Production Tool Design:

Introduction

TAUFIK
Faculty of Manufacturing Engineering
UTeM
Week 1

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 Learning Objectives
 The objectives of this chapter are to :
1. List the objectives of tool design.
2. Explain the types of tools.
3. Apply the design process of tool design.
4. Describe the functions of a tool designers.

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 Tool Design in Manufacturing
 To be competitive in manufacturing requires the
success of concurrent engineering.
 As one of the concurrent team member, tool
design member involved in product design and
production where their knowledge of fixtures and
manufacturing will result in fewer design error.

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 Tool Design
 A process of designing and developing the
tools, methods and techniques necessary to
improve manufacturing efficiency and
productivity.

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 Tool Designer and Responsibility
 Provide simple, easy-to-operate tools for maximum efficiency.
 Reduce manufacturing expenses by producing parts at the
lowest possible cost.
 Design tools that consistently produce parts of high quality.
 Increase the rate of production with existing machine tools.
 Design the tool to make it foolproof and to prevent improper
use.
 Select materials that will give adequate tool life.
 Provide protection in the design of the tools for maximum
safety of the operator.

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 Objective of Tool Design
 Production Tool is an important component of
manufacturing which contributes to
- maintain production quality (Q)
- lower production cost (C)
- reduce production lead time (D)
significantly.

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 But how….?
 Production Tool could help to:
-Provide simple, easy-to-operate tools for maximum efficiency.
-Reduce manufacturing expenses by producing parts at the lowest
possible cost.
-Design tools that consistently produce parts of high quality.
-Increase the rate of production with existing machine tools.
-Design the tool to make it foolproof and to prevent improper use.
-Select materials that will give adequate tool life.
-Provide protection in the design of the tools for maximum safety.

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 Production Tool in Mass
Production
 Mass production aims at high productivity :
-to reduce unit cost and interchangeability
-to facilities easy assembly.

 This necessitates:
-production tool to increase the rate of manufacture
-inspection device to speed up inspection procedure.

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 Production Tool
 Are generally work holders with/without
tool guiding/setting arrangement.
 These are called Jigs and Fixtures

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 Types of Tools
a. Material Cutting Tools
 The selection of cutting tools material for
particular application is among the most
important factors in production tooling, as
is the selection of production tooling
materials for holding, supporting, and
clamping the workpiece must be
maintained.

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 Types of Material Cutting
Tools
 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

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 Material Used
 High Speed Steels (HSS)
 Contains 18% tungsten (toughness &
cutting strength), 4.3% chromium
(hardenability & resistance), 1%
vandadium (retention)
 Air or oil hardened to RC 64-65 (cutting tools),
i.e. drills, reamers and cutters

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 Material used (2)
 Die Steels
 For high temperature work like forging, casting
and extrusion
 Carbon Steels
 For bushing and locator
 Collet Steels (Spring Steels)
 Tempered to RC 47 hardness
 High Tensile Steel
 For press rams

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 Material Used (3)
 Oil Hardening Non-Shrinking Tool Steel
(OHNS)
 For fine parts i.e. taps, hand reamers, milling
cutters.
 Case Hardening Steels
 For part only local hardness on small wearing
surface
 Mild Steel
 For parts not subjected to much wear

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 Material Used (4)
 Cast Iron
 For used widely in milling fixtures
 Steel Casting
 Combine steel strength & casting shape
 Nylon and Fiber
 For soft lining for clamps (prevent damage)
 Phosphor Bronze
 For replaceable nuts in screw (time consume &
costly)

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 Type of Tools
b. Workholding Devices
Workholding Devices means all devices that hold, grip, or
chuck a workpiece in a prescribed manner of firmness and
location, to perform on it a manufacturing operation.).

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 Type of Tools
c. Pressworking Tools
 The purpose production tooling in term of pressworking tools are to
hold and clamp of the workpiece during pressworking processes.  
d. Bending, Forming and Drawing Dies
 The purpose production tooling in bending, forming and drawing
dies are to support, hold, and clamp of the workpiece during
bending, forming and drawing dies processes in order to develop a
high level of the precise tolerances.
e. Tool Design for Inspection and Gaging
 Every dimensions of every work piece must be specified as being
between two limits.

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 Work Holding Devices Definition
 Work holding devices include all
devices that hold, grip or chuck a
workpiece to perform a
manufacturing operation.
 The holding force may be

applied mechanically,
electrically, hydraulically or
pneumatically.

Principles of work holding

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 Typical Workholding Devices

 Vise: it is an elementary workholder (Figure a).

