MECH152-L25 - 1
Tool Design
MECH152-L25 - 2
Types
yp of Tools
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•
•
•
•
•
•
Material Cutting Tools
Workholding Devices
Pressworking Tools
Bending, Forming
and Drawing Dies
http://www youtube com/watch?v=gkHbRVUvFgw&feature=channel page
http://www.youtube.com/watch?v=gkHbRVUvFgw&feature=channel_page
Tool Design for Inspection and Gaging
T lD
Tool
Design
i ffor JJoining
i i P
Process
Tooling
g for Casting
g
http://www.youtube.com/watch?v=z4D76vMqwD4&feature=channel_page
http://www.youtube.com/watch?v=3ciyG_hidhE&feature=channel_page
http://www.youtube.com/watch?v=4Pw_tcgIiTQ&feature=channel_page
MECH152-L25 - 3
General Considerations
•
•
•
•
•
•
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Safety and Ergonomics
Tool Materials
Heat Treatment
Surface Roughness and Finish
Tolerances and Fits
T li E
Tooling
Economics
i
Material Handling
g
MECH152-L25 - 4
Safety
y and Ergonomics
g
((I))
• Safety should be built into the design
with
ith d
due respectt tto legal
l
l requirements
i
t
• Sufficient clamping
p g and rigidity
g y of the
tool design is necessary
• Guards should be introduced to
movable parts of the machine
• Limit switches to protect workers and
product against moving parts
• Electrical equipment should be properly
grounded
MECH152-L25 - 5
Safety
y and Ergonomics
g
((II))
• Exhaust system for air polluting system
• All adjustments and clamping should be
y accessible
easily
• Quick release or emergency braking
mechanism may be needed for special
cases
• Prevent severe burns or eye injury for
welding or thermal process
• Provision for
f handling pressurized and
toxic equipment
MECH152-L25 - 6
Tool Materials (I)
()
• Tool steels (principal materials)
– Tool
T l and
d Di
Die St
Steell (t
(typical
i lh
hardness
d
RC40
RC40~60)
60)
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•
•
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•
•
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•
W, Water-Hardening Tool-Steels
O, Oil
Oil-Hardening
Hardening Tool-Steels
Tool Steels
A, Air-Hardening Medium Alloy Die-Steels
D, High-Carbon High-Chromium Die Steels
S Sh
S,
Shock-Resisting
k R i ti T
Tool-Steels
l St l
H, Hot-Work Die Steels
P,, Low-Carbon Mold Steels
T and M, Tungsten and Molydenum High-Speed Steels
L, Low-Alloy Tool-Steels
F Carbon-Tungsten
F,
Carbon Tungsten Finishing Steels
(http://www.efunda.com/materials/alloys/tool_steels/tool.cfm)
• Cast Iron
• Stainless Steel
MECH152-L25 - 7
Tool Materials (II)
( )
• Non-ferrous materials - limited
productions only (Aluminum,
g
, Zinc,, Lead,, Beryllium,
y
,
Magnesium,
Bismuth)
• Composite materials – soft tools for
limited run
MECH152-L25 - 8
Workholding
g Devices
Workholding Devices – All devices that
hold, grip, or chuck a workpiece in a
prescribed manner of firmness and
p
location, to perform on it a
manufacturing operation
operation.
MECH152-L25 - 9
Fixture & Jig
g
Fixture:
- Hold and accurately position a
http://www youtube com/watch?v=ujKyRrf Z1M&feature=channel page
workpiece http://www.youtube.com/watch?v=ujKyRrf-Z1M&feature=channel_page
Jig:
- Also be used to hold and position a
workpiece.
- Provides some means for guiding
th cutting
the
tti tool
t l
http://www.youtube.com/watch?v=2ikkuZe0zQU&feature=channel_page
MECH152-L25 - 10
Examples
p
-I
• High Rise Clamps
http://www.carrlane.com/Catalog/index.cfm
High-Rise Clamps
can be stacked on
Narrow Riser
Blocks and Spacer
Blocks to reach tall
workpieces
MECH152-L25 - 11
Examples
p
II
http://www.steelsmith.com/
• Swing Clamp
Please refer to the
price list also!
ARM: MODULAR IRON PER ASTM
A536 GRADE 65-45-12,
65 45 12 ZINC PLATED
CLEAR CHROMATE
ALL OTHER PARTS: MILD STEEL,
BLACK OXIDE FINISH
MECH152-L25 - 12
Examples
p
III
Automatic
Reversible Cam
Action Workholding
Assemblies
http://www.youtube.com/watch?v=vrrjLYn-6WY
Methods of Location
3 2 1 Principle
3-2-1
MECH152-L25 - 13
http://www.youtube.com/watch?v=wTs_IaD0JWU&feature=PlayList&p=3AFB507B668AF162&index=35
- A workpiece will be completely confined
when banked against:
-
3 points in one plane
2 points in another plane
1 point
i t iin a thi
third
d plane
l
If the planes are perpendicular to each
other
- Buttons should be as far apart
p as
possible
- Greater spread,
spread Less alignment error
MECH152-L25 - 14
Methods of Location I
12 degrees of
freedom
3 pins arrest
5 dof
MECH152-L25 - 15
Methods of Location II
5 pins arrest
8 dof
Horizontal
workpiece
6 ppins arrest
9 dof
Vertical
Ve
c
workpiece
MECH152-L25 - 16
Methods of Location III
Radical location
with
i h internal
i
l pins
i
or plug
Radical location
by external pins
MECH152-L25 - 17
Methods of Location IV
7 dof
d f
arrested by
V locator
with stop
pin
Workholder with
multiple
l i l V locators
l
MECH152-L25 - 18
Tool Forces I
Pin-type
yp drill
fixture resisting
torque and thrust
Tapping
fixture
resisting
i i
torque and
thrust
MECH152-L25 - 19
Tool Forces II
Workholder for
b
broaching
hi operation
i
Cutting
Forces
resisted by
solid jaw
j
of vise
Cuttingg force resisted
only by friction
MECH152-L25 - 20
Tool Forces III
Mechanical
methods of
transmitting and
multiplying force
(A) Screw
(B) Cam
C
(C) Wedge
(D) Toggle link
(E) Lever
(F) Combined
screw andd wedge
d
MECH152-L25 - 21
Clamping
p g Forces I
Fixture
components
p
MECH152-L25 - 22
Clamping
p g and Support
pp
http://www.youtube.com/watch?v=l-V4mplHjZ8
Clamping and
support of large
workpiece
k i
MECH152-L25 - 23
Fixture Components
p
MECH152-L25 - 24
Fixture Components
p
Toggle clamp
http://www.youtube.com/watch?v=H4r8hUyZMUY
http://www.youtube.com/watch?v=ZefYGTMKRUw
http://www.youtube.com/watch?v=nheuik2YHkI
Quick-acting
screw
Jigs and Fixture Design
Principles
MECH152-L25 - 25
• Review the workpiece to determine the
manufacturing processes
• Decide on the number of setups
• Determine for each setup
– Reference surface
– Workpiece
p
location
– Workpiece clamping and rigidity
– Ergonomics and safety
http://www.youtube.com/watch?v=ujKyRrf-Z1M&feature=channel
Fixture for Rectangular
Components
MECH152-L25 - 26
Cl
Clamping
i action
ti
• Location and holding for flat surface
• Base plate - reference surface for setup
• Clamp – quick action cam-based clamp
Fixture for Rectangular
Components
MECH152-L25 - 27
• H
Hydraulic
d li clamp
l
ffor llarger clamping
l
i fforce
• Swing
g clamp
p http://www.youtube.com/watch?v
http://www youtube com/watch?v=1RMqoQlZ-2c
1RMqoQlZ 2c
http://www.youtube.com/watch?v=jkAINXgZaCk
Fixture for Rectangular
Components
MECH152-L25 - 28
Magnetic chuck
http://www.youtube.com/watch?v=WzawhEUBLL8&feature=PlayList&p=CAC636741CCDCCB0&playnext=1&playnext_from=PL&index=4
http://www.youtube.com/watch?v=S-xKCAHpU-4&feature=PlayList&p=CAC636741CCDCCB0&playnext=1&playnext_from=PL&index=6
http://www youtube com/watch?v=8pabjZp4D2Y
http://www.youtube.com/watch?v=8pabjZp4D2Y
V cuu
Vacuum
chuck
htt //
http://www.youtube.com/watch?v=xr3lfAvQuJs&feature=related
t b
/ t h?
3lfA Q J &f t
l t d
http://www.youtube.com/watch?v=2jcQZ5W4ED4
Fixture for Rectangular
Components
MECH152-L25 - 29
Electrostatic chuck
Vacuum chuck
Fixture for Circular
Components
Round workpiece
held with strap clamp
and T bolts
Fixture for straddle
milling connecting rod
MECH152-L25 - 30
Fixture for Circular
Components
MECH152-L25 - 31
Workpiece
W
k i
held
h ld in
i a 44
jaw chuck for a boring
operation
http://www.youtube.com/watch?v=npJfKhkS0QE
Nut arbor
Fixture for Circular
Components
V block
MECH152-L25 - 32
Drill jig – V block, quickacting clamp, and drill
bushing combination
http://www.youtube.com/watch?v=QFH2kUorn88
Fixture for Circular
Components
MECH152-L25 - 33
IInternal
t
l andd
endwise
chucking
Between
B
t
centers
t
and combination
with chucking
Fixture for Circular
Components
S lid mandrel
Solid
d l
MECH152-L25 - 34
Roll lock type
expanding mandrel
Fixture for Circular
Components
Split
p busing
g and
split collet
MECH152-L25 - 35
Axial location
by collet
Collet with stopper
http://www.youtube.com/watch?v=bJIIeN4rg3E
Fixture for Circular
Components
MECH152-L25 - 36
Collet
C
ll t with
ith immediate
i
di t
bushing to eliminate
axial shift
Collet for internal chucking
MECH152-L25 - 37
Rigid
g and Elastic Workholding
g
Rigid workholding
Elastic and spring workholding
Rigid/hydraulic workholding
MECH152-L25 - 38
Accuracy
y of Work Location
A
Accuracy
off work
k llocation
ti
Concentricity of workpiece
by collet
Workholders for Irregular
Workpiece
MECH152-L25 - 39
Pump type jigs
Pump-type
MECH152-L25 - 40
Workholding
g Selection
Workpiece rotation
Tool rotation
MECH152-L25 - 41
Workholding
g Selection
Steady to
reduce
workpiece
p
vibration
Minimizing cutting
force by applying
holding force close to
ppoint of tool application
pp
http://www.youtube.com/watch?v=2o74aR0JL1k
MECH152-L25 - 42
Cutter Setup
p
MECH152-L25 - 43
Box-Type
yp Drill Jigs
g
MECH152-L25 - 44
Milling
g Fixture
MECH152-L25 - 45
Milling
g Fixture
MECH152-L25 - 46
Milling
g Fixture
I d i fixture
Indexing
fi t
http://www.youtube.com/watch?v=JkftVHaMQSs
Key slot milling
MECH152-L25 - 47
Milling
g Fixture