JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY HYDERABAD

Course Objectives:

• 1. To understand the basic knowledge of select appropriate materials for tooling applications
• 2. To grasp the Design, develop, and evaluate cutting tools and work holders for a manufactured product
• 3. To comprehend the basic knowledge of press tools for sheet metal working.

UNIT - I

Cutting tool materials and single point cutting tools: Cutting tool materials, desired properties. Types, Major Constituent, relative characteristics, latest development: ISO; classification and coding of carbides. Geometry of single point cutting tool. Influence of each geometrical parameters on the cutting tool performance. Factors involved in their selection. Tool signature and geometry in MRS, ORS, NRS. Cutting forces and design features of HSS and carbide tipped tools. Feature of high production cutting tools. Chip breakers and their types.

UNIT - II

Form tools and multi point cutting tools: Form tools: Radial and tangential: flat and circular. Form correction and tool holding methods. Drills Geometry: Variation of rake and clearance angles along tips, effect of geometrical parameters on thrust and torque effect of feed rate on rake and clearance, web thinning. Types of drill points, Grinding of drills. Milling Cutters: Major types, geometry of peripheral, end and face milling cutters. Profile sharpened and form relieved expression for minimum number of teeth. Design features, forces and power estimation, Grinding of milling cutters. Reamers: Types, geometry, Reaming allowance, design features tolerance disposition. Broachers: Pull and push types. Internal and External broaches, geometry and design features. Pull force estimation. Keyway, spline, round, square broaches.

UNIT - III

Press tools for sheet metal working: Blanking and piercing. Diet set elements. Simple and progressive dies. Estimation of punch load, clearances, centre of pressure, strip layout, methods of reducing punch load. Bending dies: Spring back and bending allowance estimation of punch load. Drawing Dies: Punch load, blank size, number of draws, methods of retaining metal in draw dies. Metal flow during drawing.

R16 B.TECH MSNT.

Metal spinning: Configuration and design features of metal spinning, shear forming and flow forming.

UNTT - IV Jigs & Fixtures: Design principles and construction features. Locating methods associated with flat, cylindrical internal and external surface. Types of locating pins. Requirements and choice of locating systems. Redundant location, fool proofing. Setting blocks, types of clamping devices and their basic elements. Quick action clamps and nuts. Equalizing and multiple clamping pneumatics. Hydraulic, magnetic and vacuum clamping. Types of drill jig and their classification. Types of jig bushes, jig feet. Indexing jigs. Economic analysis of Jigs and Fixtures. Economic tool life for minimum cost maximum production and max profit rate.

UNIT - V

Miscellaneous tools: Cam design for single spindle automatics for simple components. Tool layout estimation of cycle time. Gauge design: Taylor's principle, limit gauges for holes and shafts. Estimation of limits on Go and No Go gauges. Forgoing dies: Draft, parting line, filters. Allowances, sequence in multiple impression forging. Flashing, Trimming. Plastic Tools: Application of plastic as a tooling material viz., for Gauges, Surface plates, jigs and fixtures. Forming dies.

TEXTBOOKS:

• 1. Surendra kenav and Umesh Chandra, "Production Engineering Design (Tool Design)", Satyaprakashan, New Delhi, 1994.
• 2. Donaldson, Leain and Goold, "Tool Design", Tata McGraw Hill, New Delhi, 1983.
• 3. Amitabha Battacharya and Inyong Ham, "Design of Cutting Tools, Use of Metal Cutting Theory", ASTME publication Michigan USA, 1969. R16 B.TECH MSNT.