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1. General Tool Design 1
1. Introduction 1
2. Design Objectives 1
3. Tool Designer Responsibilities 2
4. The Design Process 3
5. Economics of Design 5
6. Economical Lot Sizes 9
7. Tool Drawings 9
8. Typical Tooling Layout Process 10
9. Safety 11
10. Material Handling in The Workplace 14
11. Tool Designer’s Guide to Machine Tools 17
12. Epilogue 20
References 20
2. Materials Used for Tooling 23
1. Introduction 23
2. Physical Properties 24
3. Mechanical Properties 25
5. Ferrous Tool Materials 28
6. Nonferrous Tool Materials 33
7. Nonmetallic Tool Materials 35
8. Heat-Treating 39
9. Instructional Support Materials 44
10. Epilogue 44
ReferenceS 45
3. Cutting Tool Design 48
1. Introduction 48
2. Form and Dimension 48
3. Basics of Metal Cutting 50
4. Chip Formation 51
5. Cutting Forces 62
6. Power Requirements 64
14. Guidelines for Cutting Tool Design 65
14. Epilogue 69
References 70
4. Tool Wear and Tool Life 72
1. Introduction 72
2. Tool Life 85
3. Single-Point Tools 86
4. Multiple-Point Cutting Tools 91
5. Linear-Travel Tools 96
6. Axial-Feed Rotary Tools 103
7. Epilogue 116
References 116
5. Workholding Concepts 119
1. Introduction 119
2. Basic Workholders 119
3. Workholder Purpose and Function 122
4. General Considerations 122
5. Locating and supporting Principles 124
6. Location types 125
7. Chip and Burr Problems 155
8. Epilogue 157
References 158
6. Clamping Principles 160
1. Introduction 160
2. Vises 193
3. Nonmechanical Clamping 201
4. Power Clamping 204
5. Epilogue 208
References 208
7. Jig and Fixture Construction Principles 211
1. Introduction 211
2. Tool Bodies 211
3. Precast Bracket Materials 213
4. Screws and Bolts 215
5. Ball Lock® Mounting System 220
6. Epilogue 221
References 221
8. Jig Design 224
1. Introduction 224
2. General Considerations 225
3. Machine Considerations 225
4. Process Considerations 226
5. Drill Jigs 227
6. Drill Jig Bushings and Liners 242
7. Jig Design Example 248
8. Epilogue 251
References 252
9. Fixture Design 254
1. Introduction 254
2. General Considerations 255
3. Types of Fixtures 259
4. Fixture Classifications 262
5. Standard Fixture Mounting 267
6. Design Fundamentals 271
7. Fixture Design Example 273
8. Epilogue 276
References 277
10. Power Presses 279
1. Introduction 279
2. Gap-Frame Presses 279
3. Straight side presses 281
4. Mechanical Versus Hydraulic Presses 284
4. Upgrading Existing Presses 288
5. Die Cushions 288
6. Hydraulic Forming Machines and Dies 289
7. Tubular Hydroforming 291
8. The high-speed straight side press 294
9. Transfer Press and Die Operations 295
References 300
Tool design is one of the most important and costly tasks in the manufacturing process. And, because the tool is the foundation of any part or product, each decision we make about how the tool is manufactured is automatically a judgement regarding the product's quality. Design is a complicated and knowledge-intensive process in all engineering areas. The basic goals of tool design are to minimise manufacturing costs and increase quality. It also aims to create tools that can withstand any force that is applied to them create tools that reduce downtime and, as a result, boost output and also to maximise efficiency, provide simple and smooth, easy-to-operate machine tools. Computational models, which emphasize the use of numerical and qualitative computational approaches, as well as artificial intelligence techniques in conjunction with computing technology, are a relatively recent addition to design models.
This book, based on the state of art knowledge, represents a major step in understanding the science of tool design. It provides a balanced treatment of current theories, trends, and advances in this field. The chapters in this book cover a wide spectrum of disciplines such as materials used for tooling, cutting tool design, tool wear and workholding concepts. A logic based discussion has been tried to make for better understanding of the subject matter. It also deals with clamping principles, fixture construction principles, jig design and power presses. Such selected concepts that redefine this subject area have been presented in this book. The various subfields along with technological progress that have future implications are glanced in it. Those with an interest in the field of tool design would find this book helpful.
Marlys Cromer is serving as a Senior Science Research Specialist at Technical Institute, Chihuahua. She has obtained her Ph.D. in Mechanical Engineering from Public University, Ottawa. Her research interests are in manufacturing engineering, industrial engineering and other processes for design and optimization. She has authored numerous books and scientific papers on gear technologies, industrial machinery design & engineering.