15MEC243 - TOOL DESIGN

VII Semester – Elective

Mechanical Engineering

Course Faculty/Mentor
Dr. P.RAGHURAM
Assistant Professor – Selection Grade
Department of Mechanical Engineering
Amrita School of Engineering, Coimbatore
Amrita Vishwa Vidyapeetham
 Tool

Single point tools

Drilling tools

Milling tools
 Tool

Bench Vise 3-jaw Chuck

4-jaw Chuck

Milling machine CNC Turning Center

Manufacturing Needs
• Productivity
– eliminate individual marking.
– positioning.
– frequent checking.
• Interchangeability
– uniform quality in manufacture.
– need for selective assembly.
• Skill Reduction
– simplify locating and clamping of the workpieces.
– tool guiding to ensure correct positioning of tools w.r.t workpiece.
– eliminate skillful setting of the work piece or tool – Skilled workers.
• Cost Reduction
– higher production.
– reduction in scrap.
– easy assembly.
Fixtures
Drill Jigs
Press Tools
Blanking & Piercing Dies
Press Tools
Drawing & Deep drawing Dies
Press Tools
Bending & Forging Dies

Bending Dies
 15MEC243 - TOOL DESIGN
COURSE OBJECTIVES

• To describe the location and clamping principles for design of

a jig or a fixture.
• To practice designing jigs and fixtures for any component.
• To practice designing a die-set for a given sheet metal
component.
 15MEC243 - TOOL DESIGN
COURSE OUTCOMES
At the end of the course, the student will be able to
CO1: Select standard components, clamping and locating devices using
basic principles of jigs and fixtures.
CO2: Formulate the design procedure and select the materials used for
manufacture.
CO3: Design jigs and fixtures for a given component.
CO4: Identify and choose the types of presses for a given sheet metal
component.
CO5: Design a die-set for a given sheet metal component using the design
procedure for various sheet metal working processes.
 15MEC243 TOOL DESIGN 3 -0 –0- 3
Design of Jigs and Fixtures: Introduction - Location Principles – Six Point Location
Principle – Locators – Clamping Principles – Clamping Devices – Drill Jigs – Drill
Bushes – Drill Jig Types – Design and Development of Jigs for given components –
Milling Fixtures – Milling Methods – Milling Fixture Types – Turning fixtures –
Broaching Fixtures – Grinding Fixtures – Assembly, Inspection and Welding
Fixtures – Modular Fixtures – Design and Development of Fixtures for given
components.
Design of Dies: Power presses types and construction details, die cutting operation,
cutting action in die and punch, center of pressure, clearance and its significance,
cutting forces, methods of reducing cutting forces, methods of punch support,
strippers, stock stops, guide pilots, knockout, design of blanking and piercing dies.
Design Concepts and description of the components of progressive dies. Design of
progressive dies. Design of compound dies. Design of combination dies.
Drawing Dies: Metal flow and factors affecting drawing, blank size calculations,
drawing force, single and double acting drawing dies, design and development of
drawing dies for different components.
Bending and Forming Dies: Spring back, bend allowance; calculation of development
length, bending force calculations types of bending dies. Curling dies.
Forging process and forging dies. (Introductory Treatment)
 15MEC243 TOOL DESIGN 3 -0 –0- 3
• Design of Jigs and Fixtures
• Design of Blanking, Piercing and Progressive Dies
• Design of Drawing Dies
• Design of Bending and Forming Dies

TEXT BOOKS
T1. P.H. Joshi, “Jigs and Fixtures Design Manual”, McGraw Hill, 2002
T2. Kempster M H A, “An Introduction to Jig and Tool Design”, Viva Books Pvt. Ltd.,
1998.
T3. Paquin and Crowley, “Die Design Fundamentals”, Industrial Press, New York, 1979.
 REFERENCE BOOKS:
R1. John G Nee, “Fundamentals of Tool Design”, Society of Manufacturing, 4th Edition,
1998.
R2. Production Technology Hand Book, HMT, Tata McGraw Hill
R3. E. K. Henriksen - "Jig and Fixture Design Manual", Industrial Press, New York, 1973
R4. Donaldson, Lecain and Goold - "Tool Design", McGraw Hill, New York, 1976
 15MEC243 - TOOL DESIGN
COURSE PLAN

LECTURE Pg. Nos. in books

TOPICS KEYWORDS Course Outcome
NO. Text book

1 Introduction/Limits and Fits   T11-10 CO2

2 Location Principles Location T1 11-16 CO1
3 Six point location principle   T1 22 CO1
4-5 Locators   T1 16-39 CO1
6 Clamping Principles Clamping T1 42-46 CO1
7 Clamping Devices   T1 46-77 CO1
8 Drill Jigs  
Drill Bushes  
T1 87-94 CO2
9
CO3
10-14 Drill Jig Types   T1 94-110

15 Assignment 1: Design and Development of Jigs for given components.

(Individual Assignment )
PERIODICAL TEST – 1
 15MEC243 - TOOL DESIGN
COURSE PLAN

LECTURE Pg. Nos. in books

NO. TOPICS KEYWORDS Text book Course Outcome

16 Milling Fixtures Tenon, T1 112 CO3

17 Milling Methods Tool Setting T1 113 CO3
18-20 Milling Fixture Types   T1 113-125 CO3
21-24 Turning fixtures   T1 127-144 CO3
25 Broaching Fixtures   T1 149-151 CO3
26 Grinding Fixtures   T1 145-149 CO3
Assembly, Inspection and  
27-28 Welding Fixtures T1 153-161 CO3

29 Modular Fixtures     CO3

Assignment 2: Design and Development of Fixtures for given components (Individual
30 Assignment )
PERIODICAL TEST – 2
 15MEC243 - TOOL DESIGN
COURSE PLAN
LECTURE KEYWOR Pg. Nos. in books
TOPICS Course Outcome
NO. DS Text book
31 Press Tools – Press Working  
  Terminology –Presses and Press
Accessories T3 632-650 CO4

32 Press Working Operations Mech/Hy

d. Press T3 650-675 CO4
33-35
Design of blanking/piercing dies   T3 676-690 CO5
36-38  
Design of drawing/bending dies T3 730-788 CO5
39-42
Dieset
Design Concepts and description of and its
the components of progressive
compone
T3 690-722 CO5
dies – Design of progressive dies
nts
43 Design of compound dies - Design  
of combination dies. T3 690-722 CO5
44 Forging process and forging dies. T3 730-788 CO5
45 Assignment 3: Design and Development of diesets for given components.
 15MEC243 - TOOL DESIGN
CONTINUOUS EVALUATION SCHEME

S.NO. COMPONENT WEIGHTAGE

1 Periodical 1 (Open book + Viva) 25

2 Periodical 2 (Open book + Viva) 25

3 Assignment (=2 x 5) 10

4 Quiz 10

  TOTAL 70

End Semester (Open book + Viva) = 30