1 / 47

Tool Design

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

holly
Download Presentation

Tool Design

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. Tool Design

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

  3. General Considerations • Safety and Ergonomics • Tool Materials • Heat Treatment • Surface Roughness and Finish • Tolerances and Fits • Tooling Economics • Material Handling

  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

  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

  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

  7. Tool Materials (II) • Non-ferrous materials - limited productions only (Aluminum, Magnesium, Zinc, Lead, Beryllium, Bismuth) • Composite materials – soft tools for limited run

  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.

  9. Fixture & Jig Fixture: - Hold and accurately position a workpiece Jig: - Also be used to hold and position a workpiece. - Provides some means for guiding the cutting tool http://www.youtube.com/watch?v=ujKyRrf-Z1M&feature=channel_page http://www.youtube.com/watch?v=2ikkuZe0zQU&feature=channel_page

  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

  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

  12. Examples III Automatic Reversible Cam Action Workholding Assemblies http://www.youtube.com/watch?v=vrrjLYn-6WY

  13. Methods of Location3-2-1 Principle 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

  14. Methods of Location I 12 degrees of freedom 3 pins arrest 5 dof

  15. Methods of Location II 6 pins arrest 9 dof 5 pins arrest 8 dof Horizontal workpiece Vertical workpiece

  16. Methods of Location III Radical location with internal pins or plug Radical location by external pins

  17. Methods of Location IV 7 dof arrested by V locator with stop pin Workholder with multiple V locators

  18. Tool Forces I Pin-type drill fixture resisting torque and thrust Tapping fixture resisting torque and thrust

  19. Tool Forces II Workholder for broaching operation Cutting Forces resisted by solid jaw of vise Cutting force resisted only by friction

  20. Tool Forces III • Mechanical methods of transmitting and multiplying force • Screw • Cam • Wedge • Toggle link • Lever • Combined screw and wedge

  21. Clamping Forces I Fixture components

  22. Clamping and Support http://www.youtube.com/watch?v=l-V4mplHjZ8 Clamping and support of large workpiece

  23. Fixture Components

  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

  25. Jigs and Fixture Design Principles • 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

  26. Fixture for Rectangular Components Clamping action • Location and holding for flat surface • Base plate - reference surface for setup • Clamp – quick action cam-based clamp

  27. Fixture for Rectangular Components • Hydraulic clamp for larger clamping force • Swing clamp http://www.youtube.com/watch?v=1RMqoQlZ-2c http://www.youtube.com/watch?v=jkAINXgZaCk

  28. Fixture for Rectangular Components 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

  29. Fixture for Rectangular Components Electrostatic chuck Vacuum chuck

  30. Fixture for Circular Components Round workpiece held with strap clamp and T bolts Fixture for straddle milling connecting rod

  31. Fixture for Circular Components Workpiece held in a 4-jaw chuck for a boring operation http://www.youtube.com/watch?v=npJfKhkS0QE Nut arbor

  32. Fixture for Circular Components Drill jig – V block, quick-acting clamp, and drill bushing combination V block http://www.youtube.com/watch?v=QFH2kUorn88

  33. Fixture for Circular Components Internal and endwise chucking Between centers and combination with chucking

  34. Fixture for Circular Components Solid mandrel Roll lock type expanding mandrel

  35. Fixture for Circular Components Axial location by collet Split busing and split collet Collet with stopper http://www.youtube.com/watch?v=bJIIeN4rg3E

  36. Fixture for Circular Components Collet with immediate bushing to eliminate axial shift Collet for internal chucking

  37. Rigid and Elastic Workholding Rigid workholding Elastic and spring workholding Rigid/hydraulic workholding

  38. Accuracy of Work Location Concentricity of workpiece by collet Accuracy of work location

  39. Workholders for Irregular Workpiece Pump-type jigs

  40. Workholding Selection Workpiece rotation Tool rotation

  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

  42. Cutter Setup

  43. Box-Type Drill Jigs

  44. Milling Fixture

  45. Milling Fixture

  46. Milling Fixture Indexing fixture http://www.youtube.com/watch?v=JkftVHaMQSs Key slot milling

  47. Milling Fixture

More Related