DEPARTMENT OF MECHANICAL ENGINEERING SESION : DECEMBER 2012

COURSE OUTLINE
COURSE CODE COURSE NAME CREDITS HOURS NAME OF LECTURER CONTACT NO. : JF609 : JIGS, FIXTURES & TOOLING DESIGN :3 : MOHD HAFIZIL BIN MAT YASIN : 013-7114669

Email add: hafizil@psmza.edu.my

SYNOPSIS : JIG, FIXTURES AND TOOLING DESIGN exposes the students to the knowledge of datum concept, geometric tolerances, and fundamentals to build the tooling based on clamping and locating principle. The topics are also covered principle of tooling applications in metal and non-metal process. All the topics discussed will help the students to understand and able to plan and identified use of tooling. Students will also expose to the application of tooling in related industries. COURSE LEARNING OUTCOMES (CLO): Upon completing this course, students should be able to: 1. Classify the fundamental of jig, fixtures and tooling design. 2. Formulate the drawing, design and tooling components. 3. construct mould design considerations and construction.

Week (Period)
W1 (09/12/12 13/12/12) W2 (16/12/12 20/12/12) W3 (23/12/12 27/12/12) W4 (30/12/12 03/01/13) W5 (06/01/13 10/01/13)

Topics & Sub-Topics REGISTRATION WEEK

Hours

1.0 TOOL DESIGN METHOD 1.1 Explain tool design procedure

CUTI KHAS PERAYAAN ( CHRISMAS DAY 25/12/2012 : TUESDAY )

1.2 Explain drafting and design techniques in tooling drawing 1.2.1 Describe drafting practice 1.2.2 Show drawing layout 1.2.3 Review the dimensioning, units and tolerances 1.2.4 Identify datum concept in tooling design 2.0 TOOLING MATERIAL 2.1 Introduce tooling material 2.1.1 Describe tool steel (ferrous tooling material), Cast iron and Mild or Low-carbon Steel, Carbon Chromium, Nickel-Chromium, and Nickel Molybdenum (mould steel) 2.2 Classify the properties of materials 2.2.1 Focus on factors that affecting tooling design 2.3 Explain relation between heat treatment and tooling design 2.3.1 Relate properties material and tooling design. QUIZ 1 3.0 JIG AND FIXTURES 3.1 Explain an introduction of Jig and Fixtures 3.1.1 Differentiate between jigs and fixtures 3.1.2 Describe the degree of freedom, 3-2-1 principles, choice of location, and redundant location 3.2 Describe the preliminary analysis and fixture planning 3.2.1 Interpret economics of Jig and Fixtures design 3.3 Explain the design of components of Jig and Fixtures 3.3.1 Describe the design of components 3.3.2 Describe the design of Locating components and Clamping elements PRESENTATION 3.4 Explain the types of Jig and Fixtures 3.4.1 Describe the details types of Jig and fixtures TEST 1 4.0 MOULD 4.1 Describe injection mould- plastic process 4.1.1 Differentiate plastic process including injection moulding, transfer moulding, extrusion, and blowing moulding 4.1.2 State the defect of plastic in injection moulding MID SEMESTER BREAK

W6 (13/01/13 17/01/13)

W7 (20/01/13 24/01/13) W8 (27/01/13 31/01/13) W9 (03/02/13 07/02/13) W10 (10/02/13 14/02/13)

Week (Period)
W11 (17/02/13 21/02/13) W12 (24/02/13 28/02/13)

Topics & Sub-Topics

4.2 Explain mould design - initial considerations 4.2.1 Determine preliminary factors of mould design

Hours 4

4.3 Explain types of injection mould 4.3.1 Identify two plate mold and three plate mold 4.3.2 Differentiate two plate mold and three plate mold 4.3.3 Describe an application of two plate moulds 4.3.4 Indicate the components attached at two plate mould 4.3.5 Define the functions of mould components 4.4 Describe the mould design and construction. 4.4.1 Define the Core, Cavity, Insert and Parting line 4.4.2 Explain the feed system in mould QUIZ 2 4.4.3 Explain an ejection system 4.4.4 Relate Mould shrinkage, tapper and tolerances 4.4.5 Describe cooling system 4.4.6 Explain the split, side cores and side cavities END OF CHAPTER PRACTICAL TASK 1 5.0 TOOL AND DIE 5.1 Explain introduction to Die cutting Operations 5.1.1 Discuss the fundamentals of Die-cutting Operation including

W13 (03/03/13 07/03/13) W14 (10/03/13 14/03/13)

W15 (07/10/12 11/10/13) W16 (24/03/13 28/03/13) W17 (31/03/13 04/04/13)

5.1.2 Differentiate the Cutting action in punch and Die operations 5.1.3 Relate Die clearance with the Cutting action in punch and Die operations

5.2 Describe of Die construction 5.2.1 Explain types of Die construction 5.2.2 Design Progressive dies, Compound dies, and Combination dies 5.2.3 Design Bending dies, Forming dies, and Drawing dies 5.2.4 Design Blanking and Piercing dies 5.3 Describe Die design Fundamental 5.3.1 Design Die Block 5.3.2 Design Punch, Punch Plate 5.3.3 Design Pilot, Strippers and pressure pad 5.3.4 Derive Force Mechanism involved in die operations 5.3.5 Classify the components of die QUIZ 3 5.3.6 Determine blank size 5.3.7 Describe Bending methods 5.3.8 Determine bending allowances, and bending pressure 5.3.9 Differentiate between bending and forming 5.3.10 Relate Drawing Dies and operations 5.3.11 Determine percent reduction, depth of draw, drawing force

W18 (07/04/13 11/04/13)

W19 (14/04/13 18/04/13)

W20 (21/04/13 25/04/13) W21 (28/04/13 02/05/13)

EXAMINATION WEEK

EXAMINATION WEEK

CONTINUOUS ASSESSMENT (CA) (100%) a. Quiz (3) 20% b. Test (1) 30% c. End of chapter (1) 20% d. Practical task (2) 20% e. Presentation (1) 10% REFERENCES Edward G. Hoffman (2004). Jig and Fixture Design, Cengage Learning Cyril Donaldson, George H LeCain, V C Goold (2005). Tool Design, Tata McGraw-Hill. Mikell P. Groover (2007). Fundamentals of Modern Manufacturing: Materials, Processes and Systems, John Wiley &Sons Serope Kalpakjian. Steven Schmid. (2006). Manufacturing Engineering and Technology, PEARSON Prentice Hall.