WITH EFFECT FROM THE ACADEMIC YEAR 2013 - 2014

ME 409                                                                 

TOOL DESIGN                                                   

(ELECTIVE - I)                                                     

Instruction                                                                                                                                                                                       4    Periods per week

Duration of University Examination                                                                                                                                                   3    Hours

University Examination                                                                                                                                                                   75    Marks

Sessional                                                                                                                                                                                        25    Marks

Unit-I

Cutting tool materials and processes: Desired properties, Types, major constituents, relative characteristics, latest developments, ISO: Classification and coding of carbide tools, Coated tools. Principles of working and applications of USM, EDM, ECM, AJM, LBM, and EBM. Superfinishingprocesses: Honing, Lapping Burnishing, Ballizing, Polishing.

Unit-II

Design of single point cutting tools, Form Tools: Design of flat and circular Form Tools and tool holding methods.

Design of Multi Point Cutting tools: Milling Cutters: Major types, design and manufacturing of peripheral, end and face milling cutters, forces and power estimation. Grinding of milling cutters.

Broaches: Pull and Push types. Internal and External broaches, geometry and design and manufacturing of Pull type and push type broaches.

Unit-Ill

Multi point cutting tools:

Twist Drill geometry, Design and manufacturing of twist drill. Effect of variation of different angles on torque and thrust forces. Types and design of shanks. Sharpening of twist drill.

Reamers: Types, geometry, Reaming allowance, tolerance disposition, Design and manufacture of twist drills.

Taps and Dies: Types, Geometry, Design and manufacturing of Taps and Dies.

Unit-IV

Design of Press tools: Die set elements. Design of Die Set for simple components in Blanking, Piercing, bending, Drawing, Forging and Spinning. Plastic Tools; Plastic Dies for simple components.

Unit-V

Jigs & Fixtures: Design principles and construction features. Locating methods associated with flat, cylindrical, internal and external surfaces. Type of locating pins. Requirements and choice of locating systems. Redundant location, fool proofing. Setting blocks, types of clamping devices and theirbasic elements. Quick action clamps and nuts. Equalising and multiple clamping pneumatics. Hydraulic, magnetic, electrical and vacuum clamping. Types of drill jigs and their classification. Types of jig bushes, jig feet, Indexing jigs. Design of Fixtures for Turning, grinding, welding and Milling. Economic analysis of Jigs and Fixtures.

Suggested Reading:

1. 1.Donaldson, Leain and Goold, Tool Design, Tata Me Graw Hill, New Delhi, 1983.

1. 2.Rodin, Design of Cutting Tools, Mir Publications, Moscow.

1. 3.AmitabhaBattacharya and Inyong Ham, Design of Cutting Tool, Use Of Metal Cutting Theory, ASTME Publication Michigan USA, 1969.

1. 4.Surender Keshav & Umesh Chandra, Production Engineering Design (Tool Design), Satya Prakashan, New Delhi-1994.