CHAPTER 1 - TOOL-DESIGN METHODS

1.1. INTRODUCTION

 Definition of TOOLING: refers to the hardware necessary to

produce a particular component.

 Tooling consists of a vast type of cutting devices, forming

devices, work holding and supporting devices, tool guiding

devices, measuring devices, molding devices etc.

 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

 such as die for die castings, dies for plastic molding, dies for

permanent molding, and dies for investment casting

4. forming dies

 Such as forging dies, rolling dies, extrusion dies, and drawing

dies.

5. Jigs and fixtures

 for guiding the tool and holding the workpiece

6. Gauges (measuring instruments)

 Such as slip gauges

1.2 TOOL and DIE DESIGN

Tool design is the process of creating and developing

methods, shapes and techniques for tooling (tools

and dies)

Which are necessary to improve manufacturing

efficiency and productivity.

e.g. Design of cutting tools

Design of press tools

1.3 Tool and Die Design objectives

The main objective of tool

design is to produce
products with lower
manufacturing cost while
maintaining quality and
production rates.
1.4 Qualities of Tool and Die Design Engineer

Before going to design tools and dies the designer should:

o Provide conventional drawings of a tool and die.

 Engineers should supply the following:

(i) Detail drawing of each part of tool

 All drawings (manufacturing drawing) released by tool designer

must be clear, complete, exact, and easily understood and must

be a genuine help to tool maker.
(ii) Sub assembly drawing, if there is

(iii) Assembly drawing

 List of parts needed to make a tool

o Should have knowledge of solid modeling tools
o Know different manufacturing processes (procedures)
to make a component using tools and dies.
o Should have knowledge of function of tools and dies
 Should understand how tools and dies perform their
functions.
o Have knowledge of standard machine elements.
 Tools and dies can be designed economically by using
standard parts like screws, bushings, dowels, handles,
clamps etc.
o Must be inventive (creative) and be able to incorporate
his ideas in design layout.
1.5 Safety as related to Tool Design
 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).
1.6 THE DESIGN PROCEDURE
1.6.1 Introduction
Brief introduction about the project topic as well
as the previous method of tooling
1.6.2 Statement of the problem
The second step in the design procedure is to
define the problem in a clear and simple
statement.
The manufacturing engineer usually provides the
tool design with the problem when designing tools
and dies.
The designer receives information about:
which tool is needed,
the capabilities 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.
1.6.3 The need analysis
The needs analysis are pinpoints that defines the problem
in terms of functional need.
The designer should analyzed by asking ‘’WH’’ and
‘’HOW’’ questions about the functional requirements
like;
1. How the tool be used by skilled or unskilled operator?
2. How many parts can be held in the tool?
3. What are the hole location tolerances on the part?
4. How should the part nest in the jig to maintain accuracy
in hole location?

By Jemal E. 06/26/2023
1.6.4 Research and Idea generation
 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,
 the dimensions of the machine,
 the limitations of the machine, and
 the amount of tonnage to blank the part.
 It may be obtained by talking to other people, taking
measurements, making calculations, looking through
handbooks and catalogs, consulting experts and making
experimental.

By Jemal E. 06/26/2023
 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 .
 Sketched idea will be combined, reworked and emerge as
developmental sketches
 Then it leading to workable design solutions.

By Jemal E. 06/26/2023
1.6.5Tentative Design Solution
Different concept design should be generate in this part.
The research and sketches should be combined into one
or two tentative design solutions.
Which may consist of rough working drawings.

By Jemal E. 06/26/2023
1.6.6 The finished design
After tentative design finished designing should be
performed.
Every thing should be design before going to manufacture.
Conventional design techniques are followed.
 Design each parameters for optimal
 Make strength analysis
 Prepare manufacturing drawing each components
 Prepare solid models
 Make simulation for mechanism
 Prepare manufacturing process sheet for each components

By Jemal E. 06/26/2023