BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI WORK INTEGRATED LEARNING PROGRAMMES Part A: Content Design Course Title
Tool and Fixture Design
Course No(s)
MT* ZC433
Credit Units
3
Credit Model
303
Course Author
Dr. Srinivasa Prakash Regalla
Version No
Ver 1.1
Date
9th January 2016
Course Objectives No CO1
To train in the analysis, design, skilful standard data utilization and decision making on the metal forming and machining tools
CO2
To train in the customized and economic design of jigs and fixtures as suitable for the specific scenario to improve i mprove productivity of shopfloor manufacturing processes
CO3
To train in the efficient decision making in the deployment of most suitable gaging and inspection methods of accurate quality control of engineering parts
Teaching methodology Text Book(s)
TB1
Donaldson C., LeCain G. H., Goold V. C. and Ghose J., “Tool Design”, 4th Edition (SIE), Tata McGraw Hill Education Private Ltd., New Delhi, 2012.
TB2
Boljanovic V., “Sheet “Sheet Metal Forming Processes and Die Design”, Design”, Industrial Press, 2004, New York.
Reference Book(s) & other resources
RB1 RB1
Venkataraman K., “Design of Jigs, Fixtures and Press Tools”, 2nd Edition, 2016, Wiley/Ane Books, New Delhi.
RB2
Joshi P. H., “Press “Press Tools Design and Construction”, Construction ”, S.Chand & Company Ltd, (1996), New Delhi.
RB3
Luqman M., “Sheet “Sheet Metal Press Tool Design and Making”, Making ”, CBS; First edition (2015), New Delhi.
Modular Content Structure
(M=Module; SM=Sub-module) M1. Gages and gage design SM1.1. Introduction SM 1.2. Fixed Gages SM 1.3. Gage Tolerances SM 1.4. Selection of materials for gages SM 1.5. Indicating gages SM 1.6. Automatic gages M2. Locating and clamping methods SM 2.1. Introduction SM 2.2. The basic principles of location SM 2.3. Locating methods and devices SM 2.4. The basic principles of clamping M3. The construction and classification of drill jigs SM 3.1. Introduction SM 3.2. Definition of a drill jig SM 3.3. Types of drill jigs M4. Design of drill jigs SM 4.1. General considerations in the design of drill jigs SM 4.2. Drill bushings SM 4.3. Methods of construction SM 4.4. Drill jigs and modern manufacturing M5. Fixturing economics, classification of fixture and design of boring fixtures SM5.1. Introduction SM5.2. Fixturing economics SM5.3. Types of fixtures SM5.4. Boring fixtures M6. Design of fixtures for other machining operations SM6.1. Broaching fixtures SM6.2.Lathe fixtures SM6.3.Grinding fixtures M7. Die construction for sheet metal blanking and piercing SM 7.1. Introduction: Fundamentals of sheet metal forming processes revisited SM.7.2. Basic die classifications and components SM 7.3. Power press types and general press information SM 7.4. Material handling equipment SM 7.5. Die clearance SM 7.6. Types of die construction M8. Design of sheet metal blanking and piercing dies SM 8.1. Die design fundamentals SM 8.2. Design of blanking and punching dies SM 8.3. Pilots
SM 8.4. Strippers and pressure pads SM 8.5. Presswork materials SM 8.6. Strip layout SM 8.7. Short run tooling for piercing M9. Critical parameters of sheet metal bending and forming SM 9.1. Fundamentals of bending and forming dies SM 9.2. Variables affecting metal flowing deep drawing bending, LDR SM 9.3. Determining blank size SM 9.4. Drawing blank size M10. Design of bending and deep drawing dies SM 10.1. Estimation of drawing force SM 10.2. Various forming dies, single-action and double-action drawing dies SM 10.3. Tool and die materials SM 10.4 Design of bending dies SM 10.5. Design of deep drawing dies M11. Using plastics as tooling materials SM 11.1. Introduction SM 11.2. Plastics commonly used as tooling materials SM 11.3. Application of epoxy plastic tools SM 11.4. Construction methods of plastic tooling SM 11.5. Metal forming operations with urethane dies SM 11.6. Calculating forces for urethane pressure pads M12. Tool