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Design of Forming Tools

- A forming tool is a type of cutting tool used to make specific parts by pressing into a workpiece and cutting away excess material, drastically reducing production costs compared to other methods. - Forming tools are made of high-grade steel, tungsten carbide, or cobalt alloys and have custom bits for each part. - Small bit sizes allow for greater pressure and less vibration during cutting for improved accuracy, speed, and bit life.

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493 views

Design of Forming Tools

- A forming tool is a type of cutting tool used to make specific parts by pressing into a workpiece and cutting away excess material, drastically reducing production costs compared to other methods. - Forming tools are made of high-grade steel, tungsten carbide, or cobalt alloys and have custom bits for each part. - Small bit sizes allow for greater pressure and less vibration during cutting for improved accuracy, speed, and bit life.

Uploaded by

kunwar
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Design of forming tools

A forming tool is a type of cutting tool used for making specific


parts.
Each forming tool has bits that are custom-made for the creation
of a specific part.
These bits are usually made of high-grade steel, tungsten carbide
or an alloy of cobalt.
A forming tool presses into an object and cuts away any
unwanted material.
This leaves behind a complex item that requires only a single cut
to produce, drastically reducing its production cost compared to
other methods.

Most forming tool bits are relatively small. The small size allows
the forming machine to put a greater amount of pressure on the
bit while still keeping the pressure even. It also reduces the
amount of vibration while cutting. Lower vibration is important
because it reduces wear on the bit, increases the accuracy of the
cut and improves the speed of the cutting process
Form tools utilized for turning applications are classified
according to type of cross section.

VARIOUS TYPES OF FORMING TOOLS


Flat Form Tool:
Straight and flat form tools have a square or rectangular crosssection with the form being along the side or end. Some times
flank face is made cylindrical contoured.
These tools are similar in appearance to the turning tools. These
are usually set centrally so that they will cut their contour which is
identical to the desired contoured of the workpiece.

VARIOUS TYPES OF FORMING TOOLS


circular Form Tool:
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.

Design and draw a circular form tool for the component shown
below using graphical method. Material of work piece is M.S.
having BHN= 120. select suitable rake and relief angle.
Solution :
For M.S having BHN 120, select

250
100

Recommended value of chip space is given by variable K and it


varies from 3 to 12mm.
Draw the front and top views of the job and mark OA=10mm,
Where A is the nearest tool tip to centre of job .
Draw a line inclined at an angle of 25 from A representing .
From same point A draw a vertical line.
draw another line AE at an angle of 10 to represent relief angle
.

Draw a vertical line at a distance of 10mm from to represent chip


space K such that AF =20+10=30mm.
Let D be the intersection point of rake face of tool and vertical
line through F.
Bisect the angle 115 at D.
At A draw a Perpendicular to AE.
Let Perpendicular to AE meet the bisector drawn at D at O1.
Then O1 is the centre of the form tool.
With O1 as centre and O1A as radius draw a point of circle
starting on A to meet the vertical drawn through F. hence the
profile of the form tool.
Let the rake face of the form tool intersect the other diameters 30
and 60mm at B and C respectively. Join A,B, and C to O1.

O1A=R1=74mm; O1B=R2=69mm,O3=R3=60mm.
Provide the wall thickness m=10mm. Draw circle representing the
mounting hole.
for the form tool provide serrations (normally 25 t o35) for
mounting and avoiding the slipping of form tool during machining
operation.
Include the sectional ( section X-X ) side view showing the profile
of the tool.
Provide a length of 5mm on each side as marginal value.

Design of Broaching tools

Broaching is a machining process that uses a toothed tool, called


a broach, to remove material.
There are two main types of broaching: linear and rotary.
In linear broaching, which is the more common process, the
broach is run linearly against a surface of the work piece to effect
the cut. Linear broaches are used in a broaching machine.
In rotary broaching, the broach is rotated and pressed into the
work piece to cut an axis symmetric shape. A rotary broach is
used in a lathe or screw machine.
In both processes the cut is performed in one pass of the broach,
which makes it very efficient.

Uses:
Broaching is used when precision machining is required,
especially for odd shapes.
Commonly machined surfaces include circular and non-circular
holes, splines, keyways, and flat surfaces.
Typical
work
pieces
include
small
to
medium
sized castings, forgings, screw machine parts, and stampings.

Design of Broaching tools:


Design the round broaching tool for the following component
made of steel.

Data:
Length to be broached: L=64mm;
Diameter of hole to be broached D=40mm
Broach allowance: Ab=0.005D+ (0.1 to 0.2) L
= 0.005*40+0.2* 64
= 1.8mm
Diameter of hole previous to broaching: D-Ab =40-1.8
=38.2
No of cutting teeth for round broach
Ab
Zc
2to 4
2S z
Note:
Sz =feed/teeth
For circular hole
steel -- 0.02 to 0.08 mm/tooth
C.I -- 0.02 to 0.08 mm/tooth
Brass or Bronze 0.04 to 0.15 mm/tooth

For key way and splines


steel 0.08 to 0.15 mm/tooth
C.I --0.08 to 0.15 mm/tooth
Brass and Bronze 0.15 to 0.3mm/tooth
Since round broach is used select Sz =0.05mm/tooth.
No of cutting teeth Z 1.8 2 20teeth
c

2 0.05

Out of 20 teeth 15 teeth are assigned for rough cutting with an Sz


value =0.05mm/tooth and remaining five teeth with an Sz value
=0.03mm/tooth. 5 more teeth are provided for sizing and
burnishing purpose.
Total no of teeth = 15+5+5=25

Pitch of cutting teeth = P=[1.25 to 1.5]

P 1.25 64 =10mm

Area of longitudinal section of the chip for one pass(AC)


=L*S2 =64*0.05=3.2mm2
It is not desirable that chip should get compressed and jam up
the entire surface allow clearance between the coils of
continuous chip and free formation of a discontinuous chip.
Effective section is taken as 3 to 6 times actual chip section.

Ae
k
Ac
K varies from 3 to 6.
Let k= 4, so
A

4* Ac 4*3.2 12.8mm

If h is the height of chip space and if chip space is assumed to


be circular,
2
then,
h

Ae

or

12.8

h2
4

Or where h=gullet radius=4mm


Land width and slope of back of the tool are given below.
w = (0.4 to 0.6)P
=(0.2 to 0.35)P
=45 to 500

Chose w=0.4 P=0.4*10=4mm


=0.2P
=450
Cutting force Fz
Minimum no of teeth in contact with the component at a time,

L
64

Zi

10

1 7.4teeth

The total length of cutting edges is given by


l DZ i 40 7 879.6mm

Cutting force = l * Q
Q=cutting force required /unit length N/mm
ranges from 100 to 450N/mm
Force = 879.6*200= 175920N
Power of broach

cuttingforce velocityofbroach
PB
KW
1000 60
Note: velocity of broach is between 4 to 5m/min for steel.
Let us select Velocity=4.5m/min
PB

175920 4.5
KW
1000 60

13.194KW

Assuming an efficiency of 0.8 for the motor,


The power of the broach becomes

13.194

16.492 KW
0.8
The rating of motor will be 17KW.
Length of broach = toothed length +pull end +
neck + front pilot+ rear pilot+ retrieving end
=250+50+50+70+70+60=600mm=0.6m
Stroke length of broach = 0.6m
Chip breaker grooves are provided to break wide or circular chip.
Upto 20mm diameter
= 6-10
20mm and more diameter = 10-12
12 chip break grooves are provided on each roughing tooth in staggered
manner.
Clearance angle are 3o,20,10 for roughing ,semi finish and finishing
tooth.
Rake angle 100 for roughing, semi finish and 50 for finish tooth

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