MECH152-L25 - 1

Tool Design

MECH152-L25 - 2

Types of Tools

Material Cutting Tools

Workholding Devices
Pressworking Tools
Bending, Forming
and Drawing Dies
http://www.youtube.com/watch?v=gkHbRVUvFgw&feature=channel_page
Tool Design for Inspection and Gaging
Tool Design for Joining Process
Tooling for Casting
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

Safety and Ergonomics

Tool Materials
Heat Treatment
Surface Roughness and Finish
Tolerances and Fits
Tooling Economics
Material Handling

MECH152-L25 - 4

Safety and Ergonomics (I)

Safety should be built into the design
with due respect to legal requirements
Sufficient clamping and rigidity 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 and Ergonomics (II)

Exhaust system for air polluting system
All adjustments and clamping should be
easily accessible
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 handling pressurized and
toxic equipment

MECH152-L25 - 6

Tool Materials (I)

Tool steels (principal materials)
Tool and Die Steel (typical hardness RC40~60)

W, Water-Hardening Tool-Steels
O, Oil-Hardening Tool-Steels
A, Air-Hardening Medium Alloy Die-Steels
D, High-Carbon High-Chromium Die Steels
S, Shock-Resisting Tool-Steels
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 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,
Magnesium, Zinc, Lead, Beryllium,
Bismuth)
Composite materials soft tools for
limited run

MECH152-L25 - 8

Workholding Devices
Workholding Devices All devices that
hold, grip, or chuck a workpiece in a
prescribed manner of firmness and
location, to perform on it a
manufacturing operation.

MECH152-L25 - 9

Fixture & Jig

Fixture:
- Hold and accurately position a
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
the cutting tool
http://www.youtube.com/watch?v=2ikkuZe0zQU&feature=channel_page

MECH152-L25 - 10

Examples - 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 II
http://www.steelsmith.com/

Swing Clamp
Please refer to the
price list also!

ARM: MODULAR IRON PER ASTM

A536 GRADE 65-45-12, ZINC PLATED
CLEAR CHROMATE
ALL OTHER PARTS: MILD STEEL,
BLACK OXIDE FINISH

MECH152-L25 - 12

Examples III

Automatic
Reversible Cam
Action Workholding
Assemblies

http://www.youtube.com/watch?v=vrrjLYn-6WY

Methods of Location
3-2-1 Principle

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 in a third plane
If the planes are perpendicular to each
other

- Buttons should be as far apart as

possible
- Greater 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 pins arrest
9 dof
Vertical
workpiece

MECH152-L25 - 16

Methods of Location III

Radical location
with internal pins
or plug

Radical location
by external pins

MECH152-L25 - 17

Methods of Location IV
7 dof
arrested by
V locator
with stop
pin

Workholder with
multiple V locators

MECH152-L25 - 18

Tool Forces I

Pin-type drill
fixture resisting
torque and thrust

Tapping
fixture
resisting
torque and
thrust

MECH152-L25 - 19

Tool Forces II
Workholder for
broaching operation

Cutting
Forces
resisted by
solid jaw
of vise
Cutting force resisted
only by friction

MECH152-L25 - 20

Tool Forces III

Mechanical
methods of
transmitting and
multiplying force
(A) Screw
(B) Cam
(C) Wedge
(D) Toggle link
(E) Lever
(F) Combined
screw and wedge

MECH152-L25 - 21

Clamping Forces I

Fixture
components

MECH152-L25 - 22

Clamping and Support

http://www.youtube.com/watch?v=l-V4mplHjZ8

Clamping and
support of large
workpiece

MECH152-L25 - 23

Fixture Components

MECH152-L25 - 24

Fixture Components
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 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

Clamping action

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

Hydraulic clamp for larger clamping force

Swing clamp http://www.youtube.com/watch?v=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

Vacuum
chuck
http://www.youtube.com/watch?v=xr3lfAvQuJs&feature=related
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 held in a 4jaw 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

Internal and
endwise
chucking

Between centers
and combination
with chucking

Fixture for Circular

Components

Solid mandrel

MECH152-L25 - 34

Roll lock type

expanding mandrel

Fixture for Circular

Components
Split busing 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 with immediate

bushing to eliminate
axial shift

Collet for internal chucking

MECH152-L25 - 37

Rigid and Elastic Workholding

Rigid workholding

Elastic and spring workholding

Rigid/hydraulic workholding

MECH152-L25 - 38

Accuracy of Work Location

Accuracy of work location

Concentricity of workpiece
by collet

Workholders for Irregular

Workpiece

MECH152-L25 - 39

Pump-type jigs

MECH152-L25 - 40

Workholding Selection

Workpiece rotation

Tool rotation

MECH152-L25 - 41

Workholding Selection
Steady to
reduce
workpiece
vibration

Minimizing cutting
force by applying
holding force close to
point of tool application

http://www.youtube.com/watch?v=2o74aR0JL1k

MECH152-L25 - 42

Cutter Setup

MECH152-L25 - 43

Box-Type Drill Jigs

MECH152-L25 - 44

Milling Fixture

MECH152-L25 - 45

Milling Fixture

MECH152-L25 - 46

Milling Fixture

Indexing fixture
http://www.youtube.com/watch?v=JkftVHaMQSs

Key slot milling

MECH152-L25 - 47

Milling Fixture