design for numerically controlled machine tools SM 12.1. Numerical control revisited SM 12.2. Fixture design for NC machine tools SM 12.3. Cutting tools for NC SM 12.4. Tool holding methods for NC SM 12.5. Automatic tool changers and tool positioners SM 12.6. Tool presetting M13. Design of lathe and milling cutting tools SM 13.1. Revisit to mechanics of machining relevant to tool design SM 13.2. Design of single point cutting tools for lathe SM 13.3. Design of milling cutters M14. Design of cutting tools for drilling and other processes SM 14.1. Design of drills SM 14.2. Design of reamers SM 14.3. Design of taps SM 14.4. Selection of carbide cutting tools SM 14.5. Tooling for automatic screw machines with the example of Browne & Sharpe machine
Learning Outcomes:
No
Learning Outcomes
LO1
To become proficient in design, selection and deployment of gages for product manufacturing inspection and measurement
LO2
To be able to design punch-die clearances and punch & die tolerances to enable high productivity blanking and piercing operations
LO3
To characterize LDR for deep drawing operations and make decisions on number of passes required for high quality deep drawn parts
LO4
To be able to design bending dies for high accuracy angle sheet metal parts with accurate estimate of blank size
LO5
To be able to design, select and customize with quantitative economic estimations fixtures and jigs for machining and forming processes
LO6
To be able to design and customize single and multi-point cutting tools for high productivity machining applications
Experiential learning components
Lab work: 1
Design a milling fixture to mill the finished surface of the casting shown in Fig.1. This has to be first meaningful operation on the rough casting. Holes are drilled after the surface is milled.
2
Design a broaching fixture to broach the slots in the V-block clamp as shown in Fig. 2.
3
Design a milling fixture to mill the 50 mm slot shown in the right angle clevis in Fig. 3. Assume that the hole and 27 mm slot have been previously machined.
4
Design a milling fixture to mill the finished surface of the clevis shown in Fig-4. Holes will be drilled after the surfaces have been machined.
5
Design a lathe boring fixture for holding the workpiece for boring the 45 mm hole as shown in Fig-5. Introduce at least one additional feature in the workpiece and then design the fixture.
Part B: Course Handout
Semester II 2015-16 Tool and Fixture Design MT* ZC433 Dr. Srinivasa Prakash Regalla
Academic Term Course Title Course No Lead Instructor Contact Session 1 Module Title: M1. Gages and gage design Type
Content Ref.
Topic Title
Study/HW Resource Reference
Pre CH
TB1Chapters 1 to 3
During CH SM1.1 SM1.2 SM1.3 SM1.4 SM1.5 SM1.6
Post CH
Self-study of tool design methods, tool making practices, tool materials and heat treatment Introduction to gages Fixed Gages Gage Tolerances Selection of materials for gages Indicating gages Automatic gages Design a single gauge to measure 3 different angles on a part Quiz-1 questions provided by instructor
TB1 Chapter 5
Design exercises to be recommende d by instructor
Contact session 2 Module Title: M2. Locating and clamping methods Type
Content Ref.
Topic Title
Study/HW Resource Reference
Pre CH
SM 2.1.
Introduction
TB1 Chapter 6
During CH
SM 2.2 to SM 2.4
TB1 Chapter 6
The basic principles of location Locating methods and devices The basic principles of clamping
Assignment-1 given by instructor
Post CH
Contact session 3 Module Title: The construction and classification of drill jigs Type
Content Ref.
Topic Title
Study/HW Resource Reference
Pre CH
SM 3.1.
Introduction
TB Chapter 7
During CH
SM 3.2. to SM 3.3
Definition of a drill jig Types of drill jigs
Post CH
Modeling some known drill jigs in CREO (Pro/Engineer): assignment for practice
TB Chapter 7 to be provided by instructor
Contact session 4 Module Title: M4. Design of drill jigs Type
Content Ref.
