TOOL DESIGN FOR ECONOMIC PRODUCTION
ME 72508  

Course Objectives:

After completion of the course students appreciate and realize the importance of the relation between tooling with design, cost and production. They can apply jigs and fixtures in production and design them as per demand.

1. Cutting tools for productive machining
   (12 hours)
   1. Mechanics of metal cutting
   2. Cutting tools materials
   3. Machinability
   4. Economics of machining
   5. Modern cutting tool techniques.
2. Press tools
   (8 hours)
   1. Types of presses
   2. Computation of capacities and tonnage requirements for blanking, piercing, bending, forming and drawing operations.
   3. Principles and design procedures for press tools
   4. Detailed design procedure for bending operation with examples.
3. Forging dies
   (8 hours)
   1. Types of forging equipment and operations
   2. Component and materials design for forging
   3. Die design for drop and press forging
   4. Die design for machine forging
   5. Tools for flash trimming and hole piercing
4. Jigs and Fixtures – introduction
   (5 hours)
   1. Definitions of jigs and fixtures
   2. Function of jigs and fixtures
   3. Analysis of locating, clamping and guiding methods
   4. Work holding principles of flat, round and irregular surfaces and methods of holding them.
5. Design of drill jigs
   (5 hours)
   1. Types of drill jigs
   2. Jig and machine relationship
   3. Jig body and jig feet
   4. Examples of typical drill jigs
      1. Plate jig, solid jig, turn over jig
      2. Pot and post jig, swing-latch jig
      3. Box jig, indexing drill jig
6. Design of fixtures
   (7 hours)
   1. Types of milling fixtures
   2. Fixtures and machine relationship
   3. Examples of typical milling fixtures
      1. Plain milling fixtures, string milling fixtures
      2. Gang milling fixtures, indexing milling fixtures
   4. Design of turning, grinding and broaching fixtures.

Practical:

Minimum of THREE assignments on Design, manufacture and use of a complete set of tooling for a component.

References:

1. ASTME, “Fundamental of Tool Design”
2. Colo C.B, “Tool Design”
3. ASTME, “Die Design Hand Book”.
4. Calvin and Hoise, “Jigs and Fixtures”
5. Jain and Gupta, “Production Technology”

Evaluation Scheme:

The questions will cover all the chapters in the syllabus. The evaluation scheme will be as indicated in the table below:

*There could be minor deviation in mark distribution.