 The clamping force is applied using a screw
mechanism. The holding force is applied using
a lever to exert a torque (T).
 T = F x a in.lb
 Where F = human force in lb.
 a = Lever length in inches. (a) Elementary Workholder (vise)
 Vise with hydraulic clamping (Figure b). The
holding force is applied using hydraulic
pressure that is applied to the vise jaws

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Design
Vise 19
with hydraulic clamping
 Special Workholding Devices
Fixtures
Fixtures
Fixtures are usually designed for a
particular work pieces. The
function of a fixture is to hold,
and clamp the workpiece in a
precise position (Figure a)

Jigsִ
A jig is a fixture that guides the
tool in addition to holding the
workpiece in a precise position
(Figure b)

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 Principles of Workholding

•The objective of work holding is to

position or locate a workpiece
in definite relation to the cutting tool, and
must clamp it
with a proper force in order to withstand the cutting forces
while maintaining that precise position.
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 Elements
 Locating Elements
 Position work piece accurately
 Clamping Elements
 Hold work piece securely.
 Tool Guiding and Setting Elements
 Aid guiding of setting of the tools in correct
position with respect the work piece

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 Design Consideration of
Workholders Positive Location
Aִfixture must be strong to
support and hold the workpiece
precisely in space to restrict each
of the 12 degrees of freedom.
Repeatability
workpiece should be located in
the same position in order to
produce parts with precise
dimensions.
Adequate Clamping Forces
Fixtures should provide adequate
clamping forces to hold and
support the workpiece against all
forces subjected to such as
The twelve degree of freedom weight, centrifugal force, inertial
forces, and cutting forces.
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 Design Consideration of
Workholders
1. Reliability
• Must maintain the clamping force during operation.
• Must be easy to maintain and lubricate.
2. Ruggedness
• Must be able to withstand impact force during
operation
• Must resist abrasion.
• Easy to maintain and replace worn parts.
3. Design and Construction Ease
• Use standard parts whenever possible.
• If possible use modular fixture
4. Low profile
• Must clear tool path and allow for tool clearance

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 Design Consideration of
Workholders
5. Workpiece Accommodation
Tolerates part variations without sacrificing positive location
or other design objectives; e.g. casting or forging workpieces
6. Rapid Easy Operation
Easy to load and unload parts to reduce cycle time
7. Freedom of Part Distortion
Adequate clamping to avoid part distortion after releasing it.
8. Flexibility
Can be used for more than one part such as family of parts
Examples: Modular fixtures, programmable fixtures, etc.

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 Advantages
 Productivity
 Eliminate individual marking, positioning, etc
 Interchangeability
 Facilitate uniform quality. No need for selective
assembly
 Skill Reduction
 Simplify locating and clamping of the WP
 Cost Reduction
 Scrap <<, easy assembly, saving labor cost

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 Inspection Devices
 Facilitate Interchangeability, uniformity
must be limited, taking into machine’s
capability
 Certain variations  allowed

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 Limits and Fits
 Largest and Smallest dimension of the
shaft (or hole)  high and low limit
 Difference between these limit 
Tolerance, i.e., permission variation
 If tolerance allowed only one side of the
nominal dimension  unilateral
0.02
 Example: 250.00  unilateral
 If tolerance both side  bilateral
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 Classification of Fits
 Running Fit:
 Push Fit
 Press Fit
 Force Fit

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 Limits and Fits

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 Limits and Fits (2)

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Sample of Fits

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 Design Process
 Overall Size and Shape of
the Part
 Type and Condition of
Material
 Type of Machining Operation
 Degree of Accuracy
Required
 Number of Pieces to be
Made

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 Tooling Drawing
Draw and dimension without crowding views or dimensions
Draw only required views

Specify surface roughness

Tolerances and firs peculiar to tools need special

consideration.
Stock size for finishing machining operation should be

indicated.
Notes must be used for heat treatment and other finishing

operations should be used

Secondary operation should be avoided is possible

Avoid use of tight tolerance.

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 Tooling Layout (1)
 as a tool to explode the part as partial part in order
to easy assemble. The actual work of creating on
paper the assembly design of equipment or tools for
manufacturing processes should be done within the
general framework of the following rules:
 Lay out the part in an identifying color (red is suggested)
 Lay out any cutting tools.
 Indicate all locating requirements for the part.

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 Tooling Layout (2)
 Indicate all clamping requirements for the part
 Lay out the details with due consideration to stock
sizes, so as to minimize machining requirements.
 Use full scale in the layout, if at all possible.
 Indicate the use of standard (purchasable as shelf
items) fixture parts whenever possible.
 Identify each different item/detail.

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 Tooling Layout Figure

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 Tooling Safety
 Safety should be designed into the tooling. More minor
injuries resulted from these.
 Never cut against a clamp because of vibration and tool
chatter. Instead parts should be nested against pins in order
to take the cutter load.
 Rigidity and fool proofing should be should always be built
into the tooling. Drill jigs should be made large enough to
hold without the danger of spinning.
 All punch presses and air or hydraulically operated tooling to
be installed with a double button interlocking protection
system.
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 Tooling Handle in the Work Place

 Tooling handling is to minimize the risk of accidents

of tooling-operator contact. The contact can be:
 An individual making the contact with the tooling-usually
the moving part, because of inattention caused by fatigue,
distraction, curiosity, or deliberate chance taking;
 From the tooling via flying chips, chemical, and hot metal
splashes, and circular saw kickbacks, to name a few;
 Caused by the direct result of a tooling malfunction,
including mechanical and electrical failure

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 Work piece

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