Topic Title
Study/HW Resource Reference
Pre CH
SM 4.1.
General considerations in the design of drill jigs
TB Chapter 7
During CH
SM 4.2. SM 4.3. SM 4.4.
TB Chapter 7
Drill bushings Methods of construction Drill jigs and modern manufacturing
Drill jig design assignment in CREO
Problem
Post CH
announced by the instructor Contact session 5 Module Title: Fixturing economics, classification of fixture and design of boring fixtures Type
Content Ref.
Topic Title
Study/HW Resource Reference
Pre CH
SM5.1.
Introduction
TB1 Chapter 8
During CH
SM5.2. SM5.3. SM5.4.
Fixturing economics Types of fixtures Boring fixtures
TB1 Chapter 8
Design of fixtures for machining and forming processes
Problems hinted by the instructor
Post CH
Contact session 6 Module Title: Design of fixtures for other machining operations Type
Content Ref.
Pre CH
During CH
Post CH
SM6.1. SM6.2. SM6.3.
Topic Title
Study/HW Resource Reference
Any standard textbook on machining such as that of Boothroyd & Knight & online
Review of lathe, broaching and grinding processes
Broaching fixtures Lathe fixtures Grinding fixtures
Design of fixtures for broaching, lathe and grinding processes
TB1 Chapter 9
Problems suggested by instructor
Contact session 7 Module Title: Die construction for sheet metal blanking and piercing Type
Content Ref.
Pre CH
SM7.1
During CH
SM.7.2. SM 7.3. SM 7.4. SM 7.5. SM 7.6.
Study/HW Resource Reference
Introduction: Fundamentals of sheet metal forming processes revisited
Post CH
TB1 Chapter 10 & TB2 Chapter 1-7
Basic die classifications and components Power press types and general press T1 Chapter 7 information Material handling equipment Die clearance Types of die construction
Creo modeling of some of the existing blanking dies
Review Session-1 Session Title: Mid-semester Review Type
Content Ref.
Topic Title
Study/HW Resource Reference
Pre CH
Review all classes
Previous Classes
During CH
Review: complete syllabus
Post CH Contact session 8 Module Title: Design of sheet metal blanking and piercing dies Type
Content Ref.
Topic Title
Study/HW Resource Reference
Pre CH
SM 8.1.
TB1-Chapter 9
Die design fundamentals
& TB2-Chapter 8 During CH
SM 8.2. SM 8.3. SM 8.4. SM 8.5. SM 8.6. SM 8.7.
Design of blanking and punching dies Pilots Strippers and pressure pads Presswork materials Strip layout Short run tooling for piercing
Post CH
Design of blanking and punching dies
T TB1Chapter 9 & TB2-Chapter 8 Suggested by instructor
Contact session 9 Module Title: Critical parameters of sheet metal bending and forming Type
Content Ref.
Topic Title
Study/HW Resource Reference
Pre CH
SM 9.1.
Fundamentals of bending and forming dies
TB1-Chapter 10 & TB2Chapters 10 and 11
During CH
SM 9.2. SM 9.3. SM 9.4.
Variables affecting metal flowing deep drawing bending, LDR TB1-Chapter Determining blank size 10 & TB2Drawing blank size Chapters 10 and 11
Post CH
Term paper on student’s exposure and observation of current problems faced in bending and forming dies in his company or another company or literature
Activity by students supervised by instructor
Contact session 10 Module Title: Design of bending and deep drawing dies
Type
Content Ref.
Topic Title
Study/HW Resource Reference
Pre CH
SM 10.1.
TB1-Chapter 10 & TB2Chapters 10 and 11
During CH
SM 10.2. SM 10.3. SM 10.4 SM 10.5.
Post CH
Estimation of drawing force
Various forming dies, single-action and double- TB1-Chapter action drawing dies 10 & TB2Tool and die materials Chapters 10 Design of bending dies and 11 Design of deep drawing dies Numerical design exercises on bending and deep drawing dies, punches and blank holders
To be prescribed by the instructor
Contact session 11 Module Title: Using plastics as tooling materials Type
Content Ref.
