6-10 Tool and Mould Design

Tool and Mould Design
Part-I
LESSON PLANS
Table of Contents
Jigs & Fixtures Classification/Types 1

Design Procedure (jigs & fixtures) 5
Principles for Clamping 7
Different Parts and Types of Jig & fixtures 9
Vise fixtures 11
Principles of location 15
Design Procedure 17
Tool guiding element 19
Form Tool 21
Press and Press Work 23
Introduction to Terminology 25
O.B. Press 27
Mechanical Press 29
Screw Press 31
Classification of Presses 33
Material Handling Equipments 35
Principles Working Of hydraulic Press 37
Multi Operation Press 39
Introduction Punch & Die Design 41
Define Punch 43
Tool& Mould Design 45
DIE 47
Die and Punch Design 49
Punch and die design procedure 51
Construction Of Simple PUNCH & DIE 53
COMPOUND & PROGRESSIVE DIE 55
Sheet Metal Dies 57
Inverted bending &Forming Dies 59
Enlist Material Used For Dies 61
Die Casting (Introduction To Die Casting) 63
Outline Of Die Casting 65
State SAE-AISI 67
Chemical Composition of S.A.E and AISI Steel 69
DIN and B.S.S Standards 71
Method of Molding 73
Injection Molding Machine 75
Types of Plastic 77
Mould and Design 79
LESSON PLAN
TITLE OF TOPIC (Short, Description) Lesson No: 01-A

Jigs & Fixtures Classification/Types Name: Tanveer Iqbal
Subject (Course Title): MECH-353 Time:
Tool& Mould Design
GENERAL OBJECTIVES:-
Student will be able to understand the
difference of fixtures as production tool used in production.
SPECIFIC OBJECTIVES:- Expected Entry behaviors
1. Understand the classification of Jigs & __________________________

fixtures
2. Understand use of Jigs & fixtures in __________________________
production
3. Understand construction criteria __________________________
4. Understand the parts of Jigs & clamping __________________________

scheme
Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch

With teacher student activities Teaching Aids/Evaluation
General Concept: Jigs & fixtures are special purpose tools

which are used to facilitate production
Definition:- when w.p are to be produced on the
A Jig may be defined as a device mass scale. Once a Jig & fixture is
which holds and positions the work locate properly set up, many number of
or guide the c-tool relative to the work duplicate parts may be readily produced
piece and usually not fix on the machine without additional set up.
table. It is usually lighter in construction.
A fixture is a work holding device which Jigs & fixtures are used :-
only holds and positions the work but 1. To reduce the cost of production.
doesn’t in itself guide, locate or position 2. To increase the production.
the c.tool. A fixture is bolted or clamped to 3. To assure high accuracy of the
the machine table. It is usually heavy in parts.
construction. 4. To provide for inter
changeability.
5. Reduce Q.C. expenses.
6. Less skilled labour.
7. Saving labour.
1
Jigs are used for drilling, reaming, taping
and counter boring operating fixtures are
used in connection with turning, milling,
grinding shaping planning and boring
operations.
Distinguish between Jigs and fixtures
JIG Fixtures
Jig is a device It doesn’t guid the
which holds w.p. cutting tool.
guid the cutting
tool.
It is light in weight. It is heavy in
weight.
Jig is not fastened It is always fasten
to the machine to the machine
table. table.
Testing & Follow Up:- (to see if leaner accompanied information or skill)
What are Jigs & fixtures and why these are used as production tool?
__________________________________________________
Special Assignment:- (Usually home work)

Make the neat sketches of different types of Jig & fixture
_______________________________________________
Tools Material & Aids:-

__________________________________________________
__________________________________________________
Reference:- (Author, title, publisher, page or chapter number, date of publication)

Tool Design 3rd Edition by Cyril Donaldson
_____________________________________________________
2
LESSON PLAN
TITLE OF TOPIC (Short, Description) Lesson No: 01-B

Jigs & Fixtures Classification/Types Name: Tanveer Iqbal
Tool& Mould Design
difference of fixtures as production tool used in production.
1. Understanding the classification of Jigs __________________________

& fixtures
2. Understanding use of Jigs & fixtures in __________________________
production
3. Understanding construction criteria __________________________
4. Understanding the parts of Jigs & __________________________

clamping scheme

Types of Jig:
1. Template jig. 1. This is the simplest type of drilling
jig. It is simply a plate made to the
shape and size of the work
piece.(simple hole).
2. Plate type jig 2. Plate type jig :- In place of simple
holes, drill bushes are provided in
the plate to guide the drill.
3. Open type jig. 3. The top of the jig is open the work
piece is placed on top.
4. Swinging leaf jig. 4. In this the top plate is arranged to
swing about a fulcrum point so that
it completely cleans the jigs for easy
loading and unloading of the work
piece. The drill bushes are fitted into
the plate.
5. Box type jig. 5. Such a jig would take the form of a
box. The body of such jig should be
as light as possible it will have to be
6. Channel type jig. filled again and again.
3
Milling Fixture
Milling Machine vice
Lath fixtures (turning fixtures)
Grinding fixtures.
Magnetic check
Vacum checking.
Bro fixtures.
Boring fixtures.
__________________________________________________
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
4
LESSON PLAN
TITLE OF TOPIC (Short, Description) Lesson No: 02-A

Design Procedure (jigs & fixtures) Name: Tanveer Iqbal
Tool& Mould Design
At the end of the topic students will be able to design the Jig & fix.
Students will be able to understand
1. The design principles. __________________________
2. The design of Jig & Fix according to the __________________________
w.p.
3. __________________________
4. __________________________

Design principles common to jigs & fixtures. Fool Proofing
The total machining time for a work piece Clearance

includes work-handling time method of
location and clamping should be such that Rigidity
the idle time is min.
Trunnions
Design of jigs and fixture should allow easy
and quick loading & unloading of the work Burr Grooves
piece.
Ejectors
Inserts
5
What is foul proofing?
__________________________________________________
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
6
LESSON PLAN

Principles for Clamping Name: Tanveer Iqbal
Tool& Mould Design
difference devices used for clamping purposes.
1. Understand the method of clamping __________________________

2. Understand the different type of clamp __________________________
3. Understand the use of clamping __________________________
4. Element regarding the time factor __________________________

1. Clamping devise
1.1 Clamping screw
1.2 Hook bolt clamps
1.3 Lever type clamps
1.4 Bridge clamps.
1.5 Heel clamps.
1.6 Swinging strap (latch)
2. Quick acting net (clamps)

2.1 C-clamps.
2.2 Quick acting net.
2.3 Com operated clamp
7
Material used for locating and clamping Locating and clamping elements are
elements. generally made from steel.
Elements which come to contact are
Dowel pins, handles. made from hardest steel.
The work piece is subject to wear silver
steel.
Wear is liable to occur; good quality case
hardened steel, torel steel or high tensile
steel may be used.
Define the lever type clamp and its type.
__________________________________________________

Sketching of locating and clamping element.
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
8
LESSON PLAN

Different Parts and Types of Jig & fixtures Name: Tanveer Iqbal
Tool& Mould Design
Students will be able to define and identify
the stand parts used in Jig /fixture.
1. Understand the different parts __________________________

2. Select the exact size of parts __________________________
3. Understand the different types of material __________________________
4. __________________________

Different types of stand parts.

Hex Nuts and bolts spring washer, plain
washer c-washer
Sketch of parts
Use of stand parts.
Types of Jigs & fixtures. Plate type, template type.
9
Swinging leaf jig.

Channel jig.
Box &Tumble Jig
Indexing Jig
Vise fix with series of special Jaws
Angle milling fix
Turning fix
Broaching fix
What is standard and where it is used?
__________________________________________________

Make neat sketch in Note Book.
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
10
LESSON PLAN
TITLE OF TOPIC (Short, Description) Lesson No:

Vise fixtures. Name: Tanveer Iqbal
Tool& Mould Design
1. ______________________ __________________________
2. ______________________ __________________________
3. ______________________ __________________________

Vise fixtures. Holding record:

 Simple pair of Jaws.  For holding thin sheet.
 Pair of jaws.  For large w.p.
 Extended jaw.  For accurate alignment.
 Wedge type jaws.  For safe the work (tilt upward)
 Link jaws
11
__________________________________________________
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
12
LESSON PLAN
TITLE OF TOPIC (Short, Description) Lesson No: 03

Different Material used in Jig/Fixture Name: Tanveer Iqbal
Tool& Mould Design
Students will be able to select the material
as per requirement and design of parts.
1. Understand the Properties of Material __________________________

2. Understand the selection of Material __________________________
3. __________________________
4. __________________________

Introduction about the material
H.S.S. Die steel, Die steel,

Enlist the material
Carbon steel, Nickel chromium steel,
Mild steel, cost iron tuber plastic nylon
etc.
Composition of material
13
 Dill bushes – carbon steel

 Body, m.s./c.iron.
 Jig fixture. Carbon steel
 Nut/bolt. M.S. etc
How to select the material for different type of parts in Jig/fixtures.
__________________________________________________
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
14
LESSON PLAN

Principles of location Name: Tanveer Iqbal
Tool& Mould Design
The students will be able to understand
the location of work piece in the Jig.
1. Understand the movement of work piec __________________________

2. Understand the restriction of movements __________________________
3. Understand the xx, yy, zz axis of movements __________________________
4. __________________________

Principles of locations When we want to stop the movements

of a work piece we consider that a w.p.
placing the space. Then how many
movements get a work piece in state of
freedom.
Xx, yy, zz – 6 movements. Rotation of

work piece xx, yy, zz axes of total
movements 12 degree of freedom.
15
Explain 3:2:1 Location Stop the movement of horizontal plan xx

(3 – locating pin)
(2 – locating pin for stop the movement
vertical plaw.
1 – locating Pin at the top of the plate.
What is the 12 degree of freedom of a work piece.
__________________________________________________
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
16
LESSON PLAN
TITLE OF TOPIC (Short, Description) Lesson No: 1.5

Design Procedure Name: Tanveer Iqbal
Subject (Course Title): MECH-353 Time: 1 hour
Tool& Mould Design
1. __________________________
2. __________________________
3. __________________________
4. __________________________

Points to be considered while a. Digidity.

designing of Jigs & fixtures. b. Locating and clamping.
c. Chip control.
d. Jig feet and legs.
e. Safety in design
f. Weight of jig.
g. Method of construction
h. Fool proofing.
17
What is feed proofing? What is Jig & fixtures and legs?
___________________

Make a next sketch of Jig feet & legs.
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
18
LESSON PLAN

Tool guiding element Name: Tanveer Iqbal
Tool& Mould Design
1. __________________________
2. __________________________
3. __________________________
4. __________________________

Headed drill bushes.
Headless drill bushes.
Explain the tool guiding element. Reverseable drill bushes.
Tool supporting element. Master/liver drill bushes
Tool clamping element.
19
Jig fixture – square, hex type, round

type.
Strap clamp, cam clamp screw clamp,

latch clamp.
Pin & button locations rest pad &

plates nest or cavity location.
How many types of total guiding elements.
How many types of total clamping elements.

Make the neat sketch of all elements. Use in jigs and fixtures.
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
20
LESSON PLAN

Form Tool Name: Tanveer Iqbal
Tool& Mould Design
the use of form tools and its types
1. Understand the use of tool __________________________

2. Understand how to turn the short __________________________
profile with form tools.
3. __________________________
4. __________________________

Form Stools: Form tools are fed radially into the work
Form tools are used to turn the short piece and depth is controlled by the
profiles on a caspstan or turret lathe depth stop.
machine. Flat
Form tool
Types of form tools: This is the simplest type but as it is
1. Flate form tools. sharpened by grinding its top face.
2. Circular form tools.
Circular form tools:

Use very extensively on single spindle
automatic bar machine.
21
Define the form tools
How many types of form tools._________________

Make a neat sketch of flat form and circular form tool.
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
22
LESSON PLAN

Press and Press Work Name: Tanveer Iqbal
Tool& Mould Design
the terminologies used in Press & Press
Work and study the Presses Classification.
1. To understand the basic method of actuation of ________________________

Press
2. To understand the Press Operation ________________________
3. ________________________
4. ________________________

PRESS AND PRESS WORK: The machine used for press work is
Press working may be defined as a chipless called Press.
manufacturing process by which various The main features of a press are
Components are made from sheet metal. A frame which support a ramor slide and
This process is also termed as cold a bed, a source of mechanism for
stamping. operating the ram in line with and to the
PRESS OPERATIONS bed. Ram is equipped with suitable
01 CUTTING OPERATION punch/punches and a die block is
02. FORMING OPERATION. attached to the bed. A stamping is
PRESSES. produced by the downward stroke of the
Presses are classified in various ways. They ram when the punch moves towards and
may be classified according to :- into the die block. The punch and die
i. Source of Power. block assembly is called die set or simply
ii. Method of actuation of slide (rams) as the die . Press working operations are
iii. No of slides. usually done at room temperature.
iv. Type of frame. In cutting operations, the work piece is
v. Type if work for which the Press stressed beyond its ultimate strength.
has been designed. The stresses caused in the metal by the
applied for will be chear stress. In
forming operation, the stresses are
below ultimate strength of the metal. In
this operation there is no cutting of
metal but only the contour of the w.p. is
changed to get the desired products.
23
CUTTING OPERATION
1. Blanking
2. Punching
3. Notching
4. Perforating
5. Triming
6. Sharing
7. Slitting.
8. Lancing
9. Nibbling.
FORMING OPERATIONS
1. Bending
2. Drawing
3. Squeezing
Explain the Press operation.
Explain the difference between Cutting Operation & Forming
Operations.
Sketching the different kinds of Press Operation
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
24
LESSON PLAN

Introduction to Terminology Name: Tanveer Iqbal
Tool& Mould Design
the terminology for Press Working.
1. To study the main components of die & __________________________

Press.
2. __________________________

Press Working Terminology

01. Bed
02. Bolster Plate.
03. Die Set
04. Die
05. Die block
06. Lower Shoe
07. Punch
08. Upper Shoe
09. Back up Plate
10. Stripper
11. Knock out
12. Pitman.
25
BED:
The bed is lower part of a press frame that
serves as a table to which a Bolster plate is
mounted.
General Press Information.
1- Press Tonnage
2- Stroke.
3- Shut height.
4- Die space.
Explain briefly about the terminology of Press and die.
__________________________________________________

Sketch the simple cutting die.
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
26
LESSON PLAN
TITLE OF TOPIC (Short, Description) Lesson No: 3.2.1

O.B. Press Name: Tanveer Iqbal
Tool& Mould Design
Students will be able to know the types of Press
and its used according to the designed work.
1. To study the Parameter of the Press. __________________________

2. To study the different types of fram. __________________________
3. To understand the working principle __________________________
4. __________________________

O.B. Press:
The open back fram may be fixed in a
vertical position or in a fixed inclined
position or it may be of inclinable type.
The most common type Press is open back

inclinable c-type fram press commonly
known “O.B.I” Press. Its frame is inclinable
backward which facilitate the removal of
scrap or parts by gravity through the open
back. It ranges from a small I tone bench
Press to floor Presses rated up to 150
tonnes.
27
Major Component of an O.B. I. Press.

1. Rectangular bed. The stationery and
usually horizontal of the Press serving as
a table to which a bolster plate is
mounted.
2. A bolster Plate, consisting of a flat steel
plate 2 to 5 thick, secured to the Press)
or lacting and supporting the die
assembly.
3. The ram, sometimes called the slide,
which reciprocates with in the Press
frame and to which the punch or upper-
die assembly is fastened.
4. A knock out, consisting of a crossbar
through a slot in the ram that contacts a
pin in the die to eject the w.p.
5. The fly wheel, which absorbs energy
from the motor continuously and
delivers its stored energy to the w.p.
intermittently, making it possible to use
a smaller motor.
6. The pitman, consisting of a connecting
rod to convey motion and pressure from
the main shaft or eccentric to the Press
Slide.
What is O.B. Press?
What is O.B.I Press?___________________________

Make a neat sketch of O.B.I Press
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
28
LESSON PLAN

Mechanical Press Name: Tanveer Iqbal
Tool& Mould Design
the basic principles of Mechanical Press.
1. To study the Mechanical Press __________________________

according to their source of actuation.
2. __________________________

Mechanical press: FLY wheel rotates freely on the crank

In Mechanical Press, the energy of fly shaft and is driven from an electric
wheel is utilized which is transmitted to the motor through v-belts. The motor runs
work piece by gears, cranks, eccentrics or continuously and stores energy in the fly
leavers. wheel. When the operator press a foot,
treadle or button, the clutch engaged
and the fly wheel is connected to the
crank shaft. The crank shaft starts
rotating and stored up energy in the fly
wheel is transmitted to the ram on its
downward stroke. The clutch to engage
or disengage the fly wheel to the drive
shaft can be a Jaw clutch, air operated
clutch, or an electromagnetic clutch. In
manual operated press the clutch is
disengaged after each cycle. But in
automatic in which the metal ship is fed
to the die automatically. There is no
need of single strokes.
29
These presses can be classified as plain
and geared. In the first design the fly
wheel is mounted directly on the drive
shaft.. On a general press the fly wheel is
carried on an auxiliary shaft which is
connected to the main shaft, through one
or more gear reductions. Depending upon
the size and energy needed. In this
arrangement, the fly wheel stores
considerably more energy. Than plain
drive on its speed is higher than the main
drive shaft.
What is the main difference between single twin & multiple gear
drive?

Sketching the different Mechanical Press drives.
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
30
LESSON PLAN

Screw Press Name: Tanveer Iqbal
Tool& Mould Design
the function of the Screw Press.
1. To study the parts __________________________

2. To study the w. principles of Screw Press __________________________
3. __________________________
4. __________________________

SCREW PRESS: Screw Press

In Screw Press drive slide is attached to the
fly wheel through a Screw. As the fly wheel
is rotated by a friction drive, it moves down
and the slide motion is continuously
accelerated. At the bottom of the stroke,
the entire energy stored in the fly wheel is
consumed by the work.
PARTS:
01 Fly wheel.
02 Friction Drive.
03 Lead Screw.
04 Slide/Ram.
05 Bolster Plate.
06 Bed.
31
Mechanical Press:
1. CAM operated.
2. Crank operated.
3. Eccentric operated
4. Pack and pinion
5. Toggle and knuckle joint.
6. CNC presses
What is the difference between Hyd. & Mech Press and its type?
__________________________________________________

Make neat sketches of Mech. Presses.
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
32
LESSON PLAN

Classification of Presses Name: Tanveer Iqbal
Tool& Mould Design
The students will be able to describe the classification of presses
1. Understand the types of frams __________________________

2. Understand the method of actuation __________________________
3. Understand the selection of presses __________________________
4. __________________________

Classification of Presses: c-fram O.B Press O.B.1 Press
Describe the classification. Single action, Double action and triple

action Press
Describe the source of power.
No. of slides  Press Tonnage
Use of special purpose  Stocke
Presses information.  Shut Height
 Die Space
33
What is mean by O.B Press O.B.1 Press?
What is Single action, Double action and triple action Press?

Make the neat sketch of O.B.1 Press
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
34
LESSON PLAN

Material Handling Equipments Name: Tanveer Iqbal
Tool& Mould Design
the function of material handling equipment during the work.
1. Understand the use of equipment __________________________

2. Understand the types of equipments __________________________
3. __________________________
4. __________________________

Material Handling Equipments:

1. Coil un winding equipment.
2. Strip straighting devices
3. Strip feeding
35
How many types of material handling equipments.
__________________________________________________
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
36
LESSON PLAN

Principles Working Of hydraulic Press Name: Tanveer Iqbal
Tool& Mould Design
Students will be able to understand the working of Hyd. Press.
1. Understand the parts of Hyd. Press. __________________________

2. Understand the function of each parts __________________________
3. Uses of Hyd. Press. __________________________
4. __________________________

PARTS OF HYDROULIC PRESS: Cylinder, Piston, Hydraulic Pump Motor,

Piston – A metal Piston Cylinder that slides Punch, Die Ram Guide Fram.
up and down inside a cylinder under the Hydraulic Press can exert its full tonnage
pressure of fluid. at any position of the ram stroke.
OVERALL WORKING: Speed and pressure are also constant
Hydroulic Press have a large cylinder and throughout the entire stroke.
piston coupled to a hydraulic pump. The
piston and press ram are one unit. The
tonnage capacity depends upon the cross
sectional area of the Piston and the
pressure developed by the pump. The
clinder is double acting in order to move
the ram in either direction. The stroke can
be varied to any length within the limits of
the hydraulic cylinder tonnage.
USES; Hydraulic Press is normally used for

many die cutting operation like Blanking,
Piercing, forming etc.
37
This is the main production tool, which is Hydraulic Press is mainly used for forming
used efficiently and economically for and drawing operation.
production of many use full items e.g.
washer, wire works and automobiles parts.
Body parts of auto mobiles.
What do you understand the parts of Hydraulic press and over all
working of Hydraulic Press
Sketch of Hydraulic Press
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
38
LESSON PLAN

Multi Operation Press Name: Tanveer Iqbal
Tool& Mould Design
the working of single and Multi-operation Press.
1. Understand the difference between __________________________

Single and Multi-operation Press
2. Understand the Tonnage, Stroke Shut __________________________
height Die space etc

Single Acting and Double Acting Press In single operation press, two or more
In Single acting press, there is one ram or operation are done in more the one
slide, which works on one design during its stroke.
movement. In multi operation press, there
are two or more Ram or slides. The outer
part is called outer slide (Blank holder, and
the inner part is called Punch. In multi
operation two or more different operation
are done in one stroke.
In tripple action, there are two slides, as
used in the double action press. Where as Used for deep drawing operation
the third slide or ram located in the press
had which moves upward in the press bed
which moves upward in the bed soom after
the other two ram slides descend.
39
Press Tonnage
All three slide movements are properly Press force that press ram exert safely.
synchronized for triple action. Stroke of press is reciprocatory motion.
USES: Distance from the top of the bed to the
Generally used for large work, like making the bottom of the slide.
panels of motor car bodies etc. Area available for mounting dies in the
PRESS TONNAGE. press.
Stroke
Shut height
Die space.
What is a press work ?
Explain the important parts of the press._______

Write notes on press tonnage, stroke shut height die space.
_______________________________________________

__________________________________________________
__________________________________________________

Text book of Tool design NISTE
_____________________________________________________
40
LESSON PLAN

Introduction Punch & Die Design Name: Tanveer Iqbal
Tool& Mould Design
Students will be able to understand the working
Punch & Die and Design of the Punch & Die.
1. Understand the design procedure __________________________

2. Understand the types of Punch & Die __________________________
and their material
3. __________________________
4. __________________________

Punch and die is a device which is used for TYPES OF PUNCHES:
metal stamping. It has two parts. - Plain Punches.
Number the upper part is called punch and - Pedestal Punches.
the lower, which is called Die. A tool - Perforated Punches.
designer should make the design of Die as Punches are varied in quality complexity
simple and easy and should keep enough of design and cost from very simple and
space for the work piece between punch cheap.
and die. Expensive Punches for large quantity
SINGLE AND COMPOIND PUNCHES: containing Production.
A single Punch performs only one
operation. The operation may be either the
cutting type or the form type. This type of
punches is usually of the simplest possible
arrangement and construction.
41
Compound Punches: All operations performed on the part in one

location.
These are single stage punches for
performing two or more operations of the
same general type e.g. a compound
blanking and piercing Punch and die where
in two cutting operations are performed.
What do you understand the design principle of punch & die?
__________________________________________________

Make a neat sketch of Punch mounted in the Punch Plate
_______________________________________________

__________________________________________________
__________________________________________________

Text book of Tool design NISTE
_____________________________________________________
42
LESSON PLAN

Define Punch Name: Tanveer Iqbal
Tool& Mould Design
the working of Punch and its holding techniques.
1. Understand the types of Punches __________________________

2. Understand the design principle __________________________
3. Understand the material used __________________________
4. __________________________

The Punch refers to the part of assembly, PUNCH DESIGN:

which is attached to the ram of the press The design of punches largely depend
and is forced into the die cavity. The punch upon the area to be pierced
is known as the male part of the press. Or blank and the pressure required
DESCRIBE THE TYPES OF PUNCHES. penetrating the work piece material.
1) plain punches Punch Plates serve to hold, position and
2) pedestal punches in some cases strengthen the Punch.
3) Perforated punches. Perforated punch generally mounted in a
4) punch moonted in punch plates punch plate because the head and
shanks are round mounting holes is
simply made with drills, reamers counter
boring.
43
Small punches are mounted in punch plate
Explain the types of punches
Explain the Punch Design __________________________

Make a neat sketch of Plain Punch
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
44
LESSON PLAN

Name: Tanveer Iqbal
Tool& Mould Design
1. __________________________
2. __________________________
3. __________________________
4. __________________________

Single and Compound Punches

1) SINGLE PUNCH
A single Punch performs only one A SINGLE PUNCH CUTTING
operation. This type is usually of the TYPE/FORMING TYPE.
simplest. Expensive punches for large quantity
Possible arrangement and construction. continuing production.
These punches are vary in quality
complexity of design and cost from very
simple and cheap.
45
COMPOUNED PUNCHES. Compound blanking and piercing Punch

These are single stage Punches for and die two cutting operation are
performing two or more operation of the performed.
same general type.
All operations are performed on the part in Compound drawing and embossing punch
one location. and die.
What do you understand the Single & Compound Punches.
__________________________________________________

Make a neat sketch of Single Punch.
_______________________________________________

__________________________________________________
__________________________________________________

text book of Tool Design NISTE
_____________________________________________________
46
LESSON PLAN

DIE Name: Tanveer Iqbal
Tool& Mould Design
Student will be able to understand the die
their material and types of dies.
1. Understand the types of dies according __________________________

to the type press
2. Understand the material for die. __________________________
3. _________________ __________________________

Die.
A die is that part of the press tool,
which has opening or cavity to receive the
punch. The dies are usually the lower
member of the press tool, which is clamped
on base plate, fitted on the table as
remains stationary.
Types of Dies according to the Method Types.

of Operation. ___ Blanking
Simple Punching
Compound Bending, Forming, Folding
Progressive Drawing
Combination Squeezing, Coining, ___
Upsetting
47
Die Block Design.
Usually die block thickness (of tool steel) The blank to drop through the die block
should be a minimum of 0.75 inches for on without jamming.
blanking parameter up to 3 inches and 1 inch
for parameter between 3 and 4 inches for
long parameter, die block should be 1.25
inches. Die block are seldom thinner than 7/8
finished thickness to allow for grinding and
for blind screw holes. Since the perimeter of
Blank is approximately 7 inches, a die block
thickness of 1.5 in is specified, including ¼
allowance. There should be a margin of 1.25
inches around the opening in the die block.
The wall of the die opening is strengthened
for a distance of 0.125” (Stock Thickener)
below this straight angular clearance of ½
allowed. The blank tool through the die block
without Jamming.
What do you understand by the function of dies and their types
__________________________________________________

__________________________________________________
_______________________________________________

Write notes on designing detail______________________
__________________________________________________

_____________________________________________________
48
LESSON PLAN

Die and Punch Design Name: Tanveer Iqbal
Tool& Mould Design
Design principle.
1. Understand the Block Design __________________________

2. Understand oil line detail __________________________
3. Understand the design procedure __________________________

Die Block Design. Block thickness (total steel) should be
minimum of 0.75” for a blanking
parameter, die block thickeners up to 3”
and 1” for a parameter 3”/4”. For long
parameter, die block thickness should be
1.25”.
Die block seldom thinner than 7/8”,
finished thickeners to allow for grinding
for blind screw holes. Perimeter of blank
is approximately 7”; thickness of die
block is 1.5”. The margin of 1.75” around
the opening of die block.
Four 3/8” cap screw and 3/8” dowell
screw located at the corner 0.75” from
Punch Design. the edge.
The shouldered punch 2.25” Punch clearance 6% of the stocle
long is held against ¼” thick hardened steel. thickener or 0.75”
Back up plate by a punch plate ¾” thick,
which is screwed and dowled to the upper
shoe.
49
Design Procedure. Outline design detail.
A 32 Ton OB.1 press can accommodate the

shut height of the die. Leaving a sheet height
of 9.5” for the conditions of this case study,
_________
S=60,000 Blocked Perimeter
L=7” App.
What do you understand by the design procedure___________
__________________________________________________

__________________________________________________
_______________________________________________

Make a neat sketch of plain punch________________________
__________________________________________________

_____________________________________________________
50
LESSON PLAN

Punch and die design procedure Name: Tanveer Iqbal
Tool& Mould Design
1. _________________ __________________________
2. _________________ __________________________
3. _________________ __________________________

20 Outline Design Detail 1. Clearance
Minutes 2. Cutting Process
3. Minimum Dia of piercing
4. Die Block
5. Die Block Thickens
6. Die Block Opening
7. Fastening of Die Block
8. Back Up Plate
9. Method Of Holding Punches
Fundamental of die design 10. Center of Pressure
11. Stripper
12. Stock Slop
13. Stock Slop Guide
14. Stripper Feeding
15. Knock Out
16. Die Set
17. Pilots
51
Explain The Design Procedure
1. Designing of press tool

2. Determine the punch and die
opening
3. Design the die block ( dimension
and surface area)
4. Provide arrangement for fixing
punch
5. Provide stock stop, stocle guide
6. Prepare a dimensional assembly
Explain the step by step by the outline design__________
What do you mean by clearance _______________________

__________________________________________________
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
52
LESSON PLAN

Construction Of Simple PUNCH & DIE Name: Tanveer Iqbal
Tool& Mould Design
Construction of simple cutting dies.
1. To know the working of simple cutting __________________________

dies
2. To know the combination of die and __________________________
punch working
3. _________________ __________________________

Plain Or Simple Die. Simple type of die usually designed for
This is very simple type of press tool, by blanking and piercing operation.
means of which very simple types of job are
prepared.
Plain or simple die also used for bending,
cup-shape jobs, whose depths are very
large.
According of the job is not essential.
53
Precision Ness. Two grades of accuracy.
Strict conformity to a rule or stand, exactness Precision and commercial.
accuracy is called precision ness.
What did you understand by the accuracy__________________
__________________________________________________

__________________________________________________
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
54
LESSON PLAN

COMPOUND & PROGRESSIVE DIE Name: Tanveer Iqbal
Tool& Mould Design
the working of Progressive & Compound Die.
1. Understand the operation of dies __________________________

2. Understand that which types of job to __________________________
be completed

Introduction PROGRESSIVE DIE.

Dies are classified by the types of operation Progressive die performs two or more
performed and by type of construction. operations at different station/stages
every time the ram descends.
Compound die
Compound die performs two or more
cutting operations during one stroke of
Drawing die the press at one station.
Drawing is the name given to production

Inverted dies of cups shells boxes and similar acticles.
Die is mounted on the Punch side &
Punches mounted on die.
55
Compound Die:
What is the main difference of compound & Progressive dies?
__________________________________________________

Make a neat sketch on your note book of Compound & Progressive
die & label its point.

__________________________________________________
__________________________________________________

_____________________________________________________
56
LESSON PLAN
TITLE OF TOPIC (Short, Description) Lesson No: 5.1, 5.2 & 5.3
Sheet Metal Dies Name: Tanveer Iqbal
Tool& Mould Design
1. __________________________
2. __________________________
3. __________________________
4. __________________________

Explain: Blanking, Piercing, Progressive and-  Sources & deweks,

--- dies.  Die Block Design.
 Punch Design.
 Punch mounted in Punch Plate.
Blanking and Piercing Die Design.  Punch Shedders.
(Die Design Fundamentals)  Strippe and Pressure Pads
 Pilot Punches.
 Strips play out
57
What is the difference between blanking die & piercing die?
__________________________________________________
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
58
LESSON PLAN

Inverted bending &Forming Dies Name: Tanveer Iqbal
Tool& Mould Design
1. __________________________
2. __________________________
3. __________________________
4. __________________________

Explain
Bending die
Inverted Die
Forming Die
59
What is Inverted Die?
__________________________________________________

Make the neat sketch of Inverted Die
_______________________________________________

__________________________________________________
__________________________________________________

_________________
_____________________________________________________
60
LESSON PLAN

Enlist Material Used For Dies Name: Tanveer Iqbal
Tool& Mould Design
Student will be able to understand the different
types of material used for die making.
1. Understand the different alloying __________________________

elements used in die making
2. _________________ __________________________
3. _________________ __________________________

Enlist The Material Used For Punches
Types Of Tool Type Of Steel % age Composition
Blanking Die Cobalt, Chromium Alloy 1.3 C, 13.0 Cr, 0.5 Mo, 3.0 Co.
Blanking Punch Manganese-Chromium 1.0 C, 0.5 W, 0.8 Cr, 0.9 MN.
Coining Dies Carbon 1.05-1.2 C.
Perforating Die Manganese-Chromium As for blanking die.
Piercing Dies Tungsten-Chromium 0.3 C, 10.0 W, 3.0 Cr.
Drop Forging Dies Nickel-Chromium 0.25 C, 0.8 Cr, 0.54 Mo.

moludonium
61
Explain the different types of alloying element used in steel____
__________________________________________________

Enlist different alloying element used in steel with percentage of
Composition_______________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
62
LESSON PLAN

Die Casting (Introduction To Die Casting) Name: Tanveer Iqbal
Tool& Mould Design
Die casting and it’s stages
1. Understand the pressure die casting __________________________

2. Understand die casting machine __________________________
3. Understand working of die casting __________________________
machine

Pressure Die Casting Machine The machine consists of mainly two
plates where the die can be mounted
vertical or horizontal position.
Hot chamber die casting machine Only metal with low melting points like
zinc, tin and load can be casted.
Only metals with higher melting
temperature such as aluminum,
magnesium and copper can be casted.
Cold chamber die casting machine
63
Hydraulic or pneumatic pumping system
Pumping System can be placed in the machine.
Which type of metal can be casted in H.C.M/C and COC Machine.
__________________________________________________

Make a neat sketch of H.C.C.C.M/C.________________________
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
64
LESSON PLAN

Outline Of Die Casting Name: Tanveer Iqbal
Tool& Mould Design
1. _________________ __________________________
2. _________________ __________________________
3. _________________ __________________________

1. Gate location & size Gate is an entrance of inject molten
2. Vents metal to flow in to the die cavity.
3. Runners Air vents may be called gas vents.
4. Riser Exhaust passage made in the mold.
5. Minimum section of thickener
6. Design cored and it’s types
7. Draft requirements
8. Core slide
9. Die material
65
Explain vents and why it is necessary._____________________
__________________________________________________

__________________________________________________
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
66
LESSON PLAN

State SAE-AISI Name: Tanveer Iqbal
Tool& Mould Design
Student will be able to understand the steel
Used in ______and its making
1. Understand the SAE __________________________

2. AISI, Steel __________________________
3. Heat treatment for tool steel __________________________

SAE & AISI STEEL.
SAE was firstly introduced by the auto
motive industry and being used by them. S.A.E
After the usefulness, this system has been Society of Automotive Engineers
adopted by other industries. This system of
steel is adopted by the number show the
chemical composition of steel. AISI
American Iron and Steel Institute.
67
Describe S.A.E & AISI Steel.
For the number of five digits, the 2nd and 3rd
number from left side, and for number of
four digits only, 2nd number from left side
shows the percentage alloy in steel and the
last two number shows the percentage of
carbon in steel.
What do you understand by S.A.E & AISI?____________________
__________________________________________________

__________________________________________________
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
68
LESSON PLAN

Chemical Composition of S.A.E and AISI Steel. Name: Tanveer Iqbal
Tool& Mould Design
Student will be able to understand the chemical
Composition of steel used in tool making.
1. Know the S.A.E classification __________________________

2. Know the alloying Element __________________________
3. Know the digit and indicate for the __________________________
chemical composition

Chemical Composition
1. Carbon steel
2. Nickel steel
3. Nickel chromium steel
4. Molybdenum steel
5. Chromium steel Ex No,
6. Chromium vanadium steel S.A.E 3415
7. Tungsten steel 3-nickel Chromium Steel
8. Silicon steel 4-Percentage of nickel chromium steel
9. Silicon manganese steel 15% of Carbon
69
Exercise No. 1
S.A.E 3415
3-for nickel steel
4-is percentage of nickel
15% of carbon 0.15
Exercise No. 2
X3140
X is used for slightly less or more quantity
of nickel-chromium.
3-is used for nickel chromium steel
1-is percentage of nickel chromium steel
40-is percentage of carbon. 40%
What are the meanings of S.A.E and AISI steel?________________
__________________________________________________

S.A.E 3147, S.A.E 1095, S.A.E 2145____________________
_______________________________________________

Chalk, Black Board and Chart________________________
__________________________________________________

_____________________________________________________
70
LESSON PLAN

DIN and B.S.S Standards Name: Tanveer Iqbal
Tool& Mould Design
Function of DIN and B.S.S standards.
1. Understand the Quality Assurance __________________________

2. Understand the Standardization __________________________
3. _________________ __________________________

INTRODUCTION. Definition.
DIN Standard A technical scientific society, Duetschus
Institute of Normeng engages in
standardization activities that advance
rationalization quality assurance,
environmental protection, safety and
communication in industries, technology,
science, government and the public
domain recognized by the German
B.S.S Standards. Federal Government as Germany’s
rational standard body.
71
German Institute for Standardization
(DIN) was founded on 18th May, 1917.
B.S.S Standard.
British standards are standards produced
by B.S.I group, which is formerly
designated as National Standard Body
(N.S.B) for U.K.
What does DIN stands for? ____________________
What does B.S.S stands for? _______________________

__________________________________________________
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
72
LESSON PLAN

Method of Molding Name: Tanveer Iqbal
Subject (Course Title): MECH-353 Time: 2 Hours
Tool& Mould Design
Method of molding
1. Understand Compression Molding __________________________

2. Understand Blow Molding __________________________
3. Understand Vaccum Molding __________________________

50 Injection Molding Injection molding:
Minutes Compression Molding is a manufacturing
Vacuum molding process for producing parts from both
Extrusion Molding thermo plastic thermoetling plastic
Blow Molding materials. Material is feed in to a heated
barrel, mixed and forced in to a mold
cavity.
Compression molding:
is a method of
molding material generally pre-heated
pressure is applied to force the material
in to contact with all mold areas , while
heat and pressure are maintained until
the molding material has cured.
73
Extrusion Molding. Vaccum Molding.
Polymer granulars are A plastic sheet is heated
placed in a feed hopper, heated to a molten until soft and pulled by a vaccum to form
state and injected at high pressure through a around a cold mold cavity; the sheet is
die with a specific profile to give a uniform allowed to cool and removed.
cross section and cools as it leaves the die Polyvinyl Chloride (PVC)
cavity. Polyethylene (PE), Polypropylene (PP)
Blow Molding.
A hollero plastic tube is
extruded in to two halves of a shaped mold,
which is seated at both ends and hot air is
injected until uniform contact of the inside
mold is made the component is allowed to
cool and removed
Define the method of molding_______________________
__________________________________________________

__________________________________________________
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
74
LESSON PLAN

Injection Molding Machine Name: Tanveer Iqbal
Tool& Mould Design
Functioning of Machine
1. _________________ __________________________
2. _________________ __________________________
3. _________________ __________________________

Plastic Injection Molding Machine Screw Type.
There are several types of injection A screw type is superior in onelting
molding machine. They are classified in to plastic material compare to plunger.
plunger type and screw type.
The injection unit melts and injects the
plastic in to the mold. The claiming unit
provides the motion and force to open and
close the mold to keep the mold close
during the injection.
75
The two parts of injection molding
machine.
First is the injection and the other is
clamping unit.
What is difference between screw type and plunger type______
__________________________________________________
Special Assignment: - (Usually home work)

Make a neat sketch of screw type injection molding machine___
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
76
LESSON PLAN

Types of Plastic Name: Tanveer Iqbal
Tool& Mould Design
1. _________________ __________________________
2. _________________ __________________________
3. _________________ __________________________

PLASTIC. Natural Resin
The word “Plastic” is originated Synthetic Plastic Resin
from English adjective “Plastic”, which
means formative. There are similar
terminologies around plastic that can be Thermostat resin Thermoplastic Resin
classified as follows.
Plastics are defined as macro molecular
substances having plasticity.
77
Plasticity is the property of material which 1. Thermo Plastic
permits it to undergo a permanent change 2. Thermoset Resin
without fracture.
Stages of Injection Molding.

 Melting
 Injection
 Solidification
 Ejection
Define plastic and its types_______________________________
How many types of Plastic? ____________________

__________________________________________________
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
78
LESSON PLAN
TITLE OF TOPIC (Short, Description) Lesson No: 9

Mould and Design Name: Tanveer Iqbal
Subject (Course Title): MECH-353 Time: 12 Hours
Tool& Mould Design
Design steps ------for design of a mold.
1. Understand the function of a mold __________________________

2. Understand the material to be used __________________________
3. _________________ __________________________

Outline Design of Injection Mold. Steps involved in designing of plastic
injection mold.
1. Basic mold structure
2. Standard parts Figures.
3. Gate and runner
4. Ejection method
5. Parting line
6. Draft angle
7. Mold shrinkage
8. Air vent
9. Mold cooling
10. Strength and fasting molecule
11. Cycle of injection molding
12. Heating mechanism
79
Figures.
What is air vent mold structure and standard parts?__________
__________________________________________________

Write in you note with neat sketches____________________
_______________________________________________

__________________________________________________
__________________________________________________

_____________________________________________________
80
Tool and Mould Design
Part-II
Operation Sheets
Table of Contents
Draw Standard Parts used in Jigs & Fixtures 1
Draw different types of clamps 3
Draw Locators 5
Draw template and plate type drill jigs 7
Draw the Swinging Lead Drill Jig 9
Draw and Indexing Jig 11
Draw Angle Milling Fixture 13
Draw Lathe Fixture for turning & boring operation 15
Draw Simple blanking die for making of blank f40 mm 17
Draw a Progressive die for making a washer of inner f 20 mm & Outer f 40 mm 19
Draw a simple drawing die for making a cup of inner 21
Draw the sketch of Injection Molding Machine 23
Assembling and disassembling of simple Mould 27
Design on Injection mold of a Mobile top by 3-D CAD 29

Operation Sheet No -1
Operation /job: - Draw Standard Parts used in Jigs & Fixtures Name: - Tanveer Iqbal
Subject: - Tool & Mould Design (MECH-353) Technology: Mechanical
Objectives: - The students will be able to know the standard parts, Time & Date
measurements, sizes, identification and uses of standard parts.
Introduction, Preparation & Motivation: -
Standard parts are used for assembly of different parts.
Machines/Equipment/ Tools/ Materials: -
1. Drawing Instruments complete
2. Drawing Table
3. Drawing Sheet
Steps/Procedure/method Key Points/Precautions For Skillful Performance
1. Follow the Drawing rules for draw the sketch. 1) Draw standard sketch of Hex, Nut & Bolt.
2. Place the drawing sheet on the top of drawing 2) Draw standard screws, (counter sinking cap,
table with T-Square. socket head screws).
3. Use the set squares while Draw the sketch. 3) Draw standard sketch of different types of
washers 1- Plain, spring and C-type washer.
Application and Try out: Why we use the standard parts for assembly.
Safety Precautions / Care:
 Always use T-square to set sheets.

 Use the proper pencils grade.
 Use templates for complicated figures.
1
Special Assignment: Sketch the given diagram
Drawing/Diagram/Sketch:
References:
Tool design by Donaldson (Third Edition)
2
Operation /job: - Draw different types of clamps. Name: - Tanveer Iqbal

Objectives: - The students will be able to understand Time & Date
The types of clamps and their uses in Jigs & fixtures.
Clamps are used for quick hold of work pieces in production field for saving of time.
2. Drawing Table
3. Drawing Sheet
1. Follow the Drawing rules for draw the sketch. 1. Draw the meat sketch of clamps.
 Latch clamp
 Hook clamp
2. Place the drawing sheet on the top of drawing  Eye – bolt
table with T-Square.  Plain wedge clamp
 Conical Clamp
 Direct Pressure clamp
3. Use the set squares while Draw the sketch.  Cam and Adjustable strap clamp
Application and Try out: Why we use the quick acting clamps.

3
References:
Tool design by Donaldson
4
Operation /job: - Draw Locators Name: - Tanveer Iqbal

Used of locator in Jigs & Fixtures.
Locators are used for the location of work piece in Jigs.
2. Drawing Table
3. Drawing Sheet
1. Follow the Drawing rules for draw the sketch. 1. Draw the neat sketch of pin & button
locators.
2. Place the drawing sheet on the top of drawing 2. Draw the neat sketch of pad and plates.
table with T-Square.
3. Draw nest or cavity location.
3. Use the set squares while Draw the sketch. 4. Draw Jig feet, Jig legs.
Application and Try out: Explain the types of locators and why it is used.

5
References:
6
Operation /job: - Draw template and plate type drill jigs Name: - Tanveer Iqbal
The use of plate and template type drill jigs.
Template type Jigs like the same size and shape of work piece.
2. Drawing Table
3. Drawing Sheet
1. Follow the Drawing rules for draw the sketch. 1. Draw the neat sketch of work piece.
2. Place the drawing sheet on the top of drawing 2. Draw the neat sketch of plate and template jigs.
3. Use the set squares while Draw the sketch.
Application and Try out: Define the plate & template type of drill jigs.

7
References:
8
Operation /job: - Draw the Swinging Lead Drill Jig. Name: - Tanveer Iqbal
The function of leaf Jig during the production.
Swinging Leaf drill jig are used in production and easy to operate the leaf is swung upon the fulcrum.
2. Drawing Table
3. Drawing Sheet
1. Follow the Drawing rules for draw the sketch. 1. Draw the neat sketch of work piece to be drill.
2. Draw the body of jig as per given drawing of work

2. Place the drawing sheet on the top of drawing piece.
3. Draw the suitable clamps and locators.
3. Use the set squares while Draw the sketch. 4. Draw the neat sketch of suitable drill bushes.
5. Draw suitable jig feet.
Application and Try out: Why we use the production tools in production.

9
References:
10
Operation /job: - Draw and Indexing Jig. Name: - Tanveer Iqbal

Objectives: - Time & Date

2. Drawing Table
3. Drawing Sheet
1. Follow the Drawing rules for draw the sketch. 1. Draw the neat sketch of work piece to be drill
with suitable size.
2. Place the drawing sheet on the top of drawing 2. Draw the body sketch of jig as per given drawing
table with T-Square. of work piece.
3. Use the set squares while Draw the sketch. 3. Draw the sketch of suitable clamps and locators,
Drill bushes indexing mechanism and jig feet.
Application and Try out: Why we use indexing jig?

11
References:
12
Operation /job: - Draw Angle Milling Fixture. Name: - Tanveer Iqbal

The function of milling fixture.
Angle milling fixtures are used to mill the top surface of round block.
2. Drawing Table
3. Drawing Sheet
1. Follow the Drawing rules for draw the sketch. 1. Draw the neat sketch of work piece to be milled.
2. Draw the main parts, the base, clamps, rest

2. Place the drawing sheet on the top of drawing blocks, locating points and gauging surface.
3. Assemble the main parts with work piece.

Application and Try out: Define fixtures and why it is used.

13
References:
14
Operation /job: - Draw Lathe Fixture for turning & boring operation Name: - Tanveer Iqbal
The holding of irregular shape of work piece for turning and boring operations.
Lathe turning fixtures are designed for holding of odd shape work piece.
2. Drawing Table
3. Drawing Sheet
1. Follow the Drawing rules for draw the sketch. 1. Draw the work piece to be turned and borded.
2. Draw sketch of turning fixture and boring fixture.

2. Place the drawing sheet on the top of drawing
3. Draw Holding Machine on lathe spindle.
Application and Try out: Define turning lathe fixture.

15
References:
16
Operation /job: - Draw Simple blanking die for making of blank f40 mm Name: - Tanveer Iqbal
Objectives: - The students will be able to calculate Time & Date
the punch after considering the elastic recovery of Material.
In blanking operation the Blank will expand after operation in size due to elastic recovery.
2. Drawing Table
3. Drawing Sheet
1. Follow the Drawing rules for draw the sketch. 1. Draw the strip layout design for blank position.
2. Calculate the punch and die opening size
considering the elastic recovery of material.
2. Place the drawing sheet on the top of drawing 3. Select the material for blank.
table with T-Square. 4. In case of soft steel 5% of t.
5. Clearance 5% of t x 2.
6. Deduct the size clearance from the punch size
3. Use the set squares while Draw the sketch. punch sise-2c.
Application and Try out: What is the elastic recovery of the material?

17
References:
18
Operation /job: - Draw a Progressive die for making a washer of inner f 20 mm & Outer f 40 mm
Name: - Tanveer Iqbal
The step for making washer from two steps.
Progressive die also called follow on die two operations will be completed at one station.
2. Drawing Table
3. Drawing Sheet
1. Follow the Drawing rules for draw the sketch. 1. Draw the piercing and blanking strip layout
design.
2. Place the drawing sheet on the top of drawing 2. Calculate the size of punch & die opening.
3. Use the set squares while Draw the sketch. 3. Draw the Pilot punch as per true size of piercing
punch.
Application and Try out: What is progressive die?

19
References:
20
Operation /job: - Draw a simple drawing die for making a cup of inner f40mm depth 30mm from 1
mm thick sheet. Name: - Tanveer Iqbal
The drawing operation.
Drawing operation is a non-cutting operation only draws the sheet metal to the desired shape.
2. Drawing Table
3. Drawing Sheet
1. Follow the Drawing rules for draw the sketch. 1. Draw the work piece to be draw.
2. Draw the single action draw die with spring

2. Place the drawing sheet on the top of drawing loaded knock out.
3. Calculate the % reduction and depth of draw.
3. Use the set squares while Draw the sketch. 4. Calculate the blank size.
5. Calculate the drawing force.
Application and Try out: What is drawing operation?

21
References:
22
Operation /job: - Draw the sketch of Injection Molding Machine. Name: - Tanveer Iqbal
The method of injection molding.
Injection molding method is to inject. The molten metal is pressure into the die.
2. Drawing Table
3. Drawing Sheet
1. Follow the Drawing rules for draw the sketch. 1. Draw the neat sketch of Injection Molding
Machine according to the given drawing.

Application and Try out: What is the method of Inject the molten metal into the die?

23
24
25
References:
26
Operation /job: - Assembling and disassembling of simple Mould. Name: - Tanveer Iqbal
The mold assembling and disassembling after the completion of cycle.
Molds are used for casting according to the mold cavity. The cavity is poured by means of sprue and
runners.
2. Drawing Table
3. Drawing Sheet
1. Follow the Drawing rules for draw the sketch. 1. Draw the neat sketch of press Mold.
2. Casting mold.
table with T-Square. 3. Blow mold.
4. Die casting mold

Application and Try out:

27
Blow Molding
References:
Tool design by Donaldson Edition
28
Operation /job: - Design on Injection mold of a Mobile top by 3-D CAD. Name: - Tanveer Iqbal
Objectives: - The students will be able to get the skill on 3 D CAD. Time & Date

2. Drawing Table
3. Drawing Sheet
1. Follow the Drawing rules for draw the sketch. 1. Work piece (create the core and cavity).
2. Generating the core and cavity.
3. Specifying the gate location.
2. Place the drawing sheet on the top of drawing 4. Sketching the runner system.
table with T-Square. 5. Creating a runner.
6. Creating a gate.
7. Creating the mold base.
3. Use the set squares while Draw the sketch. 8. Insert the ejector pins.
9. Creating the sprue bushing.
10. Creating the cooling channel.
11. Adding the cooling component.
Application and Try out:

29
References:
30

6-10 Tool and Mould Design

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

6-10 Tool and Mould Design

Uploaded by

Copyright:

Available Formats

Tool and Mould Design

Jigs & Fixtures Classification/Types 1

TITLE OF TOPIC (Short, Description) Lesson No: 01-A

1. Understand the classification of Jigs & __________________________

4. Understand the parts of Jigs & clamping __________________________

Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch

General Concept: Jigs & fixtures are special purpose tools

Distinguish between Jigs and fixtures

Special Assignment:- (Usually home work)

Tools Material & Aids:-

Reference:- (Author, title, publisher, page or chapter number, date of publication)

TITLE OF TOPIC (Short, Description) Lesson No: 01-B

1. Understanding the classification of Jigs __________________________

4. Understanding the parts of Jigs & __________________________

Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch

Special Assignment:- (Usually home work)

Tools Material & Aids:-

Reference:- (Author, title, publisher, page or chapter number, date of publication)

TITLE OF TOPIC (Short, Description) Lesson No: 02-A

Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch

Design principles common to jigs & fixtures. Fool Proofing

The total machining time for a work piece Clearance

Special Assignment:- (Usually home work)

Tools Material & Aids:-

Reference:- (Author, title, publisher, page or chapter