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DFM Lecture Notes

The document discusses the design process for tools including defining problems, analyzing requirements, developing ideas, selecting alternatives and finalizing designs. It also covers topics like cutting tools, locating and clamping workpieces, limit gauges, metal forming dies, selecting tool materials and heat treatment.

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Shreya Uppu
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36 views15 pages

DFM Lecture Notes

The document discusses the design process for tools including defining problems, analyzing requirements, developing ideas, selecting alternatives and finalizing designs. It also covers topics like cutting tools, locating and clamping workpieces, limit gauges, metal forming dies, selecting tool materials and heat treatment.

Uploaded by

Shreya Uppu
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 15

Overview of Tool Design 1

Content
• The Design Process
• Cutting Tools
• Locating and Clamping Methods
• Limit Gauges
• Metal Forming Dies
• Selection of Tooling Materials
• Heat Treatment

2
The Design Process
Comprises the planning, designing, developing, and
analysis of tools, methods and procedures
necessary to increase efficiency and productivity.

 Statement and analysis of the problem


 Analysis of the requirements
 Development of initial ideas
 Development of possible design alternatives
 Finalization of design ideas
3
1. Statement and analysis of the problem
 The first step in the design of any tool is to define the
problem or objective as it exists without tooling.

2. Analysis of the requirements


 Perform specific functions
 Meet certain minimum precision requirements
 Keep costs to a minimum
 Be available when the production schedule requires it
 Be operated safely
 Meet various other requirements such as adaptability to
the machine
 Have an acceptable working life
4
3. Development of initial ideas

 Initial design ideas are normally conceived after an


examination of the preliminary data.
 In many cases, the designer and planner (responsible for tool
request) work together in a team environment to develop
the initial design parameters.

4. Development of possible design alternatives

 During the initial concept phase of design, many ideas will


occur to the designer and/or the team. There are always
several ways to do any job.

5
5. Finalization of design ideas

 Once the initial design ideas and alternatives are determined,


the tool designer must analyze each element to determine
the best way to proceed toward the final tool design.

 Rarely is one tool alternative a clear favourite. The tool


designer must evaluate the strong points of each alternative
and weigh them against the weak points of the design.

6
Cutting Tools

 Feature to be machined
 Work material and material condition
 Tool material and coatings
 Cutting tool/insert geometry
 Tool/insert holder (size/shape)
 Use of cutting fluids
 Inspection of rotating tools (Runout)

7
Locating and Clamping
 Locating the work piece - The dimensional and positional
relationship between the work piece and the cutting tool
used on the machine.

 Generally, 9 out of 12 degrees of freedom need to be


restricted using locators.

 3 degrees of freedom (+X, +Y & +Z) are free to load the


component on the machine table.

8
 Clamping the work piece - During machining operation,
clamping is a way to counter the cutting forces and keep the
workpiece in the located position.

 After loading the component, remaining degrees of


freedom are going to be arrested using clamps.

Manual work setting

9
 Jigs & Fixtures are designed based on the locating &
clamping principles.
 If rightly designed they ensure faster loading and ensures
produce the parts at high production rate with high
precision & accuracy.

JIG Fixture

 JIGs – Ensures the drilling (position) of the hole at right


place by guiding the drill bit.
 FIXTUREs – Means for holding and locating the workpiece
during machining operation.
10
Limit Gages
Gauge (Go/No-Go) are inspection tools of rigid design, without a
scale, which used to check the maximum and minimum material
limits of the manufactured components (accept/reject).

Gauge is not recommended if the tolerances on the components


are less than 20 µm, as the tolerances become so close on the
gauges (10% of work tolerances), and difficult to manufacture
and use them because of alignment and wear related issues.

 Gauges are designed based on Taylor’s principles and prime


objective is a gauge should not accept the part which is
manufactured outside its limits.
 Limits on the No-Go gauge are critical as the part rejected will
be scrapped as it checks the minimum material limit.
11
Sheet Metal Forming Dies
 A die is a specialized tool used in manufacturing industries
to cut or shape material mostly using a press.

 A stamping die, one-of-a-kind precision tool that cuts and


forms sheet metal into a desired shape or profile.

12
Tooling Materials and Heat Treatment

It is important to consider proper selection of materials and


heat treatment at the design stage itself.

Material selection
Heat treatment
Hardness requirement
Distortion control

Material for a tool is determined by the mechanical & other


properties necessary for that tool’s proper operation, i.e.,
elastic modulus, wear resistance and dimensional stability.

13
Tooling Materials and Heat Treatment

14
Tooling Materials and Heat Treatment
The principal materials used for tools can be divided into
three major categories:
Ferrous metals, Nonferrous metals, Non-metallic materials
For most applications, more than one type of material will be
satisfactory, and a final choice normally will be governed by
material availability and economic considerations.

 Heat Treatment
Tool steels are high in alloying elements, not only helps in
attaining required material properties (hardness, strength,
toughness etc.), also allows air quenching during heat
treatment, helps in avoiding distortions.

Next Topic: 3. Introduction to Jigs & Fixtures 15

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