Introduction to Tool Design

Reading Assignment:

FTD Chapter 1

Optional Reading

Ergonomics and Safety in Tool Design

Photos: Examples of Tooling

Outline
Objectives

Reduce overall cost to manufacture a product

Increase production rate

Maintain quality

Reduce cost of tooling (cost effective)

Design safe and easy to use tools

Areas of Knowledge

Cutting tools, tool holders, cutting fluids

Machine tools

Jigs and fixtures

Gages and measuring instruments

Dies for sheet-metal cutting and forming

 Dies for forging, upsetting, cold finishing, and extrusion

Fixtures and accessories for welding, riveting, and mechanical fastening

The Design Process

Statement of the problem

Analysis of requirements

Development of initial ideas

Development of design alternatives

Finalization of design ideas

Evaluate

Requirements

Functions

Precision

Costs

Lead time

Safety

Adaptability, compatibility, standardization

Working life

Economics of Design

Remember to think lean

 Combined operations

Process cost comparisons

o Break even point (1-1)

o Total unit cost for a particular method (1-2a)

o Break even point, W&S method (1-3)

o ELS (1-4)

Break-Even Analysis

Tool Drawings

UM Valve

o Fulcrum (pdf)

o End Plate (pdf)

Real world drawing

o Cable Bracket Die (pdf)

o Cable Bracket Die (dwg)

Consider who will be making the tool

Do not crowd views

Analyze each cut

Use standard values

Use only the views necessary to define the part

 Realistic, thoughtful tolerances

Shaft easier to change than hole

Use stock sizes if possible

Notes may be necessary

Tooling Layout

Lay out the part (red is suggested)

Lay out cutting tools and holders

Indicate locating requirements

3-2-1 locating planes

Indicate clamping requirements

Use full scale if possible

Indicate standard fixture parts

Identify each item with balloons and leaders

Safety

Design out hazards if possible

Always break sharp edges

Rigidity

Fool proofing (poke-yoke)

Make drill jigs large enough to hold without spinning

 Use guards if possible

Punch Presses

Limit Switches

Feed Mechanisms

Electrical Equipment

Lockout provisions

Other Provisions

1. Straight wrists

2. Avoid static muscle loading

3. Avoid stress concentrations in soft tissue of hand

4. Reduce grip force requirements

5. Maintain optimal grip span

6. Avoid sharp edges, pinch points, and awkward movements

7. Avoid repetitive finger trigger actions

8. Protect hands from heat and cold

9. Avoid excessive vibration

10. Use gloves that fit

11.Note: There may be ANSI or other standards associated with a

particular type of tool. For example:

http://www.sciencedirect.com/science/book/9780080034911