TOOL DESIGN DATA BOOK FOR
DIPLOMA IN MECHANICAL ENGINEERING (TOOL & DIE) COURSE CODE 1220
DIRECTORATE OF TECHNICAL EDUCATION GOVERNMENT OF TAMILNADU
DIRECTORATE OF TECHNICAL EDUCATION GUINDY, CHENNAI – 25 TOOL DESIGN DATA BOOK
1. This book can be used for Board Examination by the Diploma in Mechanical Engineering (Tool & Die) students for the Tool Design subject. 2. The Use of this data book ( Institutional copy) Indian Standard specifications listed in Table 6.34 of this data book and any other related Indian standard specifications is permitted in the Board Examination for the subject 22254 - Tool Design and Drawing
Tool Design Data Book
Page 2
CONTENTS TOPIC
SL.NO
PAGE NO.
1.
Material Properties
1
2.
Sheet material SWG to mm & inch conversion
2
3.
Data for stamping dies Formulae
3
Strip layout
4
Die plate design data
5
Stripper design data
10
Punch design details
12
Punch holder data
15
Pilots
16
Finger stops
17
Automatic stops
18
Fasteners - Screws & dowels
21
Die set
23
Press data
27
Shut height
28
Punch and die materials & Heat treatment
29
Centre of Pressure
34
Spring design data
36
Tool Design Data Book
Page 3
4.
Data for bending dies
61
5.
Data for drawing dies
66
6.
Data for gauge Design
7.
ISO System of limits and fits – tolerances & deviations
70
Reference Indian standard specifications for gauge design
102
Jigs & fixtures Guidelines for selection of locators and clamps
8.
103
Locating pins
104
Clamps
106
Jig feet & buttons
108
Jig bushes
110
Screws & nuts
113
Pressure pads
117
Spherical & ‘C’ Washers
118
Wing nuts
119
Unit Conversion tables
120
Tool Design Data Book
Page 4
Table 1 - MATERIAL PROPERTIES
SHEAR STRENGTH S.No
ULTIMATE TENSILE
MATERIAL 2
N/mm
STRENGTH
A T A
N/mm2
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.
O T
L O
Stainless steel Steel 0.1% carbon ( soft) Steel 0.25%carbon ( mild) Steel 0.5% carbon Steel 0.75% carbon Steel 1% carbon Steel 1.2% carbon ( not tempered) Steel 1.25% carbon( tempered hot) Aluminium soft sheet Aluminium half hard sheet Aluminium hard sheet Brass soft sheet Brass half hard sheet Brass hard sheet Copper rolled Cupro nickel Duralumin soft sheet Duralumin treated and cold rolled Fibre hard Lead Leather Oak ( wood) Tin rolled sheet Tin coated steel sheet Zinc rolled sheet Zinc hard rolled Silver Paper using hollow dies
N
G I S E
D
Tool Design Data Book
539.70 346.95 385.5 539.70
719.6 462.6 514 719.6
616.8 655.35 724.7 1464.89 115.65 146.49 192.75 231.29 269.85 308.40 215.88 308.4 231.29 308.10 185.04 30.84 54 54 38.55 385.5 138 154.20 231.29 23.13
822.4 873.8 966.2 1953.18 154.2 195.32 257 308.38 359.8 411.20 287.84 411.20 308.39 410.80 246.72 41.12 72 72 51.4 514 184 205.6 308.38 30.84
D
O O B
Page 1
Table 2 - Sheet material SWG to mm & inch conversion
inches
Mm
SWG
inches
Mm
SWG
inches
mm
7/0
0.500
12.700
13
0.092
2.34
32
0.0108
0.27
6/0
0.464
11.79
14
0.080
2.03
5/0
0.432
10.97
15
0.072
1.83
4/0
0.400
10.16
16
0.064
1.63
3/0
0.372
9.45
17
0.056
1.42
2/0
0.348
8.84
18
0.048
1.22
1/0
0.324
8.23
19
0.040
1.02
1
0.300
7.62
20
0.036
2
0.276
7.01
21
3
0.252
6.40
22
4
0.232
5
0.212
6
0.192
33
0.0100
A T A
0.25
34
0.0092
0.23
35
0.0084
0.21
36
0.0076
0.19
37
0.0068
0.17
38
0.006
0.15
0.91
39
0.0052
0.13
0.032
IG
0.81
40
0.0048
0.12
0.028
0.71
41
0.0044
0.11
S E
N
D
5.89
23
0.024
0.61
42
0.004
0.10
5.39
24
0.022
0.56
43
0.0036
0.09
4.88
25
0.020
0.51
44
0.0032
0.08
4.47
26
0.018
0.46
45
0.0028
0.07
4.06
27
0.0164
0.42
46
0.0024
0.06
0.144
3.66
28
0.0148
0.38
47
0.002
0.05
10
0.128
3.25
29
0.0136
0.35
48
0.0016
0.04
11
0.116
2.95
30
0.0124
0.31
49
0.0012
0.03
12
0.104
2.64
31
0.0116
0.30
50
0.001
0.02
7
L O
O T
O O B
SWG
8 9
D 0.176 0.160
Tool Design Data Book
Page 2
DATA FOR STAMPING DIES FORMULAE: 1.
Cutting force = Where
A T A
S*P*T
S
=
Shear strength of the component material in N/mm2
P
=
Perimeter of the component in mm
T
=
Thickness of the component in mm
2.
Percentage of utilization
=
3.
Percentage of scrap
=
4.
Stripping Force
=
5.
Press Capacities
=
D
Area of Blank Area of Strip
G I S E
N
O O B
X 100
100 – Percentage of utilization 10 to 20% of cutting force Cutting Force x 1.3
6.Compressive force on punches = comp.stress of the punch matl. X area of cross section of punch =π2EI/LP2
7.
Buckling Forces
WHERE
E= modulus of elasticity in GN/mm2
D
I=moment of inertia in mm4
O T
L O 8.
Lp=length of punch in mm Strip layout Margin (or) Bridge
= 1.5t where ‘t’ is the sheet metal thickness in mm
The margin or the bridge thickness can also be selected from the following table
Tool Design Data Book
Page 3
Table - 3.1 - DATA FOR STRIP LAYOUT Thickness of sheet metal in mm
Web length(l)
0.5
0.75
1
1.25
1.5
in mm
1.75
2
2.5
3
A T A
Margin, (S), mm
10
1.5
1.2
1
1.4
1.5
1.8
2
50
2
1.7
1.75
1.9
2
2.2
2.5
100
3
2.4
2
2.4
2.5
2.7
3
150
3.5
2.9
2.5
2.9
3
3.2
3.5
250
4
3.4
3
3.4
3.5
3.7
350
4.5
3.9
3.5
3.9
4
4.2
N
L O
2.25
G I S E
D 4
4.5
O O B 3.5
4
2.5
2.5
2
2
2
2.8
3
3.5
3.7
4
3.2
3.5
4
4.2
4.5
3.7
4
4.5
4.7
5
4.2
4.5
5
5.2
5.5
4.7
5
5.5
5.7
6
D
O T
Tool Design Data Book
Page 4
DIE PLATE DESIGN DATA: Die block thickness
3
=
√F Where F is cutting force in Kg.
