Tool Design

Course Code: MEE4001

Lecture - 3
12-Dec-2018

Dr. R. Mohan
Associate Professor
SMBS
 TOPICS

• Tool Drawing
 Tool Drawing

Tool Drawings are used to transfer detailed

instructions from the tool designer to the
toolmaker.

The form and specifications of these drawings

are normally established within each company to
meet the particular needs

However, there are standards and conventions

that all companies follow
 Tool Drawing
Tool Drawings differ from Production
Drawings in the amount of details shown

Tool makers are highly skilled technicians.

Therefore they need less detailed information on
drawings.

Example
If the tool designer specifies two .25 inch dowel pins to be
located on 2 inch centers, he/she does not to specify the hole
size on a tool drawing.
Following standard tool making practices would automatically
make the hole smaller to allow for press fit on the dowels.
 Types of Tool Drawing
Assembly Tool Drawings
It shows the entire tool in its completed form will all parts in their
proper place.

Every details of the Tool are shown

without an individual drawing of
each part having to be made.

3rd angle
projection
 Types of Tool Drawing
Detailed Tool Drawings
It is used to show tools with many parts that must be drawn
separately to show the true sizes and shapes

Tool that is too

complex for an
assembly drawing,
detailed drawing
must be used
 Types of Tool Drawing
Using assembly along with detailed drawings,
allows the tool maker to see how each part is
located in the final tool.

Assembly and detailed drawings used together

 Types of Tool Drawing
Using assembly along with detailed drawings,
allows the tool maker to see how each part is
located in the final tool.

Assembly and detailed drawings used together

 Systems of Limits and Fits
[Based on IS 919 (Part 1):2014/ISO 286-1:2010]

The standard reference temperature is 20 C for industrial

measurements and, consequently, for dimensions defined by
the system.

Due to the inevitable inaccuracy of manufacturing methods,

a part cannot be made precisely to a given dimension, the
difference between maximum and minimum limits of size is the
tolerance.

When two parts are to be assembled, the relation resulting

from the difference between their sizes before assembly is
called a fit.
 Systems of Limits and Fits

Diagram illustrating basic size deviations and tolerances

 Systems of Limits and Fits
Tolerance
The permissible variation of a size is called tolerance. It is the difference
between the maximum and minimum permissible limits of the given
size. If the variation is provided on one side of the basic size, it is
termed as unilateral tolerance. Similarly, if the variation is provided on
both sides of the basic size, it is known as bilateral tolerance.

Limits
The two extreme permissible sizes between which the actual size is
contained are called limits.
The maximum size is called the upper limit and the minimum size is
called the lower limit.

Deviation
It is the algebraic difference between a size (actual, maximum, etc.) and
the corresponding basic size.
 Systems of Limits and Fits

Actual Deviation
It is the algebraic difference between the actual size and the
corresponding basic size.

Upper Deviation
It is the algebraic difference between the maximum limit of the size
and the corresponding basic size.

Lower Deviation
It is the algebraic difference between the minimum limit of the size
and the corresponding basic size

Fundamental deviation
The deviation closest to the basic size
 Systems of Limits and Fits
Allowance
It is the dimensional difference between the maximum material
limits of the mating parts, intentionally provided to obtain the
desired class of fit.
If the allowance is positive, it will result in minimum clearance
between the mating parts and if the allowance is negative, it will
result in maximum interference.

Nominal Size / Basic Size

Size of a feature of perfect form as defined by the drawing
specification
Here, the two limit dimensions of the shaft are
deviating in the negative direction with
respect to the basic size and those of the hole
in the positive direction. The line corresponding
to the basic size is called the zero line or line of zero
deviation
 Systems of Limits and Fits

Design Size
It is that size, from which the limits of size are derived by the
application of tolerances.
If there is no allowance, the design size is the same as the basic size.
If an allowance of 0.05 mm for clearance is applied, say to a shaft of
50 mm diameter, then its design size is (50 – 0.05) = 49.95 mm. A
tolerance is then applied to this dimension.

Actual Size
It is the size obtained after manufacture. (by measurement)
 Lower and Upper Deviations
HOLE SHAFT

Max Hole size – Basic Size = Upper Deviation

Max shaft size – Basic Size = Upper Deviation
Min Hole size – Basic Size = Lower Deviation
Min shaft size – Basic Size = Lower Deviation

Fundamental deviation
The deviation closest to the basic size.
 Types of Fits

When two parts are to be assembled, the relation

resulting from the difference between their sizes before
assembly is called a fit.

1. Clearance Fit
2. Interference Fit
3. Transition Fit
 CLEARANCE FIT

Maximum shaft dimension < Minimum hole dimension

FIT - condition of looseness or tightness between two mating parts

being assembled together
 INTERFERANCE FIT

Maximum Hole size < Minimum Shaft size

 TRANSITION FIT

Obtained by overlapping of tolerance zones of shaft and hole

……Does not guarantee neither clearance nor interference fit
 Basic Hole and Shaft Systems
To obtain different types of fits, it is general practice to vary
tolerance zone of one of the mating parts

HOLE BASED SYSTEM-

Size of hole is kept constant,
shaft size is varied to get
different fits.

SHAFT BASED SYSTEM-

Size of shaft is kept constant,
hole size is varied to get
different fits.
 Basic Hole and Shaft Systems
To obtain different types of fits, it is general practice to vary
tolerance zone of one of the mating parts

Basic hole and shaft systems for applying tolerances to parts

 Tolerance zone
The tolerance and its
position relative to the
basic size

Graphical illustration of tolerance

zones
The selection of letter freezes Representation of
one limit of hole / shaft
Tolerance
(how much away from Basic
size) 1) Letter Symbol
Basic Size
45 E8/e7

One can have different

possible combinations; eg.
45H6g7, 45H8r6, 45E5p7

E.S. – upper deviation

E.I. – lower deviation

H : lower deviation of hole is zero

h : upper deviation of shaft is zero

The selection of Representation of
Tolerance grade number
freezes the other limit of Tolerance
hole / shaft

H : lower deviation of
hole is zero
Representation of Fit Together (Letter & Grade)
on both mating
components decide quality
of fit

0.021

INTERFERENCE Φ30.035
FIT Φ30.022
Φ30.021
0.013
0.022
Φ30.000

H7 : Tol Grade 7 mean 21μ variation

(H means upper deviation zero)

p6 : Tol Grade 6 means 13μ variation

(p means upper deviation is 22 μ)
Tolerance representation
on Components
 Tolerance

Degree of accuracy expected of manufacturing process

 Machining Symbols

When preparing working drawings of parts to be cast

or forged, the drafter must identify part surfaces that
require machining or finishing.
This is done by adding a machining allowance
symbol to the surfaces that must be finished by
removal of material.
This information is essential in order to alter the
pattern maker and die maker to provide extra metal
on casting or forging to allow for the finishing.
 Machining Symbols
Like dimensioning, machining symbols are not
duplicated on the drawing.
They should be used on the same view as the
dimensions that give the size and location of the
surfaces.
The symbol is placed on the line representing the
surface or on the leader or an extension line locating
the surface.
The symbol and the inscription should be oriented so
they may from the bottom or right hand side of the
drawing
 Machining Symbols

Where all the surfaces are to be machined, a general

note such as FINISH ALL OVER(FAO) may be used
and symbol on the drawings omitted.
The machining symbol does not indicate surface
finish quality.
The surface texture symbol, is used to signify the
desired surface finish quality
Machining Symbols
The basic symbol consists of two
legs of unequal length, inclined at
approximately 60° to the line,
representing the surface considered.
This symbol may be used where it is
necessary to indicate that the
surface is machined, without
indicating the grade of roughness or
the process to be used.
 Machining Symbols

a) Basic symbol may be used where it is necessary to

indicate that the surface is machined, without
indicating the grade of roughness or the process to be
used.

b) If removal of material is not permitted, a circle is

added to the basic symbol. This symbol may also be
used in a drawing, to indicate that a surface is to be
left in the state, resulting from a preceding
manufacturing process, whether this state was
achieved by removal of material or otherwise.
 Machining Symbols

c) If the removal of material by machining is

required, a bar is added to the basic symbol

d) When special surface characteristic have to be

indicated, a line is added to the longer arm of the
basic symbol
 Machining Symbols

Application of machining symbol on drawing

 Machining Symbols

Application of machining symbol on drawing

 Machining Symbols
Indicating Machining Allowance

When the value of Machining Allowance must be

specified, it is indicated to the left of the symbol.

Indicating Value of Machining Allowance

 Machining Symbols
Indicating Machining Allowance

The value of Machining Allowance

as shown on the drawing
 Machining Symbols
Indicating Special Surface Characteristics

Indicating special surface characteristics

achieved by different process
If it is required that the final surface texture be produced by one particular
production method, this method should be indicated on an extension of the longer
arm of the symbol.
Also, any indications relating to treatment of coating may be given on the
extension of the longer arm of the symbol
 Machining Symbols
Indicating Special Surface Characteristics

Unless otherwise stated, the numerical value of the roughness,

applies to the surface roughness after treatment or coating.
If it is necessary to define surface texture, both before and after
treatment, this should be explained by a suitable note
 Indication of Surface Roughness

All surface finish control begins in the drafting room.

The designer is responsible for specifying the correct surface
finish for maximum performance and service life at the lower
cost.
In selecting the required surface finish for any particular part,
the choice is based on the designer’s experience. Field
service data and engineering tests.
Many factors influence the designer’s choice which include
the function of the parts, type of loading, the speed and
direction of movement and operating conditions.
 Indication of Surface Roughness

Two principle reasons for surface finish control are friction

reduction and the control of wear.

Whenever, a lubrication film must be maintained between two

moving parts, the surface irregularities must be small enough
to prevent penetrating the oil film under even the most severe
operating conditions.
Parts such as bearings, journal, cylinder bores, piston pins,
bushings, pad bearings, helical and worm gears, seal
surfaces and machine ways are objects where this conditions
must be fulfilled.
 Indication of Surface Roughness

Surface finish is also important to wear service of certain

pieces subject to dry friction such as machine tool bits,
threading dies, stamping dies, rolls, clutch plates and brake
drums.
Smooth finished are essential on certain high precision
pieces. In mechanisms such as injectors and high pressure
cylinders, smoothness and lack if waviness are essential to
accuracy and pressure retaining ability.
Smooth finishes are also used on micrometer anvils, gages,
gage blocks and other items
 Indication of Surface Roughness

Smoothness is often important for the visual appeal

of the finished product. For this reason, surface
finish is controlled on rolls, extrusions dies and
precision casting dies.
For gears and other parts, surface finish control
necessary to insure quite operation
Indication of Surface Roughness
represents surface roughness value
 Indication of Surface Roughness

When only one value is specified to indicate surface

roughness, it represents the maximum permissible value. If it
is necessary to impose maximum and minimum limits of
surface roughness, both the values should be shown, with
the maximum limit, a1, above the minimum limit, a2
Indication of Surface Roughness

The direction of lay is

the direction of the
predominant surface
pattern, ordinarily
determined by the
production method
employed.
Indication of Surface Roughness
Indication of Surface Roughness
Thanks