Introduction to tool design:
Tooling, requirements of a tool designer, general tool design procedure, tool engineering functions and its importance to enhance productivity and quality. Review of cutting tool materials. Tool angles and signature, Carbide inserts grades - ISO designation and applications, tool holders for turning-ISO designation.Solid type tool, brazed tip tool,throwawayindexable insert types, coated carbides and chip breakers.
Design of single point cutting tools:
Design of shank dimensions using strength and rigidity considerations for rectangular, square and round cross section and selection of tool geometry.
Design of Multi Point Cutting Tools:
Types of drills, Drill bit design - elements like back taper, web thickness, land width, margin, flute length and cross section and selection of tool geometry. Re-sharpening of drill bit. Tool holders for milling, different tapers used for mounting tool holders in milling, ISO designation. Tool mounting systems.
Design of milling cutters:
Design of elements like number of teeth and height, circular pitch, body thickness, chamfer width, fillet radius and selection of tool geometry. Profile sharpened and form relieved milling cutters. Re-sharpening of side and face milling cutter and end mill.
Jigs and Fixtures:
Functions and differences between jigs and fixtures, advantages in mass production, design principles, economics of jigs and fixtures. Location: 3-2-1 Principle of location, different types of locating elements. Clamping: Principles of clamping, types of clamping devices, and power clamping. Drill bushes;Drilljigs:different types, exercises of designing jigs for simple components.
Fixture Design:
Turning fixtures, milling fixtures, grinding fixtures,fixturing for CNC machining centers, and modular fixtures. Design exercises on fixtures for turning and millingfor simple components.
Press tools:
Classificationandworking of power presses. Concept and calculations of press tonnage and shut height of a press, 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 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 and drawing die design. Design of drawing dies for simple components.
Die casting:
Die casting alloys, terminology-core, cavity,sprue, slug, fixed and movable cores, finger cams, draft, ejector pins and 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; finishing, trimming and inspection of die casting components, safety, and modern trends in die casting dies.
TEXT BOOKS:
[1] Cyril Donaldson, George H. Lecain,V.C.Goold, “Tool Design”, Mc Graw Hill Education, 5th edition,2017.
[2]P.N.Rao, “Manufacturing technology”, Mc Graw Hill Education, 4th edition, 2013.
References:
[1] P.H.Joshi, “Jigs and Fixtures”, Mc Graw Hill Education, 3rd edition, 2010.
[2] John.G. Nee, William Dufraine, John W.Evans, Mark Hill, “ Fundamentals of Tool Design”, Society of Manufacturing Engineers, 2010.
[3] Frank W.Wilson, “Fundamentals of Tool Design”,PHI publications.
[4] Kempester M.H.A., “An introduction to Jig and Tool design”, VIVABooksPvt.Ltd., 2004.
[5] Ranganath B.J., “Metal cutting and Tool Design”, Vikas publishing house.
[6] HMT, “Production Technology”, TataMcGraw Hill, 2013.
[7] V. Arshinov& G. Alekseev, “Metal cutting theory and practice”, MIR publishers, Moscow.
[8] Rodin, “Design and production of metal cutting tools”, Beekman publishers.