection Blow Moulding
 parison is injected molded around a blowing rod
 injection mold is opened and parison is transferred to a blow
mold
 (3) soft polymer is inflated to conform to the blow mold
 blow mold is opened and blown product is removed

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 stretch blow molding
 Variation of injection blow molding in which blowing rod extends downward
into parison Resulting structure is rigid, with transparency and impact
resistance products.
 In this process, the first stage is to produce an injection mounded preform.
 The preforms are then fed to a reheating device where it is heated to the
thermoplastic temperature range.
 The reheated preforms are transferred into the blowing cavity where biaxial
orientation of preform to the shape of mould takes place

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THANK YOU

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