IM 310 - Tool Design: Department of Industrial & Manufacturing Engineering

IM‐416 Management Information Systems 1/28/2014
Department of Industrial & Manufacturing Engineering

NED University of Engineering & Technology, Karachi.
IM 310 - Tool Design
Dr. Muhammad Wasif

Assistant Professor
Ph.D. (CAD/CAM – Canada), M.Engg. (Ind. & Mfg. Engg. – NEDUET),
B.E. (Mech. Engg. – NED UET).
Member A.S.M.E. and P.E.C.
Terms related to Tool Design
 Tool is a device or implement, especially one

held in the hand, used to carry out a particular
function efficiently.
 Manufacturing (to make by hands) is the

Tools
industrial activity that changes the form of raw
materials to create products.
 The “machine-operated tools” used to perform

the metal cutting are called machine tools.
 Machining is the process using machine tools

to cut materials to desired sizes and shapes.
Machine Tool: Drill Press
IM‐310 Tool Design Dr. Muhmmad Wasif ‐ Asst. Professor (IMD), NED UET
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What is Design ?
 To design is either to formulate a plan for the satisfaction of a

specified need or to solve a specific problem.
 Product design must be functional,

safe, reliable, competitive, usable,
manufacturable, and marketable.
 Identification of need
 Definition of problem (specs)
 Synthesis (Appearance, function)
 Analysis & Optimization (test)
 Evaluation (finalization)
 Presentation
3
Product Life Cycle
If require a new tool, the
same cycle starts for the tool
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2
Manufacturing Processes and Tools
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Tool Design
 Tool design is a specialized area of manufacturing engineering which
comprises the analysis, planning, design, construction, and
application of tools, methods, and procedures necessary to increase
manufacturing productivity.
 Tool designer must have a working
knowledge of;
 Machine shop practices,
 Tool making procedures,
 Machine tool design,
 Manufacturing processes,
 Planning,
 Designing and engineering
graphics and drawing, and
 Cost analysis.
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3
Machining
Tools
Bending &
Casting
Forming
Tools
Tools Types
of
Tools
Work
Inspection
holding
Gages
Devices
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Types of Tool Design : Machining Tools

Drill Bits End Milling Tools Turning Tools
3 Flute Gen. Purpose
4 flute Gen. Purpose

2 Flutes Helix
4flute thread end mill
2 Flute Ball Nose
Parting Tool
Finishing Cut tool
Threading Tool
Gen. Purpose
Lip and Spur Drill
Twist Drill
Masonry Bits
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4
Types of Tool Design : Bending Tools
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Types of Tool Design : Casting Tools
Injection Die Casting Mold
Moulds for Plastic Part
Blow moulding
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5
Types of Tool Design : Work Holding Devices
Drilling Jig
Vice
Fixture for Drill Press

Chucks and Collets
11
Responsibilities of Tool Designer

 Cutting tools, tool-holders, and cutting fluids.
 Machine tools, particularly modified or special types.
 Jigs and fixtures.
 Gages and measuring instruments.
 Dies for sheet metal cutting and forming.
 Dies for forging, upsetting, cold finishing. and extrusion.
 Fixtures and accessories for welding, riveting. and other –mechanical

fastening.
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6
Tool Designing Pre-Requisites
 Machine Design
 Metallurgy (properties and extraction of metals)
 Electronics
 Information Technology
 CAD/CAM
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Objectives of Tool Design

 Reduce the overall cost of manufacturing a product by producing
acceptable parts at the lowest cost.
 Increase the production rate by designing tools that will produce parts
as quickly as possible.
 Maintain quality by designing tools which will consistently produce

parts with the required precision.
 Reduce the cost of special tooling by making every design as cost

effective and efficient as possible.
 Design tools which will be safe to operate.
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7
Tool Design Process

The design process consists of five basic steps;
1. Statement and analysis of the problem,
2. Analysis and requirements,
3. Development of initial ideas,
4. Development of design alternatives,
5. Finalization of design ideas.
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Tool Design Process - 1

Statement and analysis of the problem,
• Problem without tooling
• What the tool is supposed to do?
Drill four holes,
Bottleneck in assembly
• Low productivity without tooling
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8

Analysis of the requirements
 Must perform certain functions
 Must meet certain minimum precision requirements
 Must keep the cost to a minimum
 Must be available when the production schedule

requires it
 Must be operated safely
 Must meet other requirements such as adaptability to

the machine tool etc.
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Analysis of the requirements
Alternatives Function Quality Cost Date Auxiliary
Customized Multi
X Best High X X
Spindle Head
Jig for drilling X Mod. X X X
Other Ideas X Poor X X X
Drilling Jig
Customized Multi
Spindle Head
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9

