Introduction to tool design: Tooling, requirements of a tool designer, general tool design procedure. Design of Single point Cutting Tools: Design of single point lathe tool: Design of shank dimension using strength and rigidity considerations for rectangular, square and round cross section and selection of tool geometry. Solid type tool, brazed tip tool, long index able insert, throwaway index able insert types and chip breakers.
Drill bit design of elements like back taper, web thickness, land width, margin, flute length and cross section and selection of tool geometry. Design of milling cutter: Design of elements like number of teeth and height circular pitch, body thickness, chamfer width, fillet radius and selection of tool geometry.
Functions and differences between jigs and fixtures, advantages in mass production, design principles, economics of jigs and fixtures. Principles of location -3-2-1 and 4-1-1 types of locations, different types of locating elements. Clamping – Principles of clamping, types of clamping including power clamping devices. Drill jigs- Types, Drill bushes, simple exercises of designing jigs for given components.
Fixture Design Turning fixtures, milling fixtures, grinding and broaching fixtures, indexing fixtures. Design of fixtures for simple components.
Working of a power press and classification of presses. Components of a simple die, press tool operation, die accessories, shearing action in punch & die, clearance, shear on punch and die, Centre of pressure and problems, scrap strip layout. Simple, progressive, compound, combination and inverted dies. Design problems on blanking and piercing dies for simple components.
Bending dies – Introduction, bend allowance, spring back, edge bending die design. Drawing dies – Single action, double action and triple action dies, factors affecting drawing, drawing die design.
Terminology: Core, cavity, sprue, slug, fixed and movable cores, finger cams, draft, ejector pins ejector plates, gate, goosenozzle, over-flow, platten, plunger, runner, vent, water-line etc. Types of Dies: Single cavity, multicavity dies, combination dies, unit dies, advantages and disadvantages of types of dies. Die casting dies, unit dies. advantages and disadvantages of types of dies. Die casting alloys, defects in die casting, finishing trimming and inspection of die casting components, safety, modern trends in die casting dies.
Injection moulding machine and its elements, general configuration of a mould. 2 plate and 3 plate mould. Introduction, to gate, runner, parting surface, ejection system. Core and cooling system. Introduction to compression, transfer, blow moulding, extrusion, forming and calendaring.