Die block thickness and other die dimensions may also be selected from the following table:
N
G I S E
A
B
D
C Minimum Distance – Die Hole To Outside Edge
Die Block Height
1 Smooth Die Hole Contour (1.125 B)
2 Inside Corners (1.5 B)
3 Sharp Inside Corners
24
27
36
48
1.5 to 3.1
29
33
44
58
3.1 to 4.7
35
39
53
70
4.7 to 6.3
42
47
63
84
Over 6.3
48
54
72
96
D
Strip Thickness 0 to 1.5
L O
O T
A T A
O O B
(2 B)
Table 3.2 - Recommended minimum C distance for various die hole contour and die block heights B
Tool Design Data Book
Page 5
Table 3.3 - Tabulation of suggested standard die block sizes
N
A
O T
D
B
C
D
E
F
G
88.9
15.8
44.4
57.1
23.8
M8 TAPPED THROUGH HOLE
127
15.8
44.4
95.2
23.8
M8 TAPPED THROUGH HOLE
101.6
101.6
15.8
69.8
69.8
23.8
M8 TAPPED THROUGH HOLE
101.6
127
15.8
69.8
95.2
23.8
M8 TAPPED THROUGH HOLE
101.6
152.4
15.8
69.8
120.6
23.8
M10 TAPPED THROUGH HOLE
127
127
19
88.9
88.9
23.8
M10 TAPPED THROUGH HOLE
127
152.4
19
88.9
114.3
23.8
M10 TAPPED THROUGH HOLE
D 76.2
L O
G I S E
A T A
76.2
Tool Design Data Book
O O B
Page 6
O O B
Table 3.4 - Tabulation of suggested standard medium size die block sizes:
A
B
101.6
177.8
101.6
203.2
127
O T
L O
127 152.4 152.4 177.8
N
IG
S E D
19
63.5
139.7
69.8
M10 TAPPED THROUGH HOLE
28.5
19
63.5
165.1
82.5
M10 TAPPED THROUGH HOLE
28.5
19
88.9
165.1
82.5
M10 TAPPED THROUGH HOLE
28.5
19
88.9
215.9
107.9
M10 TAPPED THROUGH HOLE
28.5
203.2
19
114.3
165.1
82.5
M10 TAPPED THROUGH HOLE
28.5
254
19
114.3
215.9
107.9
M10 TAPPED THROUGH HOLE
28.5
279.4
19
139.7
241.3
120.6
M10 TAPPED THROUGH HOLE
28.5
D 254
Tool Design Data Book
F
D
C
203.2
E
A T A G
H
Page 7
Die land:-
O O B
Die land varies depending upon the no. of regrinding requirements (die life expectancy). But in general die land is given as 3 to 5 mm.
A T A
Angular clearance: - Generally 1/4o to 1o angular clearance is provided. Increased die clearance
D
weakens the die. Angular clearance may also be selected from the following table:
Table 3.5 – Anglular clearance data
N
Strip thickness in mm 0 to 1.5875
G I S E 1.5875 to 4.76 4.76 to 7.9 Over 7.9
Angular clearance per side 1/4o 1/20 3/40 10
Soft materials require greater angular clearance than hard materials.
L O
D
O T
Tool Design Data Book
Page 8
Die clearance:Clearance per side = C *T * √ (τmax/10) Where C= constant
= 0.005 for very accurate components =0.01 for normal component.
T= Sheet thickness in mm.
A T A
τmax = Shear strength of sheet material in N/mm2
Clearance per side can also be selected from the table given below:
Table 3.6 – Die clearance Material Mild steel
Die clearance per side in percentage of sheet thickness 2.5%-5%
Aluminum
1.5%-3%
N
Brass
L O
G I S E
O O B
D
1.5%-3%
D
O T
Tool Design Data Book
Page 9
STRIPPER DESIGN STRIPPER PLATE THICKNESS = A = (W/30) +2t Where A = Stripper plate thickness in mm W= Width of strip in mm
A T A
t= Thickness of sheet metal in mm.
The stripper plate thickness can also be selected from the following table:
O O B
Table 3.7 – Stripper plate thickness STRIP (thicknes s* width) 1.6x75 1.6x150 1.6x225 1.6x300
Stripper Plate thicknes s (A) in mm 6 8 10 14
3.2x75 3.2x150 3.2x225 3.2x300
10 12 14 16
4.8x75 4.8x150 4.8x225 4.8x300
12 15 18 20
6.35x75 6.35x150 6.35x225 6.35x300
D
L O 7.8x75 7.8x150 7.8x225 7.8x300
16 18 20 22 18 22 24 26
N
G I S E
D
Note:For design and manufacturing simplicity, the width and length of stripper is assumed same as that of the die plate
O T
Tool Design Data Book
Page 10
N
G I S E
A T A
O O B
D
Table 3.8 – Clearance between Strip and Strip gudie Strip thickness in mm
0-1.587
clearance for hand feed in mm
Clearance for automatic feed in mm
1.6
0.8
1.587-3.175
2.4
0.8
3.175-4.762
3.2
0.8
4.762-6.35
4.0
0.8
4.8
0.8
D
6.35-7.937
L O
O T
Tool Design Data Book
Page 11
PUNCH DESIGN DETAILS Table 3.9 - Stepped Round Punch
Table 3.10 – Round Punch
N
L O
G I S E
A T A
O O B
D
D
O T
Tool Design Data Book
Page 12
Table 3.11 – Square Punch
Table 3.12 – Quick change punch
N
L O
G I S E
A T A
O O B
D
D
O T
Tool Design Data Book
Page 13
Table 3.13 – Punch Chamfered head
L O
N
G I S E
Table 3.15 – Square Punch with shedder
O O B
Table 3.14 – Stepped Punch
A T A
D
D
O T
Tool Design Data Book
Page 14
Table 3.16 - COMMONLY USED PUNCH PL ATE SIZES:-
N
Table 3.17 - COMMONLY USED PUNCH
G I S E
PLATE SIZES
L O
D
A 50 50 75 75 75 100 100 100 125 125 125 150 150 150 150 175 175 175
A T A
D
A 0 to 7.9 7.9 to 11 11 to 12.7 12.7 to 15.8 15.8 to 17.4 17.4 to 19 19 to 22.2 22.2 to 23.8 23.8 to 25.4
B 50 75 75 100 125 100 125 150 125 150 175 150 175 200 250 175 225 275
O O B
B 12.7 15.8 19 22.2 25.4 28.5 31.7 34.9 38.1
O T
Tool Design Data Book
Page 15
Table 3.18 - PILOTS
A 3.1 4.7 6.3 7.9 9.5 11.1 12.7 14.2 15.8 17.4 19 A 20.6 22.2 23.8 25.4 26.9 28.5 30.1 31.7 33.3 34.9 38.1
ACORN TYPE PILOT B C D E MAT 3.1 0.7 3.9 2.3 D.R. 4.7 1.19 4.7 3.1 D.R. 6.3 1.5 7.1 4.7 D.R. 7.9 1.98 9.5 6.3 D.R. 9.5 2.3 11.1 7.1 D.R. 11.1 2.77 12.7 7.9 D.R. 12.7 3.1 14.2 9.5 D.R. 14.2 3.57 15.8 11.1 D.R. 15.8 3.9 17.4 11.9 D.R. 17.4 4.3 19 12.7 D.R. 19 4.7 22.2 14.2 D.R. FLATTENED POINT TYPE B C D E MAT 20.6 12.7 23.8 15.8 Tool Steel 22.2 13.4 25.4 17.4 T.S 23.8 14.2 28.5 19 T.S 25.4 15.8 31.7 20.6 T.S 26.9 16.6 33.3 22.2 T.S 28.5 17.4 36.5 23.8 T.S 30.1 18.2 38.1 25.4 T.S 31.7 19 41.2 26.9 T.S 33.3 20.6 42.8 28.5 T.S 34.9 21.4 44.4 30.1 T.S 38.1 23.8 47.6 31.7 T.S
L O
G I S E
N
A T A
O O B
D
D
O T
Tool Design Data Book
Page 16
FINGER STOPS
Table 3.19 - FINGER STOPS
A STRIP THICKNESS 0 to 1.5 1.5 to 3.1 3.1 to 4.7 4.7 to 6.3 Over 6.3 No. 1 2 3 4 5
25 32 38 45 50 B 6.3 7.9 9.5 11.1 12.7
L O
6 7 8 9 10 11 12 13 14 15
A 3.2 4.8 6.4 8.0 9.5
1 SMOOTH DIE HOLE CONTOUR FRONT FINGER SPACER STOP WIDTH No.
O T
D 37.3 44.4 51.5 58.7 65.8
D
3.2 4.8 6.4 8.0 9.5
9.5 11.1 12.7 14.2 15.8
23.8 27.7 31.7 35.7 39.6
50.8 57.9 65 72.2 79.3
.3.2 4.8 6.4 8.0 9.5
9.5 11.1 12.7 14.2 15.8
36. 40.4 44.4 48.4 52.3
63.5 70.6 73.5 81.3 88.4
D
3 SHARP CORNERS
N
FRONT SPACER WIDTH
FINGER STOP No.
FRONT SPACER WIDTH
FINGER STOP No.
38 45 50 58 64
6 7 8 9 10
50 56 63 70 75
11 12 13 14 15
G I S E
1 2 3 4 5
C 16.6 20.6 24.6 28.5 32.5
2 INSIDE CORNERS
E 1.6 2.4 3.2 4.0 4.8
F 46.22 57.37 66.92 76.50 86.05
1.6 2.4 3.2 4.0 4.8
61.31 70.86 80.41 89.99 99.56
1.6 2.4 3.2 4.0 4.8
74.01 83.56 93.11 102.69 112.26
A T A
O O B
AUTOMATIC STOPS
Tool Design Data Book
Page 17
N
Table 3.20- AUTOMATIC STOPS NO 1 2 3 4 5 6
A 101.6 477.5 965.2 1442.7 2092.9 127
NO 1 2 3 4 5 6
M 4.8Drill 9.5 depth 45° csk 4.8Drill 9.5 depth 45° csk 4.8Drill 9.5 depth 45° csk 4.8Drill 9.5 depth 45° csk 4.8Drill 9.5 depth 45° csk 4.8Drill 9.5 depth 45° csk
L O
B 6.3 6.3 6.3 7.9 7.9 7.9
C 19.8 23.8 58.4 160 302.2 441.9
D 8.7 9.5 10.3 11.1 11.9 12.7
E 6.3 6.3 6.3 7.9 7.9 7.9
G I S E
D
1.6 deep 1.6 deep 1.6 deep 1.6 deep 1.6 deep 1.6 deep
F 119.3 160 241.3 302.2 340.3 401.3
N 6° 6° 6½° 6½° 7° 7½°
A T A
D
G 241.3 281.9 360.6 441.9 523.2 604.5
O 1.5 R. 1.9 R. 1.9 R. 2.3 R. 2.3 R. 2.3 R.
O O B
H 4.7 6.3 7.9 9.5 11.1 12.7
P 12.7R. 12.7R. 12.7R. 12.7R. 12.7R. 12.7R.
I 2.3 3.1 3.1 4.7 4.7 4.7
Q 30° 30° 30° 30° 30° 30°
J 3.1 3.9 3.9 5.5 5.5 5.5
R 1.1R. 1.1R. 1.1R. 1.1R. 1.1R. 1.1R.
K 7.1R. 7.1R. 7.1R. 8.7R. 10.3R. 11.1R.
S 3.1R. 3.1R. 3.1R. 3.1R. 3.1R. 3.1R.
T 1.5 1.9 2.3 2.7 3.1 3.9
L 4.7 6.3 6.3 7.1 7.9 9.5
U 16.6 20.6 24.6 78.7 183 281.9
O T
Tool Design Data Book
Page 18
Table 3.21- AUTOMATIC STOPS
NO 1 2 3 4 5 6
A 6.3 9.5 12.7 15.8 19 22.2
NO 1 2 3 4 5 6
O 33° 33° 33° 33° 33° 33°
O T
L O NO 1 2 3 4 5 6
B 16.6 20.6 24.6 78.7 180.3 281.9
P 5.5 6.7 6.7 7.9 8.7 9.5
D 50.8 157.4 320 645.1 1127.7 76.2
E 25.4 78.7 160 241.3 322.5 401.3
R 0.8 X 45° 0.8 X 45° 0.8 X 45° 0.8 X 45° 0.8 X 45° 0.8 X 45°.
S 2.3 3.1 3.1 4.7 4.7 4.7
F 12.7 14.2 15.8 17.4 19 20.6
B 34.93 37.30 41.67 44.84 48.02 52.38
C 25.4 78.7 160 241.3 322.5 401.3
Tool Design Data Book
D 7.9 7.9 8.7 10.3 10.3 11.1
G 19 20.6 23 24.6 58.4 99
N
G I S E
Q 3.1 4.7 6.3 7.9 9.5 11.1
D
A 37.30 39.68 43.65 47.62 50.80 54.76
C 25.4 78.7 160 241.3 322.5 401.3
A T A
D H 322.5 78.7 523.2 119.3 238.7 401.3
I 3.1 3.1 3.1 3.9 3.9 3.9
J 3.1 3.1 3.1 3.9 3.9 3.9
T 6.75dr 10.31 c bore 6.35 deep 6.75dr 10.31 c bore 6.35 deep 8.33dr 11.90 c bore 7.93 deep 8.33dr 11.31 c bore 7.93deep 9.92dr 15.08 c bore14.28deep 9.92dr 15.08c bore 14.28deep
E 19 20.6 23 24.6 58.4 99
F 322.5 401.3 523.2 604.5 238.7 401.3
K 6.3 6.3 6.3 7.9 7.9 7.9
L 7.9 8.7 8.7 10.3 11.9 12.7
O O B M 9.1 10.3 11.1 12.7 14.2 15.8
N 7.9 8.7 9.5 11.1 11.9 13.4
U 4.8 drill 2.4 deep 45° csk 1.19 deep 4.8 drill 2.4 deep 45° csk 1.19 deep 4.8 drill 2.4 deep 45° csk 1.19 deep 4.8 drill 2.4 deep 45° csk 1.19 deep 4.8 drill 2.4 deep 45° csk 1.19 deep 4.8 drill 2.4 deep 45° csk 1.19 deep
G M6 TAP M6 TAP M8TAP M8TAP M10 TAP M10 TAP
Page 19
Table 3.22- AUTOMATIC STOPS
STOP NO. 1 2 3 4 5 6
A 28.5 30.1 31.7 33.3 34.9 36.5
STOP NO. 1
19.8
2 2-A
23.8 25.4
3 3-A 3-B
27.7 29.3 30.9
4 4-A 4-B 4-C
31.75 33.33 34.92 36.51
5 5-A 5-B 5-C
37.3 38.89 40.48 42.06
6 6-A 6-B
42.86 44.45 46.03
A T A
A
N
G I S E
O O B
D
Table 3.23 - FULCRUM PIN DIMENSIONS
O T
L O
D
STOP NO 1 2 3 4 5 6
A 22.22 25.40 28.575 31.75 34.925 38.10
B 2.40 3.175 3.175 4.80 4.80 4.80
Tool Design Data Book
Page 20
APPLICATION OF FASTENERS SCREWS:
O O B
Heat treated socket head cap screws can withstand double the load permissible for commercial hexagonal head bolts and nuts. S = design stress for socket head cap screw ranges from 80 to 120 N/mm2. Root area for the metric screws can be found from the following formula
A T A
A = 0.7854 (D – 1.227P)2 Where D = Diameter. Of screw in ‘mm’ P = Pitch of screw in ‘mm’ Load (N) = A x S
DOWELS:
D
Dowels are subjected to shear stress due to horizontal force resulting from die
N
clearance.
S = Dowels are rarely stressed beyond 50 to 80 N/mm2
G I S E
Horizontal Force
= Die clearance x Stripping Load
Stripping Load
= 10% of vertical Force
Load/Dowel
= Horizontal Force / No. of Dowels
Area
= Load/Dowels S
Dowel diameter = √(Area/0.7854)
D
If Dowel size becomes too big more number of smaller dowels having same total sectional
L O
area can be used. As area of dowel varies according to square of dowel diameter it is better to use two big dowels instead of a no. of smaller dowels.
O T
Tool Design Data Book
Page 21
Table 3.24 - NO OF SCREWS BASED ON STRIPPING FORCE STRIPPING FORCE IN TON N 0.2 1992.8to2491.0 0.4 3985.6 0.63 6277.3 0.8to1.0 7971.2to9964.02 1.25 12455.0 1.60 15942.4 2.5 24910.0 4.0 39856.0
O O B
M6
M8
M10 M12
M16
M20
2 3 4 6 8 * * *
* 2 2 3 4 5 8 *
* * * 2 3 3 5 8
* * * * * 2 3 3
* * * * * * * 2
SCREWS AND DOWELL COMBINATIONS
N
* * * 2 2 2 4 6
D
A T A
-
The diameter of the screws and dowels is also determined by the size of the component.
-
Generally 10mm screws are used on die components up to 150 mm2.
-
Heavy die components are usually secured with 12 to 16mm diameter screws.
-
Dowel diameter should be same as that of the cap screws.
-
Dowel should be located diagonally across from each other and as apart as possible to
G I S E
increase the locational accuracy. -
L O
D
All screws and dowels should be located from 1.5 to 2 times their diameter from the component edge.
O T
Tool Design Data Book
Page 22
20
25
20
22
25
20
22
25
20
O O B
25
30
25
Back Pillar
20
20
20
Blister Cen
30
35
28
Cent Pillar
25
30
25
Back Pillar
25
30
25
Back Pillar
30
35
28
Back Pillar
230
30
35
28
Back Pillar
254
30
35
28
Back Pillar
Table 3.25 - DIE SET DETAILS S. No.
X
D
1
60
52
2
100
3
INCH SIZE
L
W
T
B
-
04 X 04
100
100
20
22
16
52
-
04 X 06
150
100
20
22
20
150
52
-
04 X 08
200
100
25
30
20
4
100
75
-
05 X 05
130
130
5
95
100
-
05 X 06
125
150
6
120
100
-
06 X 06
150
150
7
120
120
-
06 X 07
150
180
8
-
140
130
06 X 09
230
150
9
-
170
100
06 X 12
305
150
10
150
120
-
07 X 07
180
11
150
145
-
07 X 08
180
12
160
135
-
08 X 08
200
13
160
160
-
08 X 09
200
14
160
180
15
-
160
16
-
180
200
160
200
180
200
200 205
TYPE
Back Pillar Back Pillar Back Pillar Back Pillar Back Pillar Back Pillar
08 X 10
170
08 X 12
200
305
30
35
32
Cent Pillar
170
08 X 13
200
330
30
35
32
Cent Pillar
-
09 X 09
230
230
30
35
28
Back Pillar
-
09 X 10
230
250
30
35
28
Back Pillar
185
IG
205
-
10 X 10
254
254
30
35
28
Back Pillar
-
120
200
10 X 10
254
254
30
35
28
Diago. Pillar
-
120
200
10 X 10
254
254
30
35
28
Four Pillar
200
210
-
10 X 11
254
280
30
35
32
Back Pillar
200
235
-
10 X 12
254
305
30
35
32
Back Pillar
24
-
230
200
10 X 15
254
380
35
40
32
Cent Pillar
25
230
210
-
11 X 11
280
280
30
35
32
Back Pillar
26
255
235
-
12 X 12
305
305
30
35
32
Back Pillar
27
-
165
255
12 X 12
305
305
30
35
32
Diago. Pillar
28
-
165
255
12 X 12
305
305
30
35
28
Four Pillar
29
255
260
-
12 X 13
305
330
30
35
32
Back Pillar
30
280
255
-
13 X 13
330
330
35
40
36
Back Pillar
S E
18 19 20
D 21
O T
N
A T A
D 180
Pillar (OD)
-
17
L O
Y
22 23
Tool Design Data Book
Page 23
O O B
BALL BEARING CAGES
A T A
Table 3.26 - Ball Bearing Cages
Table – 3.27 Ball Bearing Cages
Standard bearing Al./Brass
Non Standard bearing Al./Brass
D
No.
I.D.X.
O.D.X
Length X
Ball
No.
I.D.X.
1
20
26
65
3
1
15
2
25
31
70
3
3
28
36
80
4
4
32
40
80
5
32
40
95
6
36
44
90
7
40
48
90
L O
S E
D
4 4 4
Length X
Ball
21
70
3
16
22
70
3
19
25
70
3
4
24
30
70
3
5
18
24
70
3
6
30
38
80
4
7
32
40
100
4
8
36
44
105
4
9
38
46
105, 125
4
10
40
48
105, 125
4
11
48
58
105, 125
5
12
50
60
105, 125
5
13
60
70
125
5
N
IG 4
O.D.X.
2 3
O T
Tool Design Data Book
Page 24
Table 3.28 - SLEEVE BUSH FOR DIE SETS
Sleeve Bush Standard Bush D-3
I.D
O.D.
1
20
36
40
20
2
25
42
46
23
3
28
4
32
5
36
6
40
7
26
8
31
No
9 10
L O
D-4
D-2
11 12 13
Stap O.D.
O O B
A T A
Sleeve Bush Non Standard Bush
Length
Length
L-1
L
No
G I S E
N
D D-2
D-3
D-4 Stap
O.D.
O.D.
21
32
36
60
22
32
36
60
I.D.
Length L
60
1
70
2
80
3
25
36
40
70
80
4
30
42
46
70
90
5
38
50
54
80
50
54
28
52
56
28
58
62
30
60
65
30
90
6
46
60
65
90
36
40
20
60
7
30
44
50
110
42
46
23
70
8
25
38
42
90
50
54
28
80
9
15
32
36
60
52
56
28
80
10
16
32
36
60
56
60
30
90
11
31
42
46
110
44
58
62
30
90
12
36
50
54
110
48
60
65
30
90
13
20
36
-
75
14
26
36
-
80
15
33
42
46
90
D 36 40 40
O T
Tool Design Data Book
Page 25
PILLAR PINS FOR DIE SETS
A T A
Table 3.29 - Standard Pillar S. No
D
L
1
20
125, 150
2
25
140, 160, 180
3
28
4
30
5
32
6
36 40
D
180, 200 180, 190
N
G I S E
7
O O B
150, 180, 200, 230 170, 200, 250 200, 250
Table 3.30 - Non Standard Pillar
S. No
D
1
15
90, 100
16
90, 100
19
125, 150
20
100, 180
24
140, 160, 180, 200, 225
6
25
200, 250, 300
7
28
150, 225, 250, 300
8
30
150, 200, 225, 250
9
32
300, 250, 350
10
36
225, 275, 300, 350
11
40
225, 275, 300, 350, 400
12
50
200, 225, 255, 270, 300, 350
2
D 3
O T
L O
L
4 5
Tool Design Data Book
Page 26
SELECTION OF PRESS (TON)
Press capacity required =Cutting Force x 1.3 ( Select nearest higher capacity press from the data given below)
O O B
Table 3.31 - Preferred capacities of Mechanical and Hydraulic presses( as per IS 7469-1974):-
KN
O T
L O
Capacity in (Tonnes)
Capacity in (Tonnes)
KN
A T A
10
(1)
*2000
16
(1.6)
2500
(250)
25
(2.5)
*3150
( 315)
40
(4.0)
4000
( 400)
63
(6.3)
*5500
( 550)
100
(10)
6300
(630)
160
(16)
*8000
(800)
250
(25)
400
(40)
630
(63)
S E
IG
N
D
(200)
10000
(1000)
12500
(1250)
16000
(1600)
*800
(80)
20000
(2000)
1000
(100)
25000
(2500)
*1250
(125)
31500
(3150)
1600
(160)
40000
(4000)
D
Note –capacities marked with asterisk(*) are optional in the range.
Tool Design Data Book
Page 27
N
G I S E
A T A
O O B
D
D
Using the same principle, die shut height for stamping dies, bendingdies, and formingdies can also be calculated
O T
L O
Standard shut height of press as per IS 10644-1983:100, 125 ,160 ,200,250 ,315, 355, 400, 450, 500, 560, 630, 710, 800, 900, 1000,
The shut height of the tool must be kept according to the available press shut heights.
Tool Design Data Book
Page 28
Table 3.32 - PUNCH AND DIE MATERIAL SELECTION AND HEAT TREATMENT
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 29
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 30
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 31
N
O T
L O
G I S E
A T A
O O B
D
D
Table 3.33 - SELECTION OF STEEL FOR DIFFERENT APPLICATIONS
Tool Design Data Book
Page 32
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 33
CALCULATION OF CENTER OF PRESSURE:When the shape of blank to be cut is irregular, the summation of shear
O O B
forces about the centre line of press ram may not be symmetrical. Due to this bending moments will be introduced in the press ram, producing misalignment and undesirable
deflections. To avoid this the centre of pressure of the shearing action of the die must be found and while laying out the punch position on the punch holder, it should be ensured
that the centre line of the press ram passes exactly through the centre of pressure of the
A T A
blank. This centre of pressure is the centroid of the line perimeter of the blank. It should
be noted that it is not the centroid of the area of the blank. The centre of pressure can be found out by the following formula:
D
= (l1x1+l2x2+l3x3+……)/l1+l2+l3+…. = Σlx/Σl
N
= (l1y1+l2y2+l3y3+……)/l1+l2+l3+…. = Σly/Σl Where
G I S E
= x distance from centre of pressure
= y distance from centre of pressure l1,l2,l3…. = length of line elements
x1,x2,x3..= x distance of the centroids of line elements l1,l2,l3 respectively.
D
y1,y2,y3..= y distance of the centroids of line elements l1,l2,l3 respectively.
O T
L O
Tool Design Data Book
Page 34
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 35
SPRING DESIGN DATA 1. DATA FOR DESIGN OF CONVENTIONAL COIL SPRINGS SPRING SELECTION: - If the diameter and length are known then directly the spring dimensions can be selected from the tables given in page no to . Select springs with desired total load. - If diameter and length are not known, use the following spring selection steps and refer to the rate column of the dimension table for spring selection. - Step 1:- Estimate the level of production required of the die – short run, constant production etc.,
A T A
O O B
Step 2: - Determine compressed spring length “H” an operating travel “T” from the die layout
N
G I S E
Step 3:-
O T
L O
D
Determine free length “C” as follows: o Decide which load classification the spring should be selected from light, medium, heavy or extra heavy load. Then chose the figure nearest the compressed length “H” required by the die design from the appropriate charts below . read corresponding “c” free length.
D
Step 4:Estimate total initial spring load ‘L” required for all springs when springs are compressed “X” in mm Step 5:Tool Design Data Book
Page 36
- Determine ‘X” initial compression by using the following formula:
X=C-H-T
Step 6:Determine “R” ( total rate for all springs in N/mm) by using the following formula
R=L/X
N
A T A
O O B
D
Step 7:- Select springs from the table given below as follows: o The free length “C” must comply with length determined in step 3. o Divide R in step 6 by the number of spring to be used ( if known) in order to get the rate per spring. Then refer to the following pages for the catalogue number of springs having the desired rate. If the number of springs is not known, divide R from step6 by the rate of the spring you select for the correct number of springs.
O T
L O
G I S E
D
Table 3.34 – Spring Compressed length to free length conversion chart
Tool Design Data Book
Page 37
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 38
Table 3.35 – Rectangular spring – light load
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 39
Table 3.35 Contd…
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 40
Table 3.36 – Rectangular spring – Medium load
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 41
Table 3.36 Contd…
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 42
Table 3.37– Rectangular spring – Heavy load
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 43
Table 3.37 Contd….
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 44
Table 3.38 - Rectangular spring – Extra Heavy load
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 45
Table 3.38 Contd…
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 46
Table 3.39 - Rectangular spring – Ultra Heavy load
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 47
Table 3.40 - Circular spring – Light load
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 48
Table 3.41 - Circular spring – Medium load
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 49
Table 3.42- Circular spring – Heavy load
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 50
Table 3.43- Circular spring
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 51
Table 3.43 Contd….
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 52
Table 3.43 Contd…
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 53
Table 3.44 – Spring retainer
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 54
Table 3.45 - RUBBER SPRINGS
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 55
Table 3.46 - RUBBER SPRINGS
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 56
Table 3.47 - RUBBER SPRINGS
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 57
Table 3.48 - RUBBER SPRINGS
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 58
Table 3.49 - RUBBER SPRINGS
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 59
Table 3.50 RUBBER SPRINGS
Stripping Pressure (N) at Deflection of D
10
13
16
20
25
32
40
D
d
d1
t
d2
-
10
18
23
6
1.6
1290
1512
13
23
26
6
703
1060
1268
16
28
31
6
74
670
1020
1220
20
33
36
7
44
1566
2647
-
54
1357
2180
2469
25
40
43
7
64
1081
1780
2158
32
50
55
7
74
811
1707
2139
38
60
65
8
44
2433
3513
-
40
54
1779
2958
3692
64
1526
2736
3202
74
1490
2650
3182
44
3002
4359
-
54
2580
3936
4581
64
2046
3424
4226
74
1939
3180
3980
44
4737
6605
-
54
3425
5515
6672
64
3291
5070
6205
74
3158
4781
5887
44
6383
9185
-
54
5693
8674
64
4480
6961
74
3469
6491
44
8562
54
6583
64
5804
L
3mm
6mm
9mm
44
978
1401
54
734
64
O T
L O
10497 9563
N
IG
S E 12521
10008 8118 7570
A T A 60
65
8
O O B 3.0
D
-
12744 11453
D
Tool Design Data Book
Page 60
BENDING TOOL DESIGN DATA Bending Allowance(L): L = (π / 180) x A x (R + 0.5T) When R ≥ 2T L = (π / 180) x A x (R + 0.33T) When R < 2T Where A = angle of bend in degrees R = bend inside radius T = sheet thickness Developed Length = Straight arm + Bend allowance
N
G I S E
A T A
O O B
D
D
On bends, the short length should be minimum of 2.5 x stock thickness+ radius
O T
L O
Tool Design Data Book
Page 61
A T A
O O B
D
Minimum hole (and short slot) to bend distance should be 2.5 x the stock thickness + Bend radius.
N
For long slots, the distance should be 4 x the stock thickness + bend radius.
O T
L O
G I S E
D
Tool Design Data Book
Page 62
‘V’ Bending: Bending Force = (1.33LST2) / W L = length of the bent part in mm T = thickness of blank in mm S= Tensile strength of blank material in N/mm2 W = width of ‘V’ at top ‘W’ should not be less than 6 times blank thickness; preferred range is 8 to 10
N
G I S E
A T A
O O B
D
Edge radius RE = (2 to 6)t
Where, = thickness of material
Punch Radius RP = Radius of component
D
Die Radius, RD = Punch radius + thickness of material
O T
L O
Tool Design Data Book
Page 63
‘U’ Bending or channel bending:
Bending Force, F = [(0.67LST2) / W]
N
G I S E
Span, W = RE + C +RP
A T A
O O B
D
Edge Radius, RE = (2 to 6)t for non moving edge Punch Radius, RP = Part radius
Die radius, RD = RP+ (1.2 to 1.25) t s C = Die clearance
D
T =Thickness of blank in ‘mm’ L =Length of bent part.
S = ultimate tensile strength in N/mm2
O T
L O
Tool Design Data Book
Page 64
WIPING DIES:
A T A
2
Bending Force, F = [(0.333LST )/W] Span, W = RD + C + RP Die radius, RD = Part radius C = Die Radius, RP = 3 to 8T
SPRING BACK:
N
G I S E
O O B
D
For low carbon and for soft non ferrous material – 0 to 2° For 0.40 to 0.5 carbon steel and half hard material – 3 to 5° Spring back may be high in hardened material – 10 to 15° Bend radius
400N/mm2
600N/mm2
R=T
4°
7°
R = 5T
6°
12°
D
Table 4.1 – Spring back data
L O
O T
Tensile strength
Tool Design Data Book
Page 65
DRAWING DIES Type of operation:
h / d ≤ 0.5 – shallow drawing h / d > 0.5 – deep drawing Where, h = shell height d = shell diameter
A T A
Estimation of blank Diameter (Theoretical):
O O B
D = √ (d2 + 4dh)
when d / r 20 or more
D = √ (d2+4dh – 0.5r)
when d / r is between15&20
D = √ (d2+4dh – r)
when d / r is between10&15
D = √[(d – 2r)2+4d(h- r) + 2πr(d – 0.7r)] Where,
N
D – Blank diameter in mm
G I S E
d – Shell outer diameter in mm h – Shell Height in mm
D
when d / r is below 10
r – Corner radius of punch Considering Trim allowance:
Trim allowance = 0.05mm for every 10 mm diameter. Of drawn cup Where,
O T
L O
D
Initial diameter of blank (D1) = D (Theoretical diameter.) + Trim allowance
Tool Design Data Book
Page 66
t / D Consideration: t / D decides the severity of wrinkling t / D Percentage
O O B
Wrinkling is a severe and compressive load must be reduced. Upto 0.5
Blank holder must be used, so a double action press is preferable
Table 5.1 -
Above 0.5 upto 1.5
Wrinkling is moderate and low blank holding forces are permitted
Above 1.5 upto 2.5
Wrinkling is very light so, single action press is enough
A T A
No wrinkling so blank holder is Over 2.5 unnecessary even with high compressive load Selection of percentage reduction for 1st Draw using t / D ratio: (t / D) x 100
Single action 1.5
N
Double action 0.15 0.2 0.3 0.4 0.5
G I S E
2.0 2.5
Where,
D
% reduction for 1 st Draw [(D1 – D2) / D1] x 100 30 35 40 45 47.5
D1 = Blank diameter. After adding trim allowance
D
D2 = Diameter. Of 1st Draw
O T
L O
Table 5.2 - Allowable percentage reduction for successive draws
Tool Design Data Book
First draw Second draw Third draw Fourth draw
(t / D) % 25% 15% 10 %
Page 67
Table 5.3 - No. Of Draws according to h / d ratio h / d ratio
No. of First draw Draws Up to 0.75 1 40 0.75 – 1.5 2 40 1.5 - 3 3 40 3 – 4.5 4 40 Percentage of reduction P= 100(1-d/D)
Second draw -25 25 25
Third draw --15 15
Where d= ID of drawn shell D= OD of blank
A T A
Estimation of drawing pressure: Drawing pressure, p = π x d x t x S x ((D / d)– C) Where, P = Drawing force in ‘kgf’ d = Shell outer diameter
N
D = Blank diameter t = thickness of sheet in ‘mm’
G I S E
Fourth draw ---10
O O B
D
S = Ultimate tensile strength in N/mm2
C = constant to cover friction and bending (0.6 to 0.7 for ductile material) Blank holding pressure:
Blank holding pressure = 1/3rd of drawing pressure
D
Press capacity:
O T
L O
Press capacity = (Drawing pressure + Blank holding pressure) x 1.3
Tool Design Data Book
Page 68
Table 5.4 - Drawing speed Material Steel Stainless steel Aluminum Aluminum alloys Copper Brass
Single action drawing Ft / Min M / Sec 60 0.3048 180 0.9144 150 0.762 200 1.016
Double action drawing Ft / Min M / Sec 35 – 55 0.1778-0.27 20 – 30 0.1016-0.1524 100 0.508 30 – 40 0.1524 – 0.2032 85 0.4318 100 0.508
Table 5.5 - Draw die clearance
A T A
2nd draw/ Intermittent draw 1.08t – 1.1t 1.09t – 1.12t 1.12t – 1.14t 1.15t – 1.2t
1st Draw
Blank thickness(t)
Upto 0.38 1.07t – 1.09t 0.4 – 1.27 1.08t – 1.1t 1.28 – 3.18 1.1t – 1.12t 3.5 and above 1.12t – 1.14t t is the thickness of the original blank Punch radius:
N
D
O O B
Sizing draw
1.04t – 1.05t 1.05t – 1.06t 1.07t – 1.09t 1.08t – 1.1t
Punch radius = 4t to 10t (or) Radius on product drawing
G I S E
Where, t = sheet thickness
Draw radius (or) die radius: R = 6t to 8t (or) R = 0.8√[(D - d)t] Tolerance:
Tolerance = ± 0.005” (or) ± 0.127
D
Table 5.6 - Draw die material:
O T
L O
Rate of production Less than 1000 Around 1000 Nos. Above 10000 Nos. Above 10,00,000
Die material Plastic (or) zinc C.I Tool Steel Carbide Punches & die
Tool Design Data Book
Page 69
6. DATA FOR GAUGE DESIGN:-
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 70
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 71
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 72
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 73
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 74
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 75
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 76
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 77
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 78
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 79
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 80
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 81
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 82
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 83
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 84
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 85
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 86
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 87
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 88
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 89
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 90
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 91
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 92
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 93
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 94
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 95
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 96
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 97
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 98
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 99
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 100
N
O T
L O
G I S E
A T A
O O B
D
D
Tool Design Data Book
Page 101
Table 6.34 - REFERENCE INDIAN STANDARDS FOR GAUGE DESIGN:IS NO.
INDIAN STANDARD SPECIFICATION FOR
IS: 3455 – 1971
Gauging practice for Plain work pieces Gauging members for Plain plug gauges, GO and NO GO members
O O B
IS: 6137 – 1983 (Size range from 1 upto and including 40mm)
Gauging members for Plain plug gauges, GO and NO GO members IS: 6244- 1980 (Size range above 40 to 120 mm)
Gauging members for Plain plug gauges, GO and NO GO members IS: 6246 – 1980
A T A
(Size range above 120 up to and including 250 mm) IS: 7018 (Part 1)
Technical supply conditions for gauges – Part 1 General – 1983
Technical supply conditions for gauges – Part 2 - Assembly and IS: 7018 (Part 2)
D
inspection Plain Plug gauges ( Size range from 1 mm upto and – 1983 including 250 mm)
N
Technical supply conditions for gauges – Part 3- Assembly and IS: 7018 (Part 3)
G I S E
identification of screw plug gauges for ISO metric screw threads (
– 1983
Size range from M1 upto and including M200)
IS: 5388 – 1983 IS: 3477 – 1973
D
IS: 3485 - 1966
GO and NO GO Snap Gauges for size range 3 to 250 mm Plain ring gauges
Note:- Use of Institute copies of all the above Indian Standards and any other related
L O
O T
Hexagon handles for Plain and Threaded Plug gauges
Indian standards is permitted in the Tool Design and Drawing examination for the D.M.E ( Tool & Die) course.
Tool Design Data Book
Page 102
JIGS & FIXTURES Table 7.1 - GUIDELINES FOR SELECTION OF LOCATORS
SI.NO LOCATING DEVICE 1 Six point locator(3-2-1) pin and button locators 2 V-block 3
Nesting locator
4
5
V-block, horizontal (one side is fixed and other end is adjustable or cam operated) V-locator. Jack pin locator
6
Eccentric locators
APPLICATION Locating flat surfaces
O O B
Locating round circular flat Locating cylindrical profile in vertical position. Locating elliptical and irregular surfaces.
D
A T A
Locating a rough work piece. Variation in work piece size.
Table 7.2 - GUIDELINES FOR SELECTION OF CLAMPS CLAMPS SITUATIONS
N
Strap clamp
IG
Swinging strap clamp Cam operated clamp
S E
Toggle clamp Screw clamp
Effective and fast, but should be used. Adapted for many types of fixtures. Components are to grip on.
Equalizing clamp
Exerting equal pressure to hold.
Hydraulic and pneumatic clamp
Faster, uniform and effective.
L O
O T
Commonly used for rectangular work pieces. For easy loading and un loading.
D
Hydraulic clamp with rack and pinion
Circular rod in V-block
Spider clamp
Circular and symmetrical workpiece clamping. Used during facing operation.
Edge clamp
Tool Design Data Book
Page 103
Table 7.3 - LOCATING PINS (ROUND) - IS 5093
d2
h1
h2
9.5 11.5 15 19 24
d1 p6 8 10 12 16 20
7.5 9.5 11.5 15.5 19.5
8 10 14 18 22
16 18 22 25 32
31
25
24.5
25
D g6
d
10 12 16 20 25
32
O T
L O
Tool Design Data Book
d2
h1
D
11.5
12
16
15.5
15
25
24
20
19.5
18
32
31
25
24.5
22
40
39
32
31.5
25
20
D
d1 p6
12
16
S E
36
A T A
Table 7.4 - END LOCTING PLUGS - IS 5095 D d h6
N
IG
O O B
15
19
h2 16 25 40 20 32 45 25 40 60 40 63 50 80
Page 104
Table 7.5 - DIAMOND LOCATING PINS - IS 5094 D d1 d d2 e8 p6
b
h1
h2 12
12
11
8
7.5
4
8
14
13
10
9.5
5
10
18
17
12
11.5
6
14
22
21
16
28
27
20
36
35
A T A
O O B 14
18
15.5
8
18
21
19.5
10
22
28
24.5
12
25
32
D g6
d
D d1 p6
d2
d3
d4 s7
h
h1 h2
1 2
11. 5
1 0
9.5
M6
5
4 0
1 0
1 2
1 8
17
1 4
13. 5
M8
6
5 5
1 6
1 8
2 0
19
1 6
15. 5
M1 0
8
6 2
1 8
2 0
2 5
24
2 0
19. 5
M1 2
1 0
7 0
2 2
2 5
3 2
31
2 5
24. 5
M1 6
1 2
8 5
2 5
2 8
L1
l2
N
25
Table 7.6 - ROUND LOCATING STUDS - IS 5096
O T
L O
G I S E
D
Table 7.7 - V-Locator
Tool Design Data Book
l3
b1
b2
b3
d
Page 105
25
20
35
15
32
15
7
36
25
50
20
45
25
9
50
32
60
22
55
30
Table 7.8 - V-Block a 50 63 80 100
Table 7.8 - SWING CLAMP - IS 5250 d
O T
dmax 40 50 63 83
200 200
200
200
300 300
300
300
D
A T A
O O B dmin 5 5 7 7 10 12
L1 L2 L3 a
r
Size of screw
52
20
25
14
4
12
M6
L
25
11
30
N 11
16
70
24
35
20
6
16
M10
14
35
15
20
80
26
40
22
7
20
M12
18
45
18
25
90
32
45
28
9
25
M16
22
50
23
30
100
38
50
32
11
30
M20
20
G I S E
D
t
c 40 50 63 80
9
6.6
L O
w W1
b 40 50 63 80
11
7
12
9
14
60
22
30
18
5
14
M8
Table 7.9 - STRAP CLAMP – IS 4292
Tool Design Data Book
d
l1
a
b
c
h
s
For screw size
7 10 12 15 19 24
50 60 80 100(125) 125(160) 160(200)
10 13 15 21 26 30
20 22 30 40(50) 45(65) 60(80)
8 10 12 14 18 22
10 12 15 20 25 30
20 25 30 40 50 60
M6 M8 M10 M12 M16 M20 Page 106
28 35 42 45
200(250) 250(315) 315(350) 350(400)
35 45 48 53
80(105) 100(130) 125(150) 150(180)
26 34 40 45
30(40) 70 40(50) 80 45(55) 90 55(60) 100
Table 7.10 - SWING ‘C’ WASHER- IS 4298 d H13
d1
6.6 9.0 11 14 18 22
8.5 8.5 8.5 10.5 10.5 10.5
18 21 24 27 33 38
26
12.5
30
12.5
R R1
O T
L O
O O B
For bolt t or Nom screw size
R2
R3
R4
r
8 8 8 10 10 10
21.3 25.5 29.5 34.0 42.0 49.0
12
55.0
10.0 13.0 16.0 20.0 25.0 30.0 32.5
2.0 2.5 2.5 3.0 3.0 3.0
42
14.7 16.5 18.5 20.0 24.0 27.0 29.0
4.0
10
M6 M8 M10 M12 M16 M20 M24
45
12
60.0
30.0
35.0
4.0
10
M27
N
G I S E
M24 M30 M36 M39
A T A
6 6 6 8 8 8
D
D
Tool Design Data Book
Page 107
Table 7.11 - JIG BUTTON (IS 4294) MATERIAL: C45 RC
HARDNESS: 45 – 50 d1
d2
h
a
l
Under cut
6 10 16 25
4 6 8 12
5 8 5/13 8/20
1.2 1.6 2.0 2.5
6 8 10 14
A2 X 0.2 B2 X 0.2 B2 X 0.2 B2 X 0.2
40
20
13/32
3.2
20
B2 X 0.2
Table 7.12 - JIG FEET MATERIAL: FREE CUTTING STEEL – HARDNESS:56 ± 2RC
O T
L O
S
X
∞
1
11
2.0
34º 13º
1
14
2.5
22º 9º
1.5
17
2.5
18º 7º
1.5
22
3.0
20º 8º
1.0
2
27
3.0
18º 7º
1.0
2
32
4.0
13º 5º
d
b
d1
d2
e1
K
l
r1
10 20
M6
11
6
8
12.7
5
21 31
0.5
15 30
M8
13
9
10
16.2
6
28 43
0.5
20 40
M1 0
16
12
12
19.6
8
36 56
25 50
M1 2
20
15
15
25.4
10
45 70
30 60
M1 6
24
20
19
31.2
40 80
M2 0
29
N
G I S E 26
24
36.9
12
54 84
16
69 109
A T A r2
H
D 0.5 0.5
O O B
D
Tool Design Data Book
Page 108
Table 7.13 - FEET BOLT Basic size
A
B
C
D
Eø
Fø
M10
50
28
12
12-20
10
20
M10
65
28
12
12-20
10
20
M10
75
28
12
12-20
10
M10
90
28
12
12-20
10
M12
75
35
18
20-25
12
M12
90
35
18
20-25
12
M12
100
35
18
20-25
12
M12
112
35
18
20-25
12
25
M12
125
35
18
20-25
12
25
M12
140
18
20-25
12
25
M12
150
18
20-25
12
25
N
Table 7.14 - FEET NUTS
D 35 35
20 25 25 25
Basic size
M10
M10
M10
M10
M12
M12
M12
M12
M12
M12
M12
A
20
25
36
50
20
25
36
50
62
75
87
20
20
20
20
25
25
25
25
25
25
25
L O
O T
G I S E
A T A
O O B 20
Bø
D
Tool Design Data Book
Page 109
Table 7.15 - JIG BUSH FIXED BUSH
d1 Upto 1 1.0-1.8 1.8-2.6 2.6-3.3 3.3-4.0 4.0-5.0 5.0-6.0 6.0-8.0 8.0-10 10-12 12-15 15-18 18-22 22-26 26-30 30-35 35-42 42-48 48-55 55-63
O T
L O
Short l1 l2 6 6 6 8 8 8 10 10 12 12 16 16 20 20 20 25 25 32 32 36
4 4 4 6 6 6 7 7 8 8 12 12 15 15 15 20 20 25 25 30
Long l1 l2 9 9 9 12 12 12 16 16 20 20 28 28 36 36 36 45 45 56 56 72
7 7 7 9 9 9 13 13 16 16 24 24 31 31 31 40 40 50 50 66
Tool Design Data Book
d3
3 4 5 6 7 8 10 12 16 18 25 25 30 36 42 48 56 63 70 80
6 7 8 10 11 12 14 16 20 22 26 30 35 41 47 55 63 70 77 87
N
G I S E
D
d2
D
A T A
O O B
d4
r1
r2
Z
10 13 16 20 24 28 33 40 46 52 59 67 75
1.2 1.2 1.2 1.6 1.6 2.0 2.0 2.0 2.5 2.5 4.0 4.0 6.0 6.0 6.0 8.0 8.0 8.0 8.0 8.0
0.2 0.2 0.3 0.3 0.4 0.4 0.4 0.6 0.8 0.8 0.8 0.8 1.0 1.0 1.0 1.0 1.0 1.6 1.6 1.6
0.005 0.005 0.005 0.005 0.005 0.005 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.02 0.02 0.02 0.02 0.02 0.02 0.02
Page 110
Table 7.16 - LINER BUSH Short Long d1 Upto 1 1.0-1.8 1.8-2.6 2.6-3.3 3.3-4.0 4.0-5.0 5.0-6.0 6.0-8.0 8.0-10 10-12 12-15 15-18 18-22 22-26 26-30 30-35 35-42 42-48 48-55 55-63
O T
L O
6 6 6 8 8 8 10 10 12 12 16 16 20 20 20 25 25 30 30 36
9 9 9 12 12 12 16 16 20 20 28 28 36 36 36 45 45 56 56 70
d2
r1
r2
z
3 4 5 6 7 8 10 12 16 18 22 25 30 36 42 48 56 63 70 80
1.2 1.2 1.2 1.6 1.6 2.0 2.0 2.0 2.5 2.5 4.0 4.0 6.0 6.0 6.0 8.0 8.0 8.0 8.0 8.0
0.2 0.2 0.3 0.3 0.4 0.4 0.4 0.6 0.8 0.8 0.8 0.8 0.8 1.0 1.0 1.0 1.0 1.6 1.6 1.6
0.005 0.005 0.005 0.005 0.005 0.005 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.02 0.02 0.02 0.02 0.02 0.02 0.02
G I S E
N
D
A T A
O O B
D
Tool Design Data Book
Page 111
Table 7.17 - SLIP BUSH
d1
d2
d3
d4
d5
l1
l2
l3
a
b
r1
z
X
Upto 4 4-6 6-8 8-10
8 10 12 16
16 19 22 26
11 14 17 21
2.5 2.5 2.5 3.0
20 22 25 28
10 12 12 16
1 1 1 1
3 3 3 4
4 4 4 5
3 3 4 5
0.01 0.01 0.01 0.01
14 12 10 12
10-12 12-15 15-18 18-22 22-26 26-30 30-35 35-42 42-48
18 22 25 30 36 42 48 56 63
30 35 40 47 56 62 69 78 85
24 29 35 41 47 54 61 69 78
3.0 5.0 5.0 5.0 6.0 6.0 6.0 6.0 6.0
28 36 36 36 45 45 50 50 56
16 20 20 20 25 25 32 32 36
1 1 1 1 2 2 2 2 2
4 5 5 5 6 6 6 6 6
5 7 7 7 8 8 11 11 14
5 5 5 6 6 6 8 8 8
0.01 0.01 0.01 0.01 0.02 0.02 0.02 0.02 0.02
10 12 8 0 0 0 0 0 0
L O
O T
A T A
O O B
G I S E
N
D
D
Tool Design Data Book
Page 112
Table 7.18 - LOCKING SCREWS
O O B
d6 d7 d8 l4 l5 l6 h d6 m6Ø * l m n t r2 c M5 2.5 X 14 10 15 M5 2.5 X 14 12 16 M5 10 5 6 6 15 2 2.5 X 14 12 1.6 2.0 0.6 18 M5 3.0 X 14 16 20 M5 3.0 X 14 16 22 M6 5 X 20 20 26 M6 13 6 8 8 20 2 5 X 20 20 2.0 2.5 1.0 29 M6 5 X 20 20 33 M8 6 X 24 25 38 M8 6 X 24 25 41 M8 16 8 10 10 25 2.5 6 X 24 30 2.5 3.0 1.6 45 M8 6 X 24 30 48 M8 6 X 28 35 55 TOMMY NUT (Material –C 45) Basic size AØ BØ
N
O T
L O
G I S E
D
Tool Design Data Book
A T A
D
M10
25
28
M12
25
35
M16
32
38
Page 113
Table 7.19 - KNURLED THUMB NUT (Material –C 45) Basic size AØ BØ 16 M6 20 M8
22
M10
25
M12
28
M16
20 22 25 28
35
Table 7.21 – Hand nut
N
AØ 41 54 58 64 70 80
O T
L O
D
G I S E
BØ 32 38 41 45 50 56
CØ 23 27 30 32 38 45
DØ M12 M16 M20 M22 M24 M30
E 14 17 17 19 21 25
F 8 13 13 17 17 19
D
10
1.5
12
1.5
12
3
14
3
16
3
A T A
Table 7.20 - THUMB NUT (Material –C 45) d1 M6 M8 M10 M12 M16
C
D
G 3 5 5 5 6 8
d2 7 9 11 13 18
b 28 32 36 45 54
H 6 8 8 10 10 11
h 12 14 16 18 22
J 3 5 5 6 6 8
O O B e 12 14 16 18 22
K 25 35 35 41 44 52
HAND NUT (Material –C 45)
Tool Design Data Book
Page 114
d
a
d2
E
g
h
l2
M10
6
3
75
3.5
12
40
M12
7.5
4
90
4.0
15
50
M16
10.0
5
117
4.5
19
63
M20
12.5
6
150
6.5
24
80
N
Table 7.22 – Handle grip screws
O T
L O
G I S E
l l1 l l1 l l1 l l1
40 25 50 31 65 40 80 49
A T A
45 30 55 36 70 45 85 54
D
50 35 60 41 75 50 90 59
55 40 65 46 85 60 100 69
60 45 70 51 95 70 110 79
O O B 65 50 75 56 105 80 120 89
80 61
130 99
D
Tool Design Data Book
Page 115
Table 7.23 - WING/ FLY SCREWS
d
a
d2
M5
3
1.5 25
1.5
M6
4
1.5 32
2.0
M8
5
2.0 40
2.5
O T
6
3.0 50
3.5
h
h1
A T A
D
l l1 l 8 16 l1 l 9.5 20 l1 l 12.0 25 l1 7
N
G I S E
M10
L O
e
g approx.
12
25 16 28 20 35 25 50 38
30 22 40 30 55 43
O O B
35 27 45 35 60 65 48 53
D
Tool Design Data Book
Page 116
Table 7.24 - PRESSURE PADS
Max.dia. d1
d4
d5
d6
d7
10 12 16 20 25 32 40
3.8 4.8 6.4 7.4 9.5 12.5 15.5
8 10 12 15 18 22 28
4 5 7 8 10 14 18
1.5 1.5 2 2 3 3 4
e
f
h
2.5 2.5 7 2.5 2.5 8 3 3.5 9.5 3.5 5 12 4.5 6 15 6 7 19 7.5 9 24
N
G I S E 20
O T
L O
25
A T A
r1
r2
1.2 1.5 2 2 3 3 4
0.3 0.5 4.5 0.3 0.5 5 0.4 0.5 6 0.4 1 7 0.6 1 9 0.6 1 12 0.8 1 15
D
Table 7.25 - Cam clamp (Material – Mild steel) A B C 10 13 1.5 12 16 2 16 20 2.5 3
O O B
t2
t1
D 3 4 5
E 12 15 18
6
24
For screw with thread
Fastening pin
M5 M6 M8 M10 M12 M16 M20
1.5m6 x 6 1.5m6 x 8 2m6 x 8 2m6 x 14 3m6 x 14 3m6 x 16 4m6 x 20
F 60 70 90 110
G 10 12 16 20
D
Tool Design Data Book
Page 117
Table 7.26 - Quarter turn screw A M10 M12 M16
B 50 62 82
M20
100
C 35 38 47
60
D 12 15 20
E 28 32 35
22
40
F 5 6 6
10
Table 7.27 - Spherical washer A 9 11 14 18 Table 7.28 - C WASHER d H12
IG
N
O T
L O
S E
D
Tool Design Data Book
B 20 22 28 40
6.4 8.4 10.5 13 17 21 25
6 8 10 10 12 12 12
31
15
25
D 2.5 2.5 2.5 3
A T A
D l
C 20 22 28 40
O O B
E 4 6 6.5 12
F 2.5 2.5 2.5 3
G 5 6 6.5 7
80 80 80
100
For bolt or screw size M6 M8 M10 M12 M16 M20 M24
80
100
M30
D
32 32
40 40
50 50
63 63 63
Page 118
Table 7.29 - WING NUT(hot stamped or cast) IS 2636-1972 Size d
M2
M2.5
M3
M4
M5
M6
M8
M10
A(js16)
Nom max min
8 8.45 7.55
10 10.45 9.55
12 12.55 11.45
16 16.55 15.45
20 20.65 19.35
b
Nom
6
8
10
12
16
e(js16)
Nom max
20 20.6 19.4
25 25.6 24.4
32 32.8 31.2
40 40.8 39.2
50 50.8 49.2
g1(js16)
Nom max min
1.6 1.9 1.3
2 2.3 1.7
2.5 2.8 2.2
3 3.3 2.7
g2
Nom
2
h1(js16)
Nom max min
10 10.4 9.6
G I S E
min
m nom
5
r1 Nom
3
0.5
r3 Nom
O T
L O r4 Nom
D *
r2 Nom
Radiused.
2
Tool Design Data Book
M12
M16
M20
A T A
O O B M24
23 23.65 22.35
28 28.65 27.35
36 36.80 35.20
19
22
28
36
D
64 65.0 63
72 73.0 71
90 91.1 88.9
112 113.0 111.0
5 5.4 4.6
6 6.4 5.6
7 7.4 6.6
9 9.4 8.6
5
6
7
9
11
4 4.4 3.6
45 45.80 44.20
2.5
3
12 12.6 11.4
16 16.6 15.4
N 20 20.6 19.4
25 25.6 24.4
32 32.8 31.2
36 36.8 35.2
45 45.8 44.2
56 57.0 55
6
8
10
12
14
16
20
24
4
5
6
8
10
11
14
18
*
*
*
1
1
1.2
1.6
2.5
0.5
1
1
1.2
1.2
1.6
2
3
2.5
3
4
5
6
7
9
11
4
Page 119
Table 8 - Unit conversions Conversions factors 1N
PHYSICAL QUANTITY Force
0.1016 kgf
0.2248 Ibf
1 N/m2
Pressure
10.19 x 10-6 kgf/cm2
145.038x10-6 kgf/cm2
1kW
Power
1kW, 1.36hp
1.34hp
1 Nm/s
Power
0.1019 kgfm/s
0.7375 ft lpf/s
SI
MKS
FPS
Metric conversion table Multiply Inch Foot Yard Mile Inch2 Foot2 Yard2 Inch3 Yard3
Kilogram Ounce
Foot/Second2 Inch/Second2
O T
L O
N
G I S E
Pound Ton
D
Horse power
Tool Design Data Book
To get equivalent number to
A T A
By Length 25.4 0.3048 0.9144 1.609 Area 645.2 6.45 0.0929 0.8361 Volume 16.387 16.387 Mass 0.4536 907.18 Force 9.807 0.278 Acceleration 0.3048 0.0254 Power 0.746
O O B
Millimeters (mm) Meters (m) Meters (m) Kilometers(km)
D
Millimeters2(mm2) Centimeters2(cm2) Meters2 (m2) Meters2 mm3 cm3 Kilograms (kg) Kilograms (kg) Newton (N) Newton(N)
Meter per second2(m/s2) Meter per second2 Kilowatts(kW)
Page 120