Topic Title
Study/HW Resource Reference
Pre CH
SM 11.1.
TB1-Chapter 11
During CH
SM 11.2. SM 11.3. SM 11.4. SM 11.5. SM 11.6.
Post CH
Introduction Plastics commonly used as tooling materials Application of epoxy plastic tools Construction methods of plastic tooling Metal forming operations with urethane dies Calculating forces for urethane pressure pads Term paper on current scenario of using plastic tooling in automotive and allied manufacturing industries
TB1-Chapter 11
Online and other resources
Contact session 12 Module Title: Tool design for numerically controlled machine tools Type
Content Ref.
Topic Title
Study/HW Resource Reference
Pre CH
SM 12.1.
Numerical control revisited
TB1-Chapter 12
During CH
SM 12.2. SM 12.3. SM 12.4. SM 12.5. SM 12.6.
Fixture design for NC machine tools Cutting tools for NC Tool holding methods for NC Automatic tool changers and tool positioners Tool presetting
TB1-Chapter 12
Post CH
Term paper on how the tooling for CNC machines differs from that for conventional machines
Online resources and other sources
Contact session 13 Module Title: Design of lathe and milling cutting tools Type
Content Ref.
Topic Title
Study/HW Resource Reference
Pre CH
SM 13.1.
TB1-Chapter 4
During CH
SM 13.2. SM 13.3.
Post CH
Revisit to mechanics of machining relevant to tool design Design of single point cutting tools for lathe Design of milling cutters Design exercises using Creo on lathe and milling cutter design
TB1-Chapter 4 As recommende d by the instructor
Contact session 14 Module Title: Design of cutting tools for drilling and other processes Type
Pre CH
Content Ref.
Topic Title
Study/HW Resource Reference
TB1-Chapter 4
Revisit to mechanics of machining relevant to tool design
During CH
SM 14.1. SM 14.2. SM 14.3. SM 14.4. SM 14.5.
Post CH
Design of drills Design of reamers Design of taps Selection of carbide cutting tools Tooling for automatic screw machines with the example of Browne & Sharpe machine Design exercises using Creo on cutters for drilling and other processes
TB1-Chapter 4
As recommende d by the instructor
Review session-2 Session Title: Comprehensive Review Type
Content Ref.
Topic Title
Pre CH
Review all classes
During CH
Review: complete syllabus
Post CH
Study/HW Resource Reference
Doubt clarifying through email/telephone or in person
Detailed Plan for Lab work/Design work Lab No
Lab Objective
1
Design a milling fixture to mill the finished surface of the casting shown in Fig.1. This has to be first meaningful operation on the rough casting. Holes are drilled after the surface is milled.
2
Design a broaching fixture to broach the slots in the V-block clamp as shown in Fig. 2.
3
Design a milling fixture to mill the 50 mm slot shown in the right angle clevis in Fig. 3. Assume that the hole and 27 mm slot have been previously machined.
4
Design a milling fixture to mill the finished surface of the clevis shown in Fig-4. Holes will be drilled after the surfaces have been machined.
5
Design a lathe boring fixture for holding the workpiece for boring the 45 mm hole as shown in Fig-5. Introduce at least one additional feature in the workpiece and then design the fixture.
Lab Sheet Access URL
Content Reference
Textbooks & Reference Books
Evaluation Scheme Evaluation Component
Name (Quiz, Lab, Project, Mid term exam, End semester exam, etc)
Type (Open book, Closed book, Online, etc.)
Weight
EC - 1
Tool design assignments and quizzes if any
EC - 2
Mid-semester Examination
Closed Book
30
EC - 3
Comprehensive Examination
Open Book
50
Duration
Day, Date, Session, Time
20
Guidelines: The tool design exercises mentioned in the experiential learning section may be suitably modified based on the interest and background of the certain company’s working professionals. It is recommended that the tool design is exercised first on paper and then results are to be documented in CREO and presentation of the same be mandatory for relevance to best practices in industry. Important Information:
