Volume 5, Issue 1 NOV 2015
DESIGN AND ANALYSIS OF FORM TOOL
1
BIKUMALLA SRUTHI, 2 M ANIL KUMAR
1
Pg Scholar, Department of MECH, MLR INSTITUTE OF TECHNOLOGY, Ranga Reddy, Telangana, India.
2
Assistant Professor, Department of MECH, MLR INSTITUTE OF TECHNOLOGY, Ranga Reddy, Telangana, India.
Abstract A form tool is precision-ground into a pattern
that resembles the part to be formed. The form tool can
be used as a single operation and therefore eliminate
many other operations from the slides (front, rear and/or
vertical) and the turret, such as box tools. A form tool
turns one or more diameters while feeding into the work.
Before the use of form tools, diameters were turned by
multiple slide and turret operations, and thus took more
work to make the part.
In this Project we model a form tool using CATIA V5.
The advantages of form tools are (a) cycle time, (b) it
works as POKA YOKA (mistake proofing) (c)
maintains relation between operation (d) cost
optimization. This tool is designed based upon the
component drawing supplied by the customer, spindle
power and rpm of CNC machine on which this tool is
proposed. This tool is modeled by using a 3D modeling
software.
In this the design of form tool is carried out using CATIA
modeling software, analyzed using FEA software ansys
workbench.
Keywords tool, single point cutting tool, designing ,
modeling , simulation, structural simulation, stress ,
strain, deformation
I INTRODUCTION
Designing a forming tool is one of vital factor of tool
engineering, which must be known by every design
engineer. Forming a tool means giving a particular and
useful shape with required dimensions to the part. The part
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formed by forming operation is generally takes the shape
of the dir or punch. In the forming operation, the metal
flow is not uniform and localized to some extent,
depending upon the shape of the work piece. Bending
along a large radius in a straight line may also be referred
to as a forming operation. It is difficult to distinguish
between a bending and forming tools. Forming operation
may be simple and extremely complicated.
A form tool is precision-ground into a pattern that
resembles the part to be formed. The form tool can be used
as a single operation and therefore eliminate many other
operations from the slides (front, rear and/or vertical) and
the turret, such as box tools. A form tool turns one or more
diameters while feeding into the work. Before the use of
form tools, diameters were turned by multiple slide and
turret operations, and thus took more work to make the
part. For example, a form tool can turn many diameters
and in addition can also cut off the part in a single
operation and eliminate the need to index the turret. For
single-spindle machines, bypassing the need to index the
turret can dramatically increase hourly part production
rates. On long-running jobs it is common to use a roughing
tool on a different slide or turret station to remove the bulk
of the material to reduce wear on the form tool.
There are different types of form tools. Insert form tools
are the most common for short- to medium-range jobs (50
to 20,000 pcs). Circular form tools are usually for longer
jobs, since the tool wear can be ground off the tool tip
many times as the tool is rotated in its holder. There is also
a skiving tool that can be used for light finishing cuts.
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Form tools can be made of cobalt steel, carbide, or high-
speed steel. Carbide requires additional care because it is
very brittle and will chip if chatter occurs.
A drawback when using form tools is that the feed into the
work is usually slow, 0.0005" to 0.0012" per revolution
depending on the width of the tool. Wide form tools create
Flat or blocked tools are further classified according to the
setting of tool with respect to the work piece, viz. radial-
fed tools and tangential-fed tools. Further, form tools are
also classified with respect to orientation of tools with
respect to the work piece axis
VARIOUS TYPES OF FORMING TOOLS:

more heat and usually are problematic for chatter. Heat

Flat Form Tool:Straight and flat form tools have a square
and chatter reduces tool life. Also, form tools wider than
or rectangular cross-section with the form being along the
2.5 times the smaller diameter of the part being turned
side or end. These tools are similar in appearance to the
have a greater risk of the part breaking off. When turning
turning tools. These are usually set centrally so that they
longer lengths, a support from the turret can be used to
will cut their contour which is identical to the desired
increase turning length from 2.5 times to 5 times the
contoured of the work piece. A typical example of V-notch
smallest diameter of the part being turned, and this also
tool is shown in Figure. This type of tool is suitable for
can help reduce chatter. Despite the drawbacks, the
making deep straight-sided form grooves. The cutting is
elimination of extra operations often makes using form
restricted type due to the mixed chip flow. Because of the
tools the most efficient option.
existence of the good surface finish, this type of tool must

THEORY OF FORM TOOL: be operated at very low cutting speed.

PURPOSE OF FORMING TOOLS:

A form tool is defined as a cutting tool having one or more

cutting edges with well defined profile or contour that is
reproduced as the desired form on the work piece surface.
Form tools utilized for turning applications are classified
according to type of cross section. The classification is
shown in the tree diagram of Figure

Design of Metal Shaping Tools:

Figure shows a typical flat form tool without rake angle. It
is necessary to compute x to be machined in the tool in

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order that the depth BC is correct profile. This distance x is
to be planned by a fly cutter or planning tool and is
measured normal to the clearance face. The amount of x is
less than actual depth of form AB produced on the work
piece because of the clearance angle . From the geometry
of the figure x = AB cos()
Figure shows a flat form tool with rake angle. The wedge
angle is given by (90 ). Using geometry of the
figure, the depth x to be ground or machined can be
determined in the following manner:
Introduction of rake angle to facilitate cutting action
modifies the profile on the tool.
Design of Forming Tools:
Circular Form Tool:
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Volume 5, Issue 1 NOV 2015
The circular form tool is circular in shape. It has depth x or
projection of distance x produced all around the diameter
in the form of annular grooves. The outside diameter of
circular form tool is determined in accordance with the
height of profile to be turned. The graphical method is
recommended for this purpose. Circular form tool is shown
in Figure.
GRAPHICAL METHOD OF DETERMINING
PROFILE OF FORM TOOL:
STRESSES ACTING ON A FORM TOOL:
Types of stress to which tools are exposed:
The types of tool load sustained in a range of non-chip
forming manufacturing techniques, are shown in figure.
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The upper die of cutting tools is exposed to shock-like

compressive and bending loads. The cutting and the lateral
area is affected by wear strain as a result of friction
between the work piece and the tool. The bottom die is
exposed to pressure and is subjected to mainly sliding
friction (wear). The face of the upper die and the surface of
the lower die should have as high a friction co-efficient as
possible, whilst the lateral area of the upper die should
have a low friction co-efficient so that the sheet does not
move during the cutting operation.

The situation in deep drawing operations is similar. Here,

the upper die is exposed mainly to pressure and only to a
low level of bending load, the lower die is exposed mainly
to friction and to a lesser degree to pressure. As in the TOOL DAMAGE AND WEAR: Types of damage
cutting operation, care must be taken to ensure that the
sheet does not flow at the upper die area. The friction co- The types of damage shown in Fig., occur as a result of the

efficient should therefore be as high as possible at the types of stress previously described. These may render the

rounding of the upper die but low at the rounding of the tool unfit for use and include:

drawing ring.
- Wear
In forward extrusion operations, compressive and
- Mechanical crack formation
temperature stresses occur at the upper die and
compressive, tensile, friction and thermal stresses at the - Thermal crack formation
lower die. Thermal load also develops in cold extrusion
- Plastic deformation.
operations as a result of the inner friction during material
flow.

The situation in the case of reverse extrusion is similar,

although the upper die is additionally affected by bending
and friction stresses.

The types of stress listed, also occur in varying degrees in

other processes such as extrusion, forging, pressure
casting and shell casting. The high operating temperatures
are particularly liable to cause stresses which are generally
masked in forging operations by additional shock stress.
CAUSES OF DAMAGE AND THEIR MECHANISMS

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Since wear is the most important type of damage, it makes
sense to investigate its causes in more detail.
There is no one material characteristic which provides a
conclusive indication in itself, as to the level of wear
resistance of that material. This is because in the vast
majority of cases, a number of causes interact and combine
to cause wear in the tribo-technical systems in industrial
practice,
These include:
- Adhesion
- Abrasion
- Surface break-up and
- Tribo-chemical reaction
Wear inhibiting coatings are frequently equated with hard
coatings. This may be true in the case of abrasive wear, in
which there is a correlation in many cases between surface
hardness and wear resistance. However, this does not
apply to other types of wear or to a combination of
stresses, since factors other than hardness, such as surface
design, toughness etc. are also important.
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Volume 5, Issue 1 NOV 2015
The most important wear mechanisms and means of
reducing wear, are therefore discussed briefly in the
following
Adhesive wear: Occurs when bonding forces in the area
of the atomic lattice take effect between two metallic
materials. The prerequisite for this is that the lattices of the
bodies concerned, are structurally similar and that they
approach one another until there is only a short distance
between them. Furthermore, the more the lattice structures
of the materials concerned differ; the lower is their
susceptibility to adhesive wear.
Abrasive wear: Occurs when the harder of the two bodies
involved in the wear process, has pronounced roughness
beaks, which tear particles of material from the surface of
the softer body. Materials which are resistant to abrasive
wear, have outstanding hardness in comparison with the
abrading material. When there is surface breakdown, the
crystal and the structural condition is damaged irreversibly
as a result of alternating stresses and which depend on the
duration and level of stress involved. Surface breakdown is
reduced when the strength of a material is high, whereas
stress peaks and notch effects result in an increase.
Tribo-chemical reactions: Occur when the wear
processes take place only in the outermost boundary layer
of the bodies involved. This boundary or interfacial layer
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can be formed by reactions between the material and the

surrounding medium. Consequently, the wear
characteristics of the base material itself have no influence
on this process. It is not possible to specify any particular
material behavior in order to avoid the tribo-chemical
reaction, since the formation and characteristics of the
outer boundary layer are determined to an equal degree by
the material and by the surrounding medium.
Consequently, the lubricant is the primary determining
Requirements to be met by the base material and the
factor. The various types of damage sustained by tools, are
subsurface layer:
illustrated in Fig by the example of a forging die. In 70 %
of all cases in which tools become unfit for use, wear is the
underlying cause. Mechanical cracking occurs in 25 % of
all cases.

In contrast, plastic deformation and thermal cracking very

rarely mark the end of tool life. These results cannot be
transferred directly to other forming operations but wear
will be the most common type of wear there too, since Tool materials for extrusion tools
shock and temperature stress are generally lower in these
MODELING & ANALYSIS:
operations than in forging.

BASE MATERIAL AND BOUNDARY LAYER:

Requirements to be met by forming tools:

Due to the types of stress listed, there are a number of

special requirements which must be met by the base
material and the boundary layer of tools. These are shown
in Fig. The focus in the following is on the requirements to
be met by the wear and strength characteristics.
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CREATING POCKET TO CREATE COUNTER OF

A TOOL

BASIC CROSS SECTIONAL PROFILE OF FORM

TOOL
CREATING SLOT

CHAMFERING
CREATING SHAFT

THICKNESS

CREATING POCKET

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Poisson's Ratio: 0.28

MESHING:

DRAFTING OF FORM TOOL

Meshing for FORM TOOL

The above image showing the meshed modal, Default solid

Brick element was used to mesh the components. The
shown mesh method was called Tetra Hydra Mesh.
Meshing is used to deconstruct complex problem into
GENERATED DRAWING LINES
number of small problems based on finite element method.
FINATE ELEMENT ANALYSIS:
APPLYING LOADS:

Imported model from CATIA to the format of IGES

DEFINING THE MATERIAL PROPERTIES

HSS OR HIGH SPEED STEEL Rotational velocity of FORM TOOL
Yield strength: 250MPa
Density: 7.7e-006 kg mm^-3
Bulk Modulus: 1.7803e+005
Shear Modulus: 91797
Poisson's Ratio: 0.28
SILICONIZED SILICON CARBIDE
Density: 3.1e-006 kg mm^-3 Force acting on FORM TOOL
Bulk Modulus: 3.2917e+005
Shear Modulus: 1.5192e+005

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been observed that the maximum stress developed is

48.957MPA.

Equivalent Elastic Strain Distribution of SISIC

MATERIAL

Figure shows the equivalent elastic strain distribution of

form tool when the load is applied onto the contact surface.
Fixed Support of FORM TOOL
It has been observed that the maximum strain developed is

RESULTS AND DISCUSSIONS 0.00017681mm/mm.

Stress Distribution of SISIC MATERIAL

Figure shows the total stress distribution of FORM TOOL

when the load is applied onto the contact surface. It has
been observed that the maximum stress developed is
68.986MPA.

Equivalent Elastic Strain Distribution of HSS

MATERIAL

Figure shows the equivalent elastic strain distribution of

Stress Distribution of HSS MATERIAL
form tool when the load is applied onto the contact surface.
Figure shows the total stress distribution of FORM TOOL It has been observed that the maximum strain developed is
when the load is applied onto the contact surface. It has 0.00020846mm/mm.

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TOTAL DEFORMATION of SISIC MATERIAL

Second mode shape of FORM TOOL
Figure 4.5 shows the total deformation of form tool when
the load is applied onto the contact surface. It has been
observed that the total deformation developed is
0.00064053mm.

Third mode shape of FORM TOOL

TOTAL DEFORMATION of HSS MATERIAL

Figure shows the total deformation of form tool when the

load is applied onto the contact surface. It has been
observed that the total deformation developed is
Fourth mode shape of FORM TOOL
0.00080489mm.

MODAL ANALYSYS

The element type and various material properties such as

youngs modulus, density and Poissons ratio are
mentioned, and they are as

Youngs modulus: 2.35e+005Mpa Fifth mode shape of FORM TOOL

Density: 7.7e-006 kg mm^-3

Poisson's Ratio: 0.28
MODAL ANALYSYS OF HSS MATERIAL:
First mode shape of FORM TOOL

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The following conclusions are drawn from the present

work

1. The Von mises stresses of HIGH SPEED STEEL are

obtained in static analysis is 48.957MPA Mpa and

Sixth mode shape of FORM TOOL Von mises stresses of SISIC is 68.986MPA

2. The deformation in HIGH SPEED STEEL

Results:
is0.00080489mm in static analysis and deformation in
Static analysis
SiSiC is 0.00064053mm.

3. The Stain Distribution in HIGH SPEED STEEL is

0.00020846mm/mm and strain distribution in SiSiC

is 0.00017681mm/mm
Modal analysis
4. The Eigen values (natural frequencies) of HIGH

SPEED STEEL are 1546.5mm and Eigen values of

SiSiC is 1478.9mm

From above stress, strain, total deformation we can

CONCLUSION:
In this project we modeled a form tool according to
customer drawing/ requirement using CATIA V5. The
observe that both HSS and SiSiC materials gave accurate
results for form tool but according to cost HSS material is
best.
References

form tool reduces the waste as errors due to operator 1. http://www.makeitfrom.com/material-

group/Aluminum-Alloy/
fatigue, interruptions and production planning. The form
2. http://www.matweb.com/search/PropertySearch.aspx
tool mainly used to reduce the machining time and 3. http://accessengineeringlibrary.com/maps/strength-of-

analyzed and stresses are using FINITE ELEMENT materials

4. http://www.technologystudent.com/joints/matprop1.ht
ANALYSIS with SISIC material as compared to High
m
Speed Steel material 5. http://www.engineershandbook.com/Materials/mecha
nical.htm

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6. http://www.technologystudent.com/joints/matprop1.ht
m
7. https://en.wikipedia.org/wiki/Cnc-formtool
8. https://www.google.co.in/?gfe_rd=cr&ei=xgGLVfKS
Bafv8wftlJO4Dg&gws_rd=ssl#q=cnc%20form%20to
ols%20wikipedia
9. https://www.google.co.in/?gfe_rd=cr&ei=xgGLVfKS
Bafv8wftlJO4Dg&gws_rd=ssl#q=cnc+milling+machi
ne+form+tool
10. Brown & Sharpe, Automatic Screw Machine
Handbook p.
11. Jump up^ Hartness, James (1910), Hartness Flat
Turret Lathe Manual, Springfield, Vermont, USA:
Jones and Lamson Machine Company,
12. Jump up^ Kanigel, Robert (1997), The One Best Way:
Frederick Winslow Taylor and the Enigma of
Efficiency, Viking Penguin, ISBN 0-670-86402-1

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