Development of Initial Ideas
 Examination of preliminary data.
 Part print (Dimensions, Tolerances etc.)
 Process sheet (Machining processes, tooling required)
 Engineering notes (Bushes material)
 Production schedule
 Other information
Initial Design of Jig
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Development of Design Alternatives
Initial Design Alternate 1 Alternate 2
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10

Finalization of Design Ideas
 Rarely a tool alternative is favorite.
 Characteristics of each alternatives are weighted and

analyzed to select the alternative with strong points.
 Strong points includes;
Alternatives Cost Life Precision

0 L H L
1 H M H
2 M H H
Alternate 2
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Economies of Design
Temporary Tooling
Permanent Tooling
Tool Life
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11
Break-Even Charts
 To determine which of two machines is most economical,
the fixed cost and variable cost of each machine are plotted.
 The total cost is composed of the sum of the fixed and

variable costs.
 Fixed cost (FC)– initial investment on the equipment and
tools.
 Variable cost (VC)– varies with the actual number of
objects made.
 Total cost (TC) = FC+VC  n
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Break-Even Charts
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Break-Even Charts
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Tool Drawings
 Draw and dimension with due consideration for someone using the
drawing to make the item in the tool room.
 Do not crowd views or dimensions
 Analyze each cut to be sure it can be done with standard tools.
 Use only as many views as necessary to show all required detail.
 Surface roughness must be specified.
 Tolerances and fits peculiar to tools need special consideration.

 the fit tolerance should be put on the male piece and the hole should
carry a nom in al size.
 Do not tolerance both details of a pair of mating parts
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Tool Drawings
 The stock list of any tool drawings should indicate all sizes required to
obtain the right amount for each detail.
 Apply tolerances realistically. Overly tight tolerances can add a great
deal of additional cost with little or no added value to the tool.
• The function of the detail should determine the specific
tolerance , not a standard title block tolerance value.
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IM‐416 Management Information Systems 1/28/2014

Department of Industrial & Manufacturing Engineering

IM 310 - Tool Design

Dr. Muhammad Wasif

Terms related to Tool Design

 Tool is a device or implement, especially one

 Manufacturing (to make by hands) is the

 The “machine-operated tools” used to perform

 Machining is the process using machine tools

 To design is either to formulate a plan for the satisfaction of a

 Product design must be functional,

Manufacturing Processes and Tools

Types of Tool Design : Machining Tools

4 flute Gen. Purpose

4flute thread end mill

2 Flute Ball Nose

Types of Tool Design : Bending Tools

Types of Tool Design : Casting Tools

Injection Die Casting Mold

Moulds for Plastic Part

Types of Tool Design : Work Holding Devices

Fixture for Drill Press

Responsibilities of Tool Designer

 Machine tools, particularly modified or special types.

 Jigs and fixtures.

 Gages and measuring instruments.

 Dies for sheet metal cutting and forming.

 Dies for forging, upsetting, cold finishing. and extrusion.

 Fixtures and accessories for welding, riveting. and other –mechanical

Tool Designing Pre-Requisites

 Metallurgy (properties and extraction of metals)

Objectives of Tool Design

 Maintain quality by designing tools which will consistently produce

 Reduce the cost of special tooling by making every design as cost

 Design tools which will be safe to operate.

Tool Design Process

1. Statement and analysis of the problem,

2. Analysis and requirements,

3. Development of initial ideas,

4. Development of design alternatives,

5. Finalization of design ideas.

Tool Design Process - 1

Tool Design Process - 2

 Must meet certain minimum precision requirements

 Must keep the cost to a minimum

 Must be available when the production schedule

 Must be operated safely

 Must meet other requirements such as adaptability to

Tool Design Process - 2

Tool Design Process - 3

 Process sheet (Machining processes, tooling required)

 Engineering notes (Bushes material)

Tool Design Process - 4

Initial Design Alternate 1 Alternate 2

Tool Design Process - 5

 Characteristics of each alternatives are weighted and

 Strong points includes;

Alternatives Cost Life Precision

 The total cost is composed of the sum of the fixed and

 Do not crowd views or dimensions

 Analyze each cut to be sure it can be done with standard tools.

 Use only as many views as necessary to show all required detail.