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Tool Design

Course Code: MEE4001

Lecture - 2
11-Dec-2018

Dr. R. Mohan
Associate Professor
SMBS
TOPICS

• Introduction To Tool Design


Tool Design

Tool design is a specialized area of


manufacturing engineering comprising

the analysis,
planning,
design,
construction, and application of tools,
methods, and procedures necessary to increase
manufacturing productivity.
Tool Design
To carry out these responsibilities, tool designers
must have a working knowledge of
machine shop practices,
tool-making procedures,
machine tool design,
manufacturing procedures and methods,

As well as - the more conventional engineering


disciplines of
planning, designing, engineering graphics
and drawing, and cost analysis.
Tool Design

Tool Design function may be performed by

Tool Engineer in addition to his other duties in


manufacturing

Tool Design Specialist who devotes his entire


working time to tool design
Tool Design

Tool Design Area

Small company – may hire tool engineer who is


concerned with planning the process of
manufacture in addition to developing tool and
machines to produce the product.

A large company – may use small group of tool


engineers who specialise only in designing tools
needed to manufacture the product.
Tool Design

Tool Design Area

A Very large company – may have a tool


engineering department consisting of supervisor,
several tool designers responsible only for tool
design layout and several tool detailers
(draftsmen) who finish the drawing.
Tool Design

Tooling refers to the hardware necessary to


produce a particular product. Which Includes

Cutting devices
Jigs
Fixtures
Dies
Gauges…
Objectives of Tool Design

The main objective of tool design is


to increase production while
maintaining quality and lowering
costs
Every design must be created with
these objectives in mind
Objectives of Tool Design
1. Reduce the overall cost to manufacture a product by
making acceptable parts at the lowest cost.
2. Increase the production rate by designing tools to
produce the parts as quickly as possible
3. Maintain quality by designing tools to consistently
produce parts with the required precision.
4. Reduce the cost of special tooling by making every design
as cost-effective and efficient as possible.
5. Design tools to be safe and easy to operate.
6. Design the tool to make it foolproof and to prevent
improper use
Objectives of Tool Design
Check List to meet the Objectives of Tool Design
1. Does the design require the operator to work close to
revolving tools?
2. Does the tool have a means to secure it to the machine
table?
3. Will the fixture keys fit the table of the intended
machine?
4. Will the tool perform with a high degree of repeatability?
5. Has every possible detail been studied to protect the
operator from injury?
6. Are all sharp edges and burrs removed?
7. Is there any possibility of the clamp loosening or the
work being pulled from the tool?
Objectives of Tool Design
Check List to meet the Objectives of Tool Design
8. Have the human ergonomics been considered in the
design?
9. Will coolants and cutting fluids freely drain from the
tool?
10. Is the tool easy to clean?
11. Are coolant flow and chips directed away from the
operator?
12. Are loose parts attached with a cable or secured safely?
13. Is the tool easy for the operator to load and unload?
14. Can the tool be loaded and unloaded quickly and safely?
15. Is enough leverage allowed for hand-held jigs?
Tool Design in Manufacturing
Manufacturing for global competitiveness clearly requires
the success of concurrent engineering.
Concurrent engineering is a process that allows the design
team to be involved in a comprehensive plan for product
design and production.
Concurrent engineering allows the tool design team
member to be involved in product design and
production where their knowledge of fixtures and
manufacturing processes will result in fewer design errors.
Concurrent engineering teams consist of product
designers, process planning engineers, tool designers,
quality control engineers, production management, and
machining technicians.
Tool Design in Manufacturing
Team members contribute based on their area of expertise.
The product, a method for manufacturing, tooling concepts,
and a quality plan are developed that suits the selected
manufacturing facility.

In this way, problems are not discovered on the production


floor, but are corrected early in the concurrent process.

This ultimately saves time and money while speeding up the


process of getting product to market earlier.

Concurrent engineering allows a company to have a distinct


economic advantage in a global market.
Tool Design in Manufacturing

The tool designer develops a plan for maintaining the


concepts developed by the team with respect to economic
guidelines.

Expert computer systems are now part of the design


environment, and they support an integrated approach for
tracking time and money allocated for the project and
provide immediate information at any point in the concurrent
process.
Thanks