Tool Design Data Bookpdf

TOOL DESIGN DATA BOOK
FOR
DIPLOMA IN MECHANICAL ENGINEERING (TOOL & DIE)

COURSE CODE 1220
DIRECTORATE OF TECHNICAL EDUCATION

GOVERNMENT OF TAMILNADU
DIRECTORATE OF TECHNICAL EDUCATION

GUINDY, CHENNAI 25
TOOL DESIGN DATA BOOK
1. This book can be used for Board Examination by the

Diploma in Mechanical Engineering (Tool & Die) students
for the Tool Design subject.
2. The Use of this data book ( Institutional copy) Indian
Standard specifications listed in Table 6.34 of this data
book and any other related Indian standard specifications
is permitted in the Board Examination for the subject
22254 - Tool Design and Drawing
Tool Design Data Book
Page 2
CONTENTS
TOPIC
SL.NO
PAGE
NO.
1.
Material Properties
2.
Sheet material SWG to mm & inch conversion
3.
Data for stamping dies

Formulae
Strip layout
Die plate design data
Stripper design data
10
Punch design details
12
Punch holder data
15
Pilots
16
Finger stops
17
Automatic stops
18
Fasteners - Screws & dowels
21
Die set
23
Press data
27
Shut height
28
Punch and die materials & Heat treatment
29
Centre of Pressure
34
Spring design data
36
Page 3
4.
Data for bending dies
61
5.
Data for drawing dies
66
6.
Data for gauge Design
7.
ISO System of limits and fits tolerances & deviations
70
Reference Indian standard specifications for gauge design
102
Jigs & fixtures

Guidelines for selection of locators and clamps
8.
103
Locating pins
104
Clamps
106
Jig feet & buttons
108
Jig bushes
110
Screws & nuts
113
Pressure pads
117
Spherical & C Washers
118
Wing nuts
119
Unit Conversion tables
120
Page 4
Table 1 - MATERIAL PROPERTIES
SHEAR STRENGTH
S.No
ULTIMATE TENSILE
MATERIAL
2
N/mm
STRENGTH
A
T
A
N/mm2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
O
T
L
O
Stainless steel
Steel 0.1% carbon ( soft)
Steel 0.25%carbon ( mild)
Steel 0.5% carbon
Steel 0.75% carbon
Steel 1% carbon
Steel 1.2% carbon ( not tempered)
Steel 1.25% carbon( tempered hot)
Aluminium soft sheet
Aluminium half hard sheet
Aluminium hard sheet
Brass soft sheet
Brass half hard sheet
Brass hard sheet
Copper rolled
Cupro nickel
Duralumin soft sheet
Duralumin treated and cold rolled
Fibre hard
Lead
Leather
Oak ( wood)
Tin rolled sheet
Tin coated steel sheet
Zinc rolled sheet
Zinc hard rolled
Silver
Paper using hollow dies
G
I
S
E
539.70
346.95
385.5
539.70
719.6
462.6
514
719.6
616.8
655.35
724.7
1464.89
115.65
146.49
192.75
231.29
269.85
308.40
215.88
308.4
231.29
308.10
185.04
30.84
54
54
38.55
385.5
138
154.20
231.29
23.13
822.4
873.8
966.2
1953.18
154.2
195.32
257
308.38
359.8
411.20
287.84
411.20
308.39
410.80
246.72
41.12
72
72
51.4
514
184
205.6
308.38
30.84
O
O
B
Page 1
Table 2 - Sheet material SWG to mm & inch conversion
inches
Mm
SWG
inches
Mm
SWG
inches
mm
7/0
0.500
12.700
13
0.092
2.34
32
0.0108
0.27
6/0
0.464
11.79
14
0.080
2.03
5/0
0.432
10.97
15
0.072
1.83
4/0
0.400
10.16
16
0.064
1.63
3/0
0.372
9.45
17
0.056
1.42
2/0
0.348
8.84
18
0.048
1.22
1/0
0.324
8.23
19
0.040
1.02
0.300
7.62
20
0.036
0.276
7.01
21
0.252
6.40
22
0.232
0.212
0.192
33
0.0100
A
T
A
0.25
34
0.0092
0.23
35
0.0084
0.21
36
0.0076
0.19
37
0.0068
0.17
38
0.006
0.15
0.91
39
0.0052
0.13
0.032
IG
0.81
40
0.0048
0.12
0.028
0.71
41
0.0044
0.11
S
E
5.89
23
0.024
0.61
42
0.004
0.10
5.39
24
0.022
0.56
43
0.0036
0.09
4.88
25
0.020
0.51
44
0.0032
0.08
4.47
26
0.018
0.46
45
0.0028
0.07
4.06
27
0.0164
0.42
46
0.0024
0.06
0.144
3.66
28
0.0148
0.38
47
0.002
0.05
10
0.128
3.25
29
0.0136
0.35
48
0.0016
0.04
11
0.116
2.95
30
0.0124
0.31
49
0.0012
0.03
12
0.104
2.64
31
0.0116
0.30
50
0.001
0.02
L
O
O
T
O
O
B
SWG
8
9
D
0.176
0.160
Page 2
DATA FOR STAMPING DIES

FORMULAE:
1.
Cutting force =
Where
A
T
A
S*P*T
Shear strength of the component material in N/mm2
Perimeter of the component in mm
Thickness of the component in mm
2.
Percentage of utilization
3.
Percentage of scrap
4.
Stripping Force
5.
Press Capacities
Area of Blank
Area of Strip
G
I
S
E
O
O
B
X 100
100 Percentage of utilization

10 to 20% of cutting force
Cutting Force x 1.3
6.Compressive force on punches = comp.stress of the punch matl. X area of cross section of punch
=2EI/LP2
7.
Buckling Forces
WHERE
E= modulus of elasticity in GN/mm2
I=moment of inertia in mm4
O
T
L
O
8.
Lp=length of punch in mm
Strip layout
Margin (or) Bridge
= 1.5t where t is the sheet metal thickness in mm
The margin or the bridge thickness can also be selected from the following table
Page 3
Table - 3.1 - DATA FOR STRIP LAYOUT

Thickness of sheet metal in mm
Web
length(l)
0.5
0.75
1.25
1.5
in mm
1.75
2.5
A
T
A
Margin, (S), mm
10
1.5
1.2
1.4
1.5
1.8
50
1.7
1.75
1.9
2.2
2.5
100
2.4
2.4
2.5
2.7
150
3.5
2.9
2.5
2.9
3.2
3.5
250
3.4
3.4
3.5
3.7
350
4.5
3.9
3.5
3.9
4.2
L
O
2.25
G
I
S
E
D
4
4.5
O
O
B
3.5
2.5
2.5
2.8
3.5
3.7
3.2
3.5
4.2
4.5
3.7
4.5
4.7
4.2
4.5
5.2
5.5
4.7
5.5
5.7
O
T
Page 4
DIE PLATE DESIGN DATA:

Die block thickness
F Where F is cutting force in Kg.
Die block thickness and other die dimensions may also be selected from the
following table:
G
I
S
E
C
Minimum Distance Die Hole To Outside Edge
Die Block Height
1
Smooth Die Hole Contour
(1.125 B)
2
Inside Corners
(1.5 B)
3
Sharp Inside Corners
24
27
36
48
1.5 to 3.1
29
33
44
58
3.1 to 4.7
35
39
53
70
4.7 to 6.3
42
47
63
84
Over 6.3
48
54
72
96
Strip Thickness
0 to 1.5
L
O
O
T
A
T
A
O
O
B
(2 B)
Table 3.2 - Recommended minimum C distance for various die hole contour and die block heights B
Page 5
Table 3.3 - Tabulation of suggested standard die block sizes
O
T
88.9
15.8
44.4
57.1
23.8
M8 TAPPED THROUGH HOLE
127
15.8
44.4
95.2
23.8
101.6
101.6
15.8
69.8
69.8
23.8
101.6
127
15.8
69.8
95.2
23.8
101.6
152.4
15.8
69.8
120.6
23.8
127
127
19
88.9
88.9
23.8
127
152.4
19
88.9
114.3
23.8
D
76.2
L
O
G
I
S
E
A
T
A
76.2
O
O
B
Page 6
O
O
B
Table 3.4 - Tabulation of suggested standard medium size die block sizes:
101.6
177.8
101.6
203.2
127
O
T
L
O
127
152.4
152.4
177.8
IG
S
E
D
19
63.5
139.7
69.8
28.5
19
63.5
165.1
82.5
28.5
19
88.9
165.1
82.5
28.5
19
88.9
215.9
107.9
28.5
203.2
19
114.3
165.1
82.5
28.5
254
19
114.3
215.9
107.9
28.5
279.4
19
139.7
241.3
120.6
28.5
D
254
203.2
A
T
A
G
Page 7
Die land:-
O
O
B
Die land varies depending upon the no. of regrinding requirements (die life expectancy). But in
general die land is given as 3 to 5 mm.
A
T
A
Angular clearance: - Generally 1/4o to 1o angular clearance is provided. Increased die clearance
weakens the die. Angular clearance may also be selected from the following table:
Table 3.5 Anglular clearance data
Strip thickness in mm
0 to 1.5875
G
I
S
E
1.5875 to 4.76
4.76 to 7.9
Over 7.9
Angular clearance per side

1/4o
1/20
3/40
10
Soft materials require greater angular clearance than hard materials.
L
O
O
T
Page 8
Die clearance:Clearance per side = C *T * (max/10)

Where C= constant
= 0.005 for very accurate components

=0.01 for normal component.
T= Sheet thickness in mm.
A
T
A
max = Shear strength of sheet material in N/mm2
Clearance per side can also be selected from the table given below:
Table 3.6 Die clearance

Material
Mild steel
Die clearance per side in percentage

of sheet thickness
2.5%-5%
Aluminum
1.5%-3%
Brass
L
O
G
I
S
E
O
O
B
1.5%-3%
O
T
Page 9
STRIPPER DESIGN
STRIPPER PLATE THICKNESS = A = (W/30) +2t
Where A = Stripper plate thickness in mm
W= Width of strip in mm
A
T
A
t= Thickness of sheet metal in mm.
The stripper plate thickness can also be selected from the following table:
O
O
B
Table 3.7 Stripper plate thickness

STRIP
(thicknes
s*
width)
1.6x75
1.6x150
1.6x225
1.6x300
Stripper
Plate
thicknes
s (A)
in mm
6
8
10
14
3.2x75
3.2x150
3.2x225
3.2x300
10
12
14
16
4.8x75
4.8x150
4.8x225
4.8x300
12
15
18
20
6.35x75
6.35x150
6.35x225
6.35x300
L
O
7.8x75
7.8x150
7.8x225
7.8x300
16
18
20
22
18
22
24
26
G
I
S
E
Note:For design and manufacturing simplicity, the width and length of stripper is
assumed same as that of the die plate
O
T
Page 10
G
I
S
E
A
T
A
O
O
B
Table 3.8 Clearance between Strip and Strip gudie

Strip thickness in mm
0-1.587
clearance for hand feed in mm
Clearance for automatic feed in mm
1.6
0.8
1.587-3.175
2.4
0.8
3.175-4.762
3.2
0.8
4.762-6.35
4.0
0.8
4.8
0.8
6.35-7.937
L
O
O
T
Page 11
PUNCH DESIGN DETAILS

Table 3.9 - Stepped Round Punch
Table 3.10 Round Punch
L
O
G
I
S
E
A
T
A
O
O
B
O
T
Page 12
Table 3.11 Square Punch
Table 3.12 Quick change punch
L
O
G
I
S
E
A
T
A
O
O
B
O
T
Page 13
Table 3.13 Punch Chamfered head
L
O
G
I
S
E
Table 3.15 Square Punch with shedder
O
O
B
Table 3.14 Stepped Punch
A
T
A
O
T
Page 14
Table 3.16 - COMMONLY USED PUNCH PL ATE SIZES:-
Table 3.17 - COMMONLY USED PUNCH
G
I
S
E
PLATE SIZES
L
O
A
50
50
75
75
75
100
100
100
125
125
125
150
150
150
150
175
175
175
A
T
A
A
0 to 7.9
7.9 to 11
11 to 12.7
12.7 to 15.8
15.8 to 17.4
17.4 to 19
19 to 22.2
22.2 to 23.8
23.8 to 25.4
B
50
75
75
100
125
100
125
150
125
150
175
150
175
200
250
175
225
275
O
O
B
B
12.7
15.8
19
22.2
25.4
28.5
31.7
34.9
38.1
O
T
Page 15
Table 3.18 - PILOTS
A
3.1
4.7
6.3
7.9
9.5
11.1
12.7
14.2
15.8
17.4
19
A
20.6
22.2
23.8
25.4
26.9
28.5
30.1
31.7
33.3
34.9
38.1
ACORN TYPE PILOT

B
C
D
E
MAT
3.1
0.7
3.9
2.3
D.R.
4.7
1.19 4.7
3.1
D.R.
6.3
1.5
7.1
4.7
D.R.
7.9
1.98 9.5
6.3
D.R.
9.5
2.3
11.1 7.1
D.R.
11.1 2.77 12.7 7.9
D.R.
12.7 3.1
14.2 9.5
D.R.
14.2 3.57 15.8 11.1 D.R.
15.8 3.9
17.4 11.9 D.R.
17.4 4.3
19
12.7 D.R.
19
4.7
22.2 14.2 D.R.
FLATTENED POINT TYPE
B
C
D
E
MAT
20.6 12.7 23.8 15.8 Tool Steel
22.2 13.4 25.4 17.4 T.S
23.8 14.2 28.5 19
T.S
25.4 15.8 31.7 20.6 T.S
26.9 16.6 33.3 22.2 T.S
28.5 17.4 36.5 23.8 T.S
30.1 18.2 38.1 25.4 T.S
31.7 19
41.2 26.9 T.S
33.3 20.6 42.8 28.5 T.S
34.9 21.4 44.4 30.1 T.S
38.1 23.8 47.6 31.7 T.S
L
O
G
I
S
E
A
T
A
O
O
B
O
T
Page 16
FINGER STOPS
Table 3.19 - FINGER STOPS
A
STRIP
THICKNESS
0 to 1.5
1.5 to 3.1
3.1 to 4.7
4.7 to 6.3
Over 6.3
No.
1
2
3
4
5
25
32
38
45
50
B
6.3
7.9
9.5
11.1
12.7
L
O
6
7
8
9
10
11
12
13
14
15
A
3.2
4.8
6.4
8.0
9.5
1
SMOOTH DIE HOLE
CONTOUR
FRONT
FINGER
SPACER
STOP
WIDTH
No.
O
T
D
37.3
44.4
51.5
58.7
65.8
3.2
4.8
6.4
8.0
9.5
9.5
11.1
12.7
14.2
15.8
23.8
27.7
31.7
35.7
39.6
50.8
57.9
65
72.2
79.3
.3.2
4.8
6.4
8.0
9.5
9.5
11.1
12.7
14.2
15.8
36.
40.4
44.4
48.4
52.3
63.5
70.6
73.5
81.3
88.4
3
SHARP CORNERS
FRONT
SPACER
WIDTH
FINGER
STOP
No.
FRONT
SPACER
WIDTH
FINGER
STOP No.
38
45
50
58
64
6
7
8
9
10
50
56
63
70
75
11
12
13
14
15
G
I
S
E
1
2
3
4
5
C
16.6
20.6
24.6
28.5
32.5
2
INSIDE CORNERS
E
1.6
2.4
3.2
4.0
4.8
F
46.22
57.37
66.92
76.50
86.05
1.6
2.4
3.2
4.0
4.8
61.31
70.86
80.41
89.99
99.56
1.6
2.4
3.2
4.0
4.8
74.01
83.56
93.11
102.69
112.26
A
T
A
O
O
B
AUTOMATIC STOPS
Page 17
Table 3.20- AUTOMATIC STOPS

NO
1
2
3
4
5
6
A
101.6
477.5
965.2
1442.7
2092.9
127
NO
1
2
3
4
5
6
M
4.8Drill 9.5 depth 45 csk
L
O
B
6.3
6.3
6.3
7.9
7.9
7.9
C
19.8
23.8
58.4
160
302.2
441.9
D
8.7
9.5
10.3
11.1
11.9
12.7
E
6.3
6.3
6.3
7.9
7.9
7.9
G
I
S
E
1.6 deep
1.6 deep
1.6 deep
1.6 deep
1.6 deep
1.6 deep
F
119.3
160
241.3
302.2
340.3
401.3
N
6
6
6
6
7
7
A
T
A
G
241.3
281.9
360.6
441.9
523.2
604.5
O
1.5 R.
1.9 R.
1.9 R.
2.3 R.
2.3 R.
2.3 R.
O
O
B
H
4.7
6.3
7.9
9.5
11.1
12.7
P
12.7R.
12.7R.
12.7R.
12.7R.
12.7R.
12.7R.
I
2.3
3.1
3.1
4.7
4.7
4.7
Q
30
30
30
30
30
30
J
3.1
3.9
3.9
5.5
5.5
5.5
R
1.1R.
1.1R.
1.1R.
1.1R.
1.1R.
1.1R.
K
7.1R.
7.1R.
7.1R.
8.7R.
10.3R.
11.1R.
S
3.1R.
3.1R.
3.1R.
3.1R.
3.1R.
3.1R.
T
1.5
1.9
2.3
2.7
3.1
3.9
L
4.7
6.3
6.3
7.1
7.9
9.5
U
16.6
20.6
24.6
78.7
183
281.9
O
T
Page 18
NO
1
2
3
4
5
6
A
6.3
9.5
12.7
15.8
19
22.2
NO
1
2
3
4
5
6
O
33
33
33
33
33
33
O
T
L
O
NO
1
2
3
4
5
6
B
16.6
20.6
24.6
78.7
180.3
281.9
P
5.5
6.7
6.7
7.9
8.7
9.5
D
50.8
157.4
320
645.1
1127.7
76.2
E
25.4
78.7
160
241.3
322.5
401.3
R
0.8 X 45
0.8 X 45
0.8 X 45
0.8 X 45
0.8 X 45
0.8 X 45.
S
2.3
3.1
3.1
4.7
4.7
4.7
F
12.7
14.2
15.8
17.4
19
20.6
B
34.93
37.30
41.67
44.84
48.02
52.38
C
25.4
78.7
160
241.3
322.5
401.3
D
7.9
7.9
8.7
10.3
10.3
11.1
G
19
20.6
23
24.6
58.4
99
G
I
S
E
Q
3.1
4.7
6.3
7.9
9.5
11.1
A
37.30
39.68
43.65
47.62
50.80
54.76
C
25.4
78.7
160
241.3
322.5
401.3
A
T
A
D
H
322.5
78.7
523.2
119.3
238.7
401.3
I
3.1
3.1
3.1
3.9
3.9
3.9
J
3.1
3.1
3.1
3.9
3.9
3.9
T
6.75dr 10.31 c bore 6.35 deep
6.75dr 10.31 c bore 6.35 deep
8.33dr 11.90 c bore 7.93 deep
8.33dr 11.31 c bore 7.93deep
9.92dr 15.08 c bore14.28deep
9.92dr 15.08c bore 14.28deep
E
19
20.6
23
24.6
58.4
99
F
322.5
401.3
523.2
604.5
238.7
401.3
K
6.3
6.3
6.3
7.9
7.9
7.9
L
7.9
8.7
8.7
10.3
11.9
12.7
O
O
B
M
9.1
10.3
11.1
12.7
14.2
15.8
N
7.9
8.7
9.5
11.1
11.9
13.4
U
4.8 drill 2.4 deep 45 csk 1.19 deep
G
M6 TAP
M6 TAP
M8TAP
M8TAP
M10 TAP
M10 TAP
Page 19
STOP
NO.
1
2
3
4
5
6
A
28.5
30.1
31.7
33.3
34.9
36.5
STOP
NO.
1
19.8
2
2-A
23.8
25.4
3
3-A
3-B
27.7
29.3
30.9
4
4-A
4-B
4-C
31.75
33.33
34.92
36.51
5
5-A
5-B
5-C
37.3
38.89
40.48
42.06
6
6-A
6-B
42.86
44.45
46.03
A
T
A
G
I
S
E
O
O
B
Table 3.23 - FULCRUM PIN DIMENSIONS
O
T
L
O
STOP NO
1
2
3
4
5
6
A
22.22
25.40
28.575
31.75
34.925
38.10
B
2.40
3.175
3.175
4.80
4.80
4.80
Page 20
APPLICATION OF FASTENERS
SCREWS:
O
O
B
Heat treated socket head cap screws can withstand double the load permissible for
commercial hexagonal head bolts and nuts.
S = design stress for socket head cap screw ranges from 80 to 120 N/mm2.
Root area for the metric screws can be found from the following formula
A
T
A
A = 0.7854 (D 1.227P)2
Where D = Diameter. Of screw in mm
P = Pitch of screw in mm
Load (N) = A x S
DOWELS:
Dowels are subjected to shear stress due to horizontal force resulting from die
clearance.
S = Dowels are rarely stressed beyond 50 to 80 N/mm2
G
I
S
E
Horizontal Force
= Die clearance x Stripping Load
Stripping Load
= 10% of vertical Force
Load/Dowel
= Horizontal Force / No. of Dowels
Area
= Load/Dowels
S
Dowel diameter = (Area/0.7854)
If Dowel size becomes too big more number of smaller dowels having same total sectional
L
O
area can be used. As area of dowel varies according to square of dowel diameter it is better
to use two big dowels instead of a no. of smaller dowels.
O
T
Page 21
Table 3.24 - NO OF SCREWS BASED ON STRIPPING FORCE

STRIPPING FORCE IN
TON
N
0.2
1992.8to2491.0
0.4
3985.6
0.63
6277.3
0.8to1.0
7971.2to9964.02
1.25
12455.0
1.60
15942.4
2.5
24910.0
4.0
39856.0
O
O
B
M6
M8
M10 M12
M16
M20
2
3
4
6
8
*
*
*
*
2
2
3
4
5
8
*
*
*
*
2
3
3
5
8
*
*
*
*
*
2
3
3
*
*
*
*
*
*
*
2
SCREWS AND DOWELL COMBINATIONS
*
*
*
2
2
2
4
6
A
T
A
The diameter of the screws and dowels is also determined by the size of the component.
Generally 10mm screws are used on die components up to 150 mm2.
Heavy die components are usually secured with 12 to 16mm diameter screws.
Dowel diameter should be same as that of the cap screws.
Dowel should be located diagonally across from each other and as apart as possible to
G
I
S
E
increase the locational accuracy.

-
L
O
All screws and dowels should be located from 1.5 to 2 times their diameter from the
component edge.
O
T
Page 22
20
25
20
22
25
20
22
25
20
O
O
B
25
30
25
Back Pillar
20
20
20
Blister Cen
30
35
28
Cent Pillar
25
30
25
Back Pillar
25
30
25
Back Pillar
30
35
28
Back Pillar
230
30
35
28
Back Pillar
254
30
35
28
Back Pillar
Table 3.25 - DIE SET DETAILS

S. No.
60
52
100
INCH SIZE
04 X 04
100
100
20
22
16
52
04 X 06
150
100
20
22
20
150
52
04 X 08
200
100
25
30
20
100
75
05 X 05
130
130
95
100
05 X 06
125
150
120
100
06 X 06
150
150
120
120
06 X 07
150
180
140
130
06 X 09
230
150
170
100
06 X 12
305
150
10
150
120
07 X 07
180
11
150
145
07 X 08
180
12
160
135
08 X 08
200
13
160
160
08 X 09
200
14
160
180
15
160
16
180
200
160
200
180
200
200
205
TYPE
Back Pillar
Back Pillar
Back Pillar
Back Pillar
Back Pillar
Back Pillar
08 X 10
170
08 X 12
200
305
30
35
32
Cent Pillar
170
08 X 13
200
330
30
35
32
Cent Pillar
09 X 09
230
230
30
35
28
Back Pillar
09 X 10
230
250
30
35
28
Back Pillar
185
IG
205
10 X 10
254
254
30
35
28
Back Pillar
120
200
10 X 10
254
254
30
35
28
Diago. Pillar
120
200
10 X 10
254
254
30
35
28
Four Pillar
200
210
10 X 11
254
280
30
35
32
Back Pillar
200
235
10 X 12
254
305
30
35
32
Back Pillar
24
230
200
10 X 15
254
380
35
40
32
Cent Pillar
25
230
210
11 X 11
280
280
30
35
32
Back Pillar
26
255
235
12 X 12
305
305
30
35
32
Back Pillar
27
165
255
12 X 12
305
305
30
35
32
Diago. Pillar
28
165
255
12 X 12
305
305
30
35
28
Four Pillar
29
255
260
12 X 13
305
330
30
35
32
Back Pillar
30
280
255
13 X 13
330
330
35
40
36
Back Pillar
S
E
18
19
20
D
21
O
T
A
T
A
D
180
Pillar (OD)
17
L
O
22
23
Page 23
O
O
B
BALL BEARING CAGES
A
T
A
Table 3.26 - Ball Bearing Cages
Table 3.27 Ball Bearing Cages
Standard bearing Al./Brass
Non Standard bearing Al./Brass
No.
I.D.X.
O.D.X
Length X
Ball
No.
I.D.X.
20
26
65
15
25
31
70
28
36
80
32
40
80
32
40
95
36
44
90
40
48
90
L
O
S
E
4
4
4
Length X
Ball
21
70
16
22
70
19
25
70
24
30
70
18
24
70
30
38
80
32
40
100
36
44
105
38
46
105, 125
10
40
48
105, 125
11
48
58
105, 125
12
50
60
105, 125
13
60
70
125
IG
4
O.D.X.
2
3
O
T
Page 24
Table 3.28 - SLEEVE BUSH FOR DIE SETS
Sleeve Bush Standard Bush

D-3
I.D
O.D.
20
36
40
20
25
42
46
23
28
32
36
40
26
31
No
9
10
L
O
D-4
D-2
11
12
13
Stap
O.D.
O
O
B
A
T
A
Sleeve Bush Non Standard Bush
Length
Length
L-1
No
G
I
S
E
D
D-2
D-3
D-4 Stap
O.D.
O.D.
21
32
36
60
22
32
36
60
I.D.
Length L
60
70
80
25
36
40
70
80
30
42
46
70
90
38
50
54
80
50
54
28
52
56
28
58
62
30
60
65
30
90
46
60
65
90
36
40
20
60
30
44
50
110
42
46
23
70
25
38
42
90
50
54
28
80
15
32
36
60
52
56
28
80
10
16
32
36
60
56
60
30
90
11
31
42
46
110
44
58
62
30
90
12
36
50
54
110
48
60
65
30
90
13
20
36
75
14
26
36
80
15
33
42
46
90
D
36
40
40
O
T
Page 25
PILLAR PINS FOR DIE SETS
A
T
A
Table 3.29 - Standard Pillar

S. No
20
125, 150
25
140, 160, 180
28
30
32
36
40
180, 200
180, 190
G
I
S
E
O
O
B
150, 180, 200, 230

170, 200, 250
200, 250
Table 3.30 - Non Standard Pillar
S. No
15
90, 100
16
90, 100
19
125, 150
20
100, 180
24
140, 160, 180, 200, 225
25
200, 250, 300
28
150, 225, 250, 300
30
150, 200, 225, 250
32
300, 250, 350
10
36
225, 275, 300, 350
11
40
225, 275, 300, 350, 400
12
50
200, 225, 255, 270, 300, 350
D
3
O
T
L
O
4
5
Page 26
SELECTION OF PRESS (TON)
Press capacity required =Cutting Force x 1.3 ( Select nearest higher capacity
press
from the data given below)
O
O
B
Table 3.31 - Preferred capacities of Mechanical and Hydraulic presses( as per IS

7469-1974):-
KN
O
T
L
O
Capacity in
(Tonnes)
Capacity in
(Tonnes)
KN
A
T
A
10
(1)
*2000
16
(1.6)
2500
(250)
25
(2.5)
*3150
( 315)
40
(4.0)
4000
( 400)
63
(6.3)
*5500
( 550)
100
(10)
6300
(630)
160
(16)
*8000
(800)
250
(25)
400
(40)
630
(63)
S
E
IG
(200)
10000
(1000)
12500
(1250)
16000
(1600)
*800
(80)
20000
(2000)
1000
(100)
25000
(2500)
*1250
(125)
31500
(3150)
1600
(160)
40000
(4000)
Note capacities marked with asterisk(*) are optional in the range.
Page 27
G
I
S
E
A
T
A
O
O
B
Using the same principle, die shut height for stamping dies, bendingdies, and
formingdies can also be calculated
O
T
L
O
Standard shut height of press as per IS 10644-1983:100, 125 ,160 ,200,250 ,315, 355, 400, 450, 500, 560, 630, 710, 800, 900, 1000,
The shut height of the tool must be kept according to the available press shut heights.
Page 28
Table 3.32 - PUNCH AND DIE MATERIAL SELECTION AND HEAT

TREATMENT
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 29
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 30
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 31
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Table 3.33 - SELECTION OF STEEL FOR DIFFERENT

APPLICATIONS
Page 32
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 33
CALCULATION OF CENTER OF PRESSURE:When the shape of blank to be cut is irregular, the summation of shear
O
O
B
forces about the centre line of press ram may not be symmetrical. Due to this bending
moments will be introduced in the press ram, producing misalignment and undesirable
deflections. To avoid this the centre of pressure of the shearing action of the die must be
found and while laying out the punch position on the punch holder, it should be ensured
that the centre line of the press ram passes exactly through the centre of pressure of the
A
T
A
blank. This centre of pressure is the centroid of the line perimeter of the blank. It should
be noted that it is not the centroid of the area of the blank. The centre of pressure can be
found out by the following formula:
= (l1x1+l2x2+l3x3+)/l1+l2+l3+. = lx/l
= (l1y1+l2y2+l3y3+)/l1+l2+l3+. = ly/l
Where
G
I
S
E
= x distance from centre of pressure
= y distance from centre of pressure

l1,l2,l3. = length of line elements
x1,x2,x3..= x distance of the centroids of line elements l1,l2,l3 respectively.
y1,y2,y3..= y distance of the centroids of line elements l1,l2,l3 respectively.
O
T
L
O
Page 34
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 35
SPRING DESIGN DATA

1. DATA FOR DESIGN OF CONVENTIONAL COIL SPRINGS
SPRING SELECTION:
- If the diameter and length are known then directly the spring
dimensions can be selected from the tables given in page no
to
. Select springs with desired total load.
- If diameter and length are not known, use the following spring selection
steps and refer to the rate column of the dimension table for spring
selection.
- Step 1:- Estimate the level of production required of the die short run,
constant production etc.,
A
T
A
O
O
B
Step 2:
- Determine compressed spring length H an operating travel T from
the die layout
G
I
S
E
Step 3:-
O
T
L
O
Determine free length C as follows:

o Decide which load classification the spring should be selected
from light, medium, heavy or extra heavy load. Then chose the
figure nearest the compressed length H required by the die
design from the appropriate charts below . read corresponding
c free length.
Step 4:Estimate total initial spring load L required for all springs when
springs are compressed X in mm
Step 5:Tool Design Data Book
Page 36
- Determine X initial compression by using the following formula:
X=C-H-T
Step 6:Determine R ( total rate for all springs in N/mm) by using the
following formula
R=L/X
A
T
A
O
O
B
Step 7:- Select springs from the table given below as follows:
o The free length C must comply with length determined in step
3.
o Divide R in step 6 by the number of spring to be used ( if
known) in order to get the rate per spring. Then refer to the
following pages for the catalogue number of springs having the
desired rate. If the number of springs is not known, divide R
from step6 by the rate of the spring you select for the correct
number of springs.
O
T
L
O
G
I
S
E
Table 3.34 Spring Compressed length to free length conversion chart
Page 37
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 38
Table 3.35 Rectangular spring light load
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 39
Table 3.35 Contd
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 40
Table 3.36 Rectangular spring Medium load
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 41
Table 3.36 Contd
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 42
Table 3.37 Rectangular spring Heavy load
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 43
Table 3.37 Contd.
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 44
Table 3.38 - Rectangular spring Extra Heavy load
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 45
Table 3.38 Contd
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 46
Table 3.39 - Rectangular spring Ultra Heavy load
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 47
Table 3.40 - Circular spring Light load
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 48
Table 3.41 - Circular spring Medium load
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 49
Table 3.42- Circular spring Heavy load
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 50
Table 3.43- Circular spring
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 51
Table 3.43 Contd.
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 52
Table 3.43 Contd
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 53
Table 3.44 Spring retainer
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 54
Table 3.45 - RUBBER SPRINGS
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 55
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 56
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 57
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 58
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 59
Table 3.50 RUBBER SPRINGS
Stripping Pressure (N) at Deflection of

D
10
13
16
20
25
32
40
d1
d2
10
18
23
1.6
1290
1512
13
23
26
703
1060
1268
16
28
31
74
670
1020
1220
20
33
36
44
1566
2647
54
1357
2180
2469
25
40
43
64
1081
1780
2158
32
50
55
74
811
1707
2139
38
60
65
44
2433
3513
40
54
1779
2958
3692
64
1526
2736
3202
74
1490
2650
3182
44
3002
4359
54
2580
3936
4581
64
2046
3424
4226
74
1939
3180
3980
44
4737
6605
54
3425
5515
6672
64
3291
5070
6205
74
3158
4781
5887
44
6383
9185
54
5693
8674
64
4480
6961
74
3469
6491
44
8562
54
6583
64
5804
3mm
6mm
9mm
44
978
1401
54
734
64
O
T
L
O
10497
9563
IG
S
E
12521
10008
8118
7570
A
T
A
60
65
O
O
B
3.0
12744
11453
Page 60
BENDING TOOL DESIGN DATA

Bending Allowance(L):
L = ( / 180) x A x (R + 0.5T) When R 2T
L = ( / 180) x A x (R + 0.33T) When R < 2T
Where A = angle of bend in degrees
R = bend inside radius
T = sheet thickness
Developed Length = Straight arm + Bend allowance
G
I
S
E
A
T
A
O
O
B
On bends, the short length should be minimum of 2.5 x stock thickness+ radius
O
T
L
O
Page 61
A
T
A
O
O
B
Minimum hole (and short slot) to bend distance should be 2.5 x the stock thickness + Bend
radius.
For long slots, the distance should be 4 x the stock thickness + bend radius.
O
T
L
O
G
I
S
E
Page 62
V Bending:
Bending Force = (1.33LST2) / W
L = length of the bent part in mm
T = thickness of blank in mm
S= Tensile strength of blank material in N/mm2
W = width of V at top
W should not be less than 6 times blank thickness; preferred range is 8 to 10
G
I
S
E
A
T
A
O
O
B
Edge radius RE = (2 to 6)t
Where, = thickness of material
Punch Radius RP = Radius of component
Die Radius, RD = Punch radius + thickness of material
O
T
L
O
Page 63
U Bending or channel bending:
Bending Force, F = [(0.67LST2) / W]
G
I
S
E
Span, W = RE + C +RP
A
T
A
O
O
B
Edge Radius, RE = (2 to 6)t for non moving edge

Punch Radius, RP = Part radius
Die radius, RD = RP+ (1.2 to 1.25) t s

C = Die clearance
T =Thickness of blank in mm
L =Length of bent part.
S = ultimate tensile strength in N/mm2
O
T
L
O
Page 64
WIPING DIES:
A
T
A
Bending Force, F = [(0.333LST )/W]

Span, W = RD + C + RP
Die radius, RD = Part radius
C = Die Radius, RP = 3 to 8T
SPRING BACK:
G
I
S
E
O
O
B
For low carbon and for soft non ferrous material 0 to 2

For 0.40 to 0.5 carbon steel and half hard material 3 to 5
Spring back may be high in hardened material 10 to 15
Bend radius
400N/mm2
600N/mm2
R=T
R = 5T
12
Table 4.1 Spring back data
L
O
O
T
Tensile strength
Page 65
DRAWING DIES
Type of operation:
h / d 0.5 shallow drawing

h / d > 0.5 deep drawing
Where,
h = shell height
d = shell diameter
A
T
A
Estimation of blank Diameter (Theoretical):
O
O
B
D = (d2 + 4dh)
when d / r 20 or more
D = (d2+4dh 0.5r)
when d / r is between15&20
D = (d2+4dh r)
when d / r is between10&15
D = [(d 2r)2+4d(h- r) + 2r(d 0.7r)]

Where,
D Blank diameter in mm
G
I
S
E
d Shell outer diameter in mm

h Shell Height in mm
when d / r is below 10
r Corner radius of punch

Considering Trim allowance:
Trim allowance = 0.05mm for every 10 mm diameter. Of drawn cup

Where,
O
T
L
O
Initial diameter of blank (D1) = D (Theoretical diameter.) + Trim allowance
Page 66
t / D Consideration:
t / D decides the severity of wrinkling
t / D Percentage
O
O
B
Wrinkling is a severe and compressive load

must be reduced.
Upto 0.5
Blank holder must be used, so a double

action press is preferable
Table 5.1 -
Above 0.5 upto 1.5
Wrinkling is moderate and low blank

holding forces are permitted
Above 1.5 upto 2.5
Wrinkling is very light so, single action

press is enough
A
T
A
No wrinkling so blank holder is

Over 2.5
unnecessary even with high compressive
load
Selection of percentage reduction for 1st Draw using t / D ratio:
(t / D) x 100
Single action
1.5
Double action
0.15
0.2
0.3
0.4
0.5
G
I
S
E
2.0
2.5
Where,
% reduction for 1 st Draw

[(D1 D2) / D1] x 100
30
35
40
45
47.5
D1 = Blank diameter. After adding trim allowance
D2 = Diameter. Of 1st Draw
O
T
L
O
Table 5.2 - Allowable percentage reduction for successive draws
First draw
Second draw
Third draw
Fourth draw
(t / D) %
25%
15%
10 %
Page 67
Table 5.3 - No. Of Draws according to h / d ratio

h / d ratio
No. of
First draw
Draws
Up to 0.75
1
40
0.75 1.5
2
40
1.5 - 3
3
40
3 4.5
4
40
Percentage of reduction P= 100(1-d/D)
Second
draw
-25
25
25
Third draw
--15
15
Where
d= ID of drawn shell
D= OD of blank
A
T
A
Estimation of drawing pressure:

Drawing pressure, p = x d x t x S x ((D / d) C)
Where,
P = Drawing force in kgf
d = Shell outer diameter
D = Blank diameter
t = thickness of sheet in mm
G
I
S
E
Fourth
draw
---10
O
O
B
S = Ultimate tensile strength in N/mm2
C = constant to cover friction and bending (0.6 to 0.7 for ductile material)
Blank holding pressure:
Blank holding pressure = 1/3rd of drawing pressure
Press capacity:
O
T
L
O
Press capacity = (Drawing pressure + Blank holding pressure) x 1.3
Page 68
Table 5.4 - Drawing speed

Material
Steel
Stainless steel
Aluminum
Aluminum alloys
Copper
Brass
Single action drawing

Ft / Min
M / Sec
60
0.3048
180
0.9144
150
0.762
200
1.016
Double action drawing

Ft / Min
M / Sec
35 55
0.1778-0.27
20 30
0.1016-0.1524
100
0.508
30 40
0.1524 0.2032
85
0.4318
100
0.508
Table 5.5 - Draw die clearance
A
T
A
2nd draw/
Intermittent draw
1.08t 1.1t
1.09t 1.12t
1.12t 1.14t
1.15t 1.2t
1st Draw
Blank thickness(t)
Upto 0.38
1.07t 1.09t
0.4 1.27
1.08t 1.1t
1.28 3.18
1.1t 1.12t
3.5 and above
1.12t 1.14t
t is the thickness of the original blank
Punch radius:
O
O
B
Sizing draw
1.04t 1.05t
1.05t 1.06t
1.07t 1.09t
1.08t 1.1t
Punch radius = 4t to 10t (or) Radius on product drawing
G
I
S
E
Where, t = sheet thickness
Draw radius (or) die radius:

R = 6t to 8t
(or)
R = 0.8[(D - d)t]
Tolerance:
Tolerance = 0.005 (or) 0.127
Table 5.6 - Draw die material:
O
T
L
O
Rate of production
Less than 1000
Around 1000 Nos.
Above 10000 Nos.
Above 10,00,000
Die material
Plastic (or) zinc
C.I
Tool Steel
Carbide Punches & die
Page 69
6. DATA FOR GAUGE DESIGN:-
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 70
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 71
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 72
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 73
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 74
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 75
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 76
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 77
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 78
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 79
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 80
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 81
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 82
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 83
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 84
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 85
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 86
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 87
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 88
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 89
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 90
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 91
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 92
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 93
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 94
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 95
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 96
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 97
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 98
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 99
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 100
O
T
L
O
G
I
S
E
A
T
A
O
O
B
Page 101
Table 6.34 - REFERENCE INDIAN STANDARDS FOR GAUGE DESIGN:IS NO.
INDIAN STANDARD SPECIFICATION FOR
IS: 3455 1971
Gauging practice for Plain work pieces

Gauging members for Plain plug gauges, GO and NO GO members
O
O
B
IS: 6137 1983

(Size range from 1 upto and including 40mm)

IS: 6244- 1980
(Size range above 40 to 120 mm)

IS: 6246 1980
A
T
A
(Size range above 120 up to and including 250 mm)

IS: 7018 (Part 1)
Technical supply conditions for gauges Part 1 General

1983
Technical supply conditions for gauges Part 2 - Assembly and

IS: 7018 (Part 2)
inspection Plain Plug gauges ( Size range from 1 mm upto and

1983
including 250 mm)
Technical supply conditions for gauges Part 3- Assembly and

IS: 7018 (Part 3)
G
I
S
E
identification of screw plug gauges for ISO metric screw threads (
1983
Size range from M1 upto and including M200)
IS: 5388 1983

IS: 3477 1973
IS: 3485 - 1966
GO and NO GO Snap Gauges for size range 3 to 250 mm

Plain ring gauges
Note:- Use of Institute copies of all the above Indian Standards and any other related
L
O
O
T
Hexagon handles for Plain and Threaded Plug gauges
Indian standards is permitted in the Tool Design and Drawing examination for the D.M.E (
Tool & Die) course.
Page 102
JIGS & FIXTURES

Table 7.1 - GUIDELINES FOR SELECTION OF LOCATORS
SI.NO
LOCATING DEVICE
1
Six point locator(3-2-1) pin and button
locators
2
V-block
3
Nesting locator
V-block, horizontal (one side is fixed and

other end is adjustable or cam operated)
V-locator.
Jack pin locator
Eccentric locators
APPLICATION
Locating flat surfaces
O
O
B
Locating round circular

flat
Locating cylindrical
profile in vertical
position.
Locating elliptical and
irregular surfaces.
A
T
A
Locating a rough work

piece.
Variation in work piece
size.
Table 7.2 - GUIDELINES FOR SELECTION OF CLAMPS

CLAMPS
SITUATIONS
Strap clamp
IG
Swinging strap clamp

Cam operated clamp
S
E
Toggle clamp
Screw clamp
Effective and fast, but should be used.

Adapted for many types of fixtures.
Components are to grip on.
Equalizing clamp
Exerting equal pressure to hold.
Hydraulic and pneumatic clamp
Faster, uniform and effective.
L
O
O
T
Commonly used for rectangular work

pieces.
For easy loading and un loading.
Hydraulic clamp with rack and pinion
Circular rod in V-block
Spider clamp
Circular and symmetrical workpiece

clamping.
Used during facing operation.
Edge clamp
Page 103
Table 7.3 - LOCATING PINS (ROUND) - IS 5093
d2
h1
h2
9.5
11.5
15
19
24
d1
p6
8
10
12
16
20
7.5
9.5
11.5
15.5
19.5
8
10
14
18
22
16
18
22
25
32
31
25
24.5
25
D g6
10
12
16
20
25
32
O
T
L
O
d2
h1
11.5
12
16
15.5
15
25
24
20
19.5
18
32
31
25
24.5
22
40
39
32
31.5
25
20
d1
p6
12
16
S
E
36
A
T
A
Table 7.4 - END LOCTING PLUGS - IS 5095

D
d
h6
IG
O
O
B
15
19
h2
16
25
40
20
32
45
25
40
60
40
63
50
80
Page 104
Table 7.5 - DIAMOND LOCATING PINS - IS 5094

D
d1
d
d2
e8
p6
h1
h2
12
12
11
7.5
14
13
10
9.5
10
18
17
12
11.5
14
22
21
16
28
27
20
36
35
A
T
A
O
O
B
14
18
15.5
18
21
19.5
10
22
28
24.5
12
25
32
D
g6
D
d1
p6
d2
d3
d4
s7
h1 h2
1
2
11.
5
1
0
9.5
M6
4
0
1
0
1
2
1
8
17
1
4
13.
5
M8
5
5
1
6
1
8
2
0
19
1
6
15.
5
M1
0
6
2
1
8
2
0
2
5
24
2
0
19.
5
M1
2
1
0
7
0
2
2
2
5
3
2
31
2
5
24.
5
M1
6
1
2
8
5
2
5
2
8
L1
l2
25
Table 7.6 - ROUND LOCATING STUDS - IS 5096
O
T
L
O
G
I
S
E
Table 7.7 - V-Locator
l3
b1
b2
b3
Page 105
25
20
35
15
32
15
36
25
50
20
45
25
50
32
60
22
55
30
Table 7.8 - V-Block

a
50
63
80
100
Table 7.8 - SWING CLAMP - IS 5250

d
O
T
dmax
40
50
63
83
200 200
200
200
300 300
300
300
A
T
A
O
O
B
dmin
5
5
7
7
10
12
L1 L2 L3 a
Size
of
screw
52
20
25
14
12
M6
25
11
30
N
11
16
70
24
35
20
16
M10
14
35
15
20
80
26
40
22
20
M12
18
45
18
25
90
32
45
28
25
M16
22
50
23
30
100
38
50
32
11
30
M20
20
G
I
S
E
c
40
50
63
80
6.6
L
O
w W1
b
40
50
63
80
11
12
14
60
22
30
18
14
M8
Table 7.9 - STRAP CLAMP IS 4292
l1
For
screw
size
7
10
12
15
19
24
50
60
80
100(125)
125(160)
160(200)
10
13
15
21
26
30
20
22
30
40(50)
45(65)
60(80)
8
10
12
14
18
22
10
12
15
20
25
30
20
25
30
40
50
60
M6
M8
M10
M12
M16
M20
Page 106
28
35
42
45
200(250)
250(315)
315(350)
350(400)
35
45
48
53
80(105)
100(130)
125(150)
150(180)
26
34
40
45
30(40) 70
40(50) 80
45(55) 90
55(60) 100
Table 7.10 - SWING C WASHER- IS 4298

d
H13
d1
6.6
9.0
11
14
18
22
8.5
8.5
8.5
10.5
10.5
10.5
18
21
24
27
33
38
26
12.5
30
12.5
R R1
O
T
L
O
O
O
B
For
bolt
t
or
Nom
screw
size
R2
R3
R4
8
8
8
10
10
10
21.3
25.5
29.5
34.0
42.0
49.0
12
55.0
10.0
13.0
16.0
20.0
25.0
30.0
32.5
2.0
2.5
2.5
3.0
3.0
3.0
42
14.7
16.5
18.5
20.0
24.0
27.0
29.0
4.0
10
M6
M8
M10
M12
M16
M20
M24
45
12
60.0
30.0
35.0
4.0
10
M27
G
I
S
E
M24
M30
M36
M39
A
T
A
6
6
6
8
8
8
Page 107
Table 7.11 - JIG BUTTON (IS 4294)

MATERIAL: C45
RC
HARDNESS: 45 50
d1
d2
Under cut
6
10
16
25
4
6
8
12
5
8
5/13
8/20
1.2
1.6
2.0
2.5
6
8
10
14
A2 X 0.2
B2 X 0.2
B2 X 0.2
B2 X 0.2
40
20
13/32
3.2
20
B2 X 0.2
Table 7.12 - JIG FEET

MATERIAL: FREE CUTTING STEEL HARDNESS:56 2RC
O
T
L
O
11
2.0
34
13
14
2.5
22
9
1.5
17
2.5
18
7
1.5
22
3.0
20
8
1.0
27
3.0
18
7
1.0
32
4.0
13
5
d1
d2
e1
r1
10
20
M6
11
12.7
21
31
0.5
15
30
M8
13
10
16.2
28
43
0.5
20
40
M1
0
16
12
12
19.6
36
56
25
50
M1
2
20
15
15
25.4
10
45
70
30
60
M1
6
24
20
19
31.2
40
80
M2
0
29
G
I
S
E
26
24
36.9
12
54
84
16
69
109
A
T
A
r2
D
0.5
0.5
O
O
B
Page 108
Table 7.13 - FEET BOLT

Basic
size
M10
50
28
12
12-20
10
20
M10
65
28
12
12-20
10
20
M10
75
28
12
12-20
10
M10
90
28
12
12-20
10
M12
75
35
18
20-25
12
M12
90
35
18
20-25
12
M12
100
35
18
20-25
12
M12
112
35
18
20-25
12
25
M12
125
35
18
20-25
12
25
M12
140
18
20-25
12
25
M12
150
18
20-25
12
25
Table 7.14 - FEET NUTS
D
35
35
20
25
25
25
Basic
size
M10
M10
M10
M10
M12
M12
M12
M12
M12
M12
M12
20
25
36
50
20
25
36
50
62
75
87
20
20
20
20
25
25
25
25
25
25
25
L
O
O
T
G
I
S
E
A
T
A
O
O
B
20
Page 109
Table 7.15 - JIG BUSH

FIXED BUSH
d1
Upto 1
1.0-1.8
1.8-2.6
2.6-3.3
3.3-4.0
4.0-5.0
5.0-6.0
6.0-8.0
8.0-10
10-12
12-15
15-18
18-22
22-26
26-30
30-35
35-42
42-48
48-55
55-63
O
T
L
O
Short
l1
l2
6
6
6
8
8
8
10
10
12
12
16
16
20
20
20
25
25
32
32
36
4
4
4
6
6
6
7
7
8
8
12
12
15
15
15
20
20
25
25
30
Long
l1
l2
9
9
9
12
12
12
16
16
20
20
28
28
36
36
36
45
45
56
56
72
7
7
7
9
9
9
13
13
16
16
24
24
31
31
31
40
40
50
50
66
d3
3
4
5
6
7
8
10
12
16
18
25
25
30
36
42
48
56
63
70
80
6
7
8
10
11
12
14
16
20
22
26
30
35
41
47
55
63
70
77
87
G
I
S
E
d2
A
T
A
O
O
B
d4
r1
r2
10
13
16
20
24
28
33
40
46
52
59
67
75
1.2
1.2
1.2
1.6
1.6
2.0
2.0
2.0
2.5
2.5
4.0
4.0
6.0
6.0
6.0
8.0
8.0
8.0
8.0
8.0
0.2
0.2
0.3
0.3
0.4
0.4
0.4
0.6
0.8
0.8
0.8
0.8
1.0
1.0
1.0
1.0
1.0
1.6
1.6
1.6
0.005
0.005
0.005
0.005
0.005
0.005
0.01
0.01
0.01
0.01
0.01
0.01
0.01
0.02
0.02
0.02
0.02
0.02
0.02
0.02
Page 110
Table 7.16 - LINER BUSH

Short
Long
d1
Upto 1
1.0-1.8
1.8-2.6
2.6-3.3
3.3-4.0
4.0-5.0
5.0-6.0
6.0-8.0
8.0-10
10-12
12-15
15-18
18-22
22-26
26-30
30-35
35-42
42-48
48-55
55-63
O
T
L
O
6
6
6
8
8
8
10
10
12
12
16
16
20
20
20
25
25
30
30
36
9
9
9
12
12
12
16
16
20
20
28
28
36
36
36
45
45
56
56
70
d2
r1
r2
3
4
5
6
7
8
10
12
16
18
22
25
30
36
42
48
56
63
70
80
1.2
1.2
1.2
1.6
1.6
2.0
2.0
2.0
2.5
2.5
4.0
4.0
6.0
6.0
6.0
8.0
8.0
8.0
8.0
8.0
0.2
0.2
0.3
0.3
0.4
0.4
0.4
0.6
0.8
0.8
0.8
0.8
0.8
1.0
1.0
1.0
1.0
1.6
1.6
1.6
0.005
0.005
0.005
0.005
0.005
0.005
0.01
0.01
0.01
0.01
0.01
0.01
0.01
0.02
0.02
0.02
0.02
0.02
0.02
0.02
G
I
S
E
A
T
A
O
O
B
Page 111
Table 7.17 - SLIP BUSH
d1
d2
d3
d4
d5
l1
l2
l3
r1
Upto 4
4-6
6-8
8-10
8
10
12
16
16
19
22
26
11
14
17
21
2.5
2.5
2.5
3.0
20
22
25
28
10
12
12
16
1
1
1
1
3
3
3
4
4
4
4
5
3
3
4
5
0.01
0.01
0.01
0.01
14
12
10
12
10-12
12-15
15-18
18-22
22-26
26-30
30-35
35-42
42-48
18
22
25
30
36
42
48
56
63
30
35
40
47
56
62
69
78
85
24
29
35
41
47
54
61
69
78
3.0
5.0
5.0
5.0
6.0
6.0
6.0
6.0
6.0
28
36
36
36
45
45
50
50
56
16
20
20
20
25
25
32
32
36
1
1
1
1
2
2
2
2
2
4
5
5
5
6
6
6
6
6
5
7
7
7
8
8
11
11
14
5
5
5
6
6
6
8
8
8
0.01
0.01
0.01
0.01
0.02
0.02
0.02
0.02
0.02
10
12
8
0
0
0
0
0
0
L
O
O
T
A
T
A
O
O
B
G
I
S
E
Page 112
Table 7.18 - LOCKING SCREWS
O
O
B
d6 d7 d8
l4
l5
l6
h d6 m6 * l
m
n
t
r2
c
M5
2.5 X 14
10
15
M5
2.5 X 14
12
16
M5 10 5
6
6
15
2
2.5 X 14
12 1.6 2.0 0.6 18
M5
3.0 X 14
16
20
M5
3.0 X 14
16
22
M6
5 X 20
20
26
M6 13 6
8
8
20
2
5 X 20
20 2.0 2.5 1.0 29
M6
5 X 20
20
33
M8
6 X 24
25
38
M8
6 X 24
25
41
M8 16 8
10 10 25 2.5
6 X 24
30 2.5 3.0 1.6 45
M8
6 X 24
30
48
M8
6 X 28
35
55
TOMMY NUT (Material C 45)
Basic size
A
B
O
T
L
O
G
I
S
E
A
T
A
M10
25
28
M12
25
35
M16
32
38
Page 113
Table 7.19 - KNURLED THUMB NUT (Material C 45)

Basic size A
B
16
M6
20
M8
22
M10
25
M12
28
M16
20
22
25
28
35
Table 7.21 Hand nut
A
41
54
58
64
70
80
O
T
L
O
G
I
S
E
B
32
38
41
45
50
56
C
23
27
30
32
38
45
D
M12
M16
M20
M22
M24
M30
E
14
17
17
19
21
25
F
8
13
13
17
17
19
10
1.5
12
1.5
12
14
16
A
T
A
Table 7.20 - THUMB NUT (Material C 45)

d1
M6
M8
M10
M12
M16
G
3
5
5
5
6
8
d2
7
9
11
13
18
b
28
32
36
45
54
H
6
8
8
10
10
11
h
12
14
16
18
22
J
3
5
5
6
6
8
O
O
B
e
12
14
16
18
22
K
25
35
35
41
44
52
HAND NUT (Material C 45)
Page 114
d2
l2
M10
75
3.5
12
40
M12
7.5
90
4.0
15
50
M16
10.0
117
4.5
19
63
M20
12.5
150
6.5
24
80
Table 7.22 Handle grip screws
O
T
L
O
G
I
S
E
l
l1
l
l1
l
l1
l
l1
40
25
50
31
65
40
80
49
A
T
A
45
30
55
36
70
45
85
54
50
35
60
41
75
50
90
59
55
40
65
46
85
60
100
69
60
45
70
51
95
70
110
79
O
O
B
65
50
75
56
105
80
120
89
80
61
130
99
Page 115
Table 7.23 - WING/ FLY SCREWS
d2
M5
1.5 25
1.5
M6
1.5 32
2.0
M8
2.0 40
2.5
O
T
3.0 50
3.5
h1
A
T
A
l
l1
l
8 16
l1
l
9.5 20
l1
l
12.0 25
l1
7
G
I
S
E
M10
L
O
g
approx.
12
25
16
28
20
35
25
50
38
30
22
40
30
55
43
O
O
B
35
27
45
35
60 65
48 53
Page 116
Table 7.24 - PRESSURE PADS
Max.dia.
d1
d4
d5
d6
d7
10
12
16
20
25
32
40
3.8
4.8
6.4
7.4
9.5
12.5
15.5
8
10
12
15
18
22
28
4
5
7
8
10
14
18
1.5
1.5
2
2
3
3
4
2.5 2.5 7
2.5 2.5 8
3 3.5 9.5
3.5 5 12
4.5 6 15
6
7 19
7.5 9 24
G
I
S
E
20
O
T
L
O
25
A
T
A
r1
r2
1.2
1.5
2
2
3
3
4
0.3 0.5 4.5

0.3 0.5 5
0.4 0.5 6
0.4 1
7
0.6 1
9
0.6 1 12
0.8 1 15
Table 7.25 - Cam clamp (Material Mild steel)

A
B
C
10
13
1.5
12
16
2
16
20
2.5
3
O
O
B
t2
t1
D
3
4
5
E
12
15
18
24
For screw
with thread
Fastening
pin
M5
M6
M8
M10
M12
M16
M20
1.5m6 x 6
1.5m6 x 8
2m6 x 8
2m6 x 14
3m6 x 14
3m6 x 16
4m6 x 20
F
60
70
90
110
G
10
12
16
20
Page 117
Table 7.26 - Quarter turn screw

A
M10
M12
M16
B
50
62
82
M20
100
C
35
38
47
60
D
12
15
20
E
28
32
35
22
40
F
5
6
6
10
Table 7.27 - Spherical washer

A
9
11
14
18
Table 7.28 - C WASHER
d
H12
IG
O
T
L
O
S
E
B
20
22
28
40
6.4
8.4
10.5
13
17
21
25
6
8
10
10
12
12
12
31
15
25
D
2.5
2.5
2.5
3
A
T
A
D
l
C
20
22
28
40
O
O
B
E
4
6
6.5
12
F
2.5
2.5
2.5
3
G
5
6
6.5
7
80
80
80
100
For
bolt
or
screw
size
M6
M8
M10
M12
M16
M20
M24
80
100
M30
32
32
40
40
50
50
63
63
63
Page 118
Table 7.29 - WING NUT(hot stamped or cast) IS 2636-1972

Size d
M2
M2.5
M3
M4
M5
M6
M8
M10
A(js16)
Nom
max
min
8
8.45
7.55
10
10.45
9.55
12
12.55
11.45
16
16.55
15.45
20
20.65
19.35
Nom
10
12
16
e(js16)
Nom
max
20
20.6
19.4
25
25.6
24.4
32
32.8
31.2
40
40.8
39.2
50
50.8
49.2
g1(js16)
Nom
max
min
1.6
1.9
1.3
2
2.3
1.7
2.5
2.8
2.2
3
3.3
2.7
g2
Nom
h1(js16)
Nom
max
min
10
10.4
9.6
G
I
S
E
min
m nom
r1 Nom
0.5
r3 Nom
O
T
L
O
r4 Nom
D
*
r2 Nom
Radiused.
M12
M16
M20
A
T
A
O
O
B
M24
23
23.65
22.35
28
28.65
27.35
36
36.80
35.20
19
22
28
36
64
65.0
63
72
73.0
71
90
91.1
88.9
112
113.0
111.0
5
5.4
4.6
6
6.4
5.6
7
7.4
6.6
9
9.4
8.6
11
4
4.4
3.6
45
45.80
44.20
2.5
12
12.6
11.4
16
16.6
15.4
N
20
20.6
19.4
25
25.6
24.4
32
32.8
31.2
36
36.8
35.2
45
45.8
44.2
56
57.0
55
10
12
14
16
20
24
10
11
14
18
1.2
1.6
2.5
0.5
1.2
1.2
1.6
2.5
11
Page 119
Table 8 - Unit conversions

Conversions factors
1N
PHYSICAL
QUANTITY
Force
0.1016 kgf
0.2248 Ibf
1 N/m2
Pressure
10.19 x 10-6 kgf/cm2
145.038x10-6 kgf/cm2
1kW
Power
1kW, 1.36hp
1.34hp
1 Nm/s
Power
0.1019 kgfm/s
0.7375 ft lpf/s
SI
MKS
FPS
Metric conversion table

Multiply
Inch
Foot
Yard
Mile
Inch2
Foot2
Yard2
Inch3
Yard3
Kilogram
Ounce
Foot/Second2
Inch/Second2
O
T
L
O
G
I
S
E
Pound
Ton
Horse power
To get equivalent number

to
A
T
A
By
Length
25.4
0.3048
0.9144
1.609
Area
645.2
6.45
0.0929
0.8361
Volume
16.387
16.387
Mass
0.4536
907.18
Force
9.807
0.278
Acceleration
0.3048
0.0254
Power
0.746
O
O
B
Millimeters (mm)
Meters (m)
Meters (m)
Kilometers(km)
Millimeters2(mm2)
Centimeters2(cm2)
Meters2 (m2)
Meters2
mm3
cm3
Kilograms (kg)
Kilograms (kg)
Newton (N)
Newton(N)
Meter per second2(m/s2)

Meter per second2
Kilowatts(kW)
Page 120

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TOOL DESIGN DATA BOOK

DIPLOMA IN MECHANICAL ENGINEERING (TOOL & DIE)

DIRECTORATE OF TECHNICAL EDUCATION

DIRECTORATE OF TECHNICAL EDUCATION

1. This book can be used for Board Examination by the

Tool Design Data Book

Sheet material SWG to mm & inch conversion

Data for stamping dies

Die plate design data

Stripper design data

Punch design details

Punch holder data

Fasteners - Screws & dowels

Punch and die materials & Heat treatment

Spring design data

Tool Design Data Book

Data for bending dies

Data for drawing dies

Data for gauge Design

ISO System of limits and fits tolerances & deviations

Reference Indian standard specifications for gauge design

Jigs & fixtures

Jig feet & buttons

Screws & nuts

Spherical & C Washers

Unit Conversion tables

Tool Design Data Book

Table 1 - MATERIAL PROPERTIES

Tool Design Data Book

Table 2 - Sheet material SWG to mm & inch conversion

Tool Design Data Book

DATA FOR STAMPING DIES

Shear strength of the component material in N/mm2

Perimeter of the component in mm

Thickness of the component in mm

100 Percentage of utilization

E= modulus of elasticity in GN/mm2

I=moment of inertia in mm4

= 1.5t where t is the sheet metal thickness in mm

Tool Design Data Book

Table - 3.1 - DATA FOR STRIP LAYOUT

Tool Design Data Book

DIE PLATE DESIGN DATA:

F Where F is cutting force in Kg.

Die Block Height

Tool Design Data Book

Table 3.3 - Tabulation of suggested standard die block sizes

M8 TAPPED THROUGH HOLE

M8 TAPPED THROUGH HOLE

M8 TAPPED THROUGH HOLE

M8 TAPPED THROUGH HOLE

M10 TAPPED THROUGH HOLE

M10 TAPPED THROUGH HOLE

M10 TAPPED THROUGH HOLE

Tool Design Data Book

M10 TAPPED THROUGH HOLE

M10 TAPPED THROUGH HOLE

M10 TAPPED THROUGH HOLE

M10 TAPPED THROUGH HOLE

M10 TAPPED THROUGH HOLE

M10 TAPPED THROUGH HOLE

M10 TAPPED THROUGH HOLE

Tool Design Data Book

Table 3.5 Anglular clearance data

Die clearance:Clearance per side = C T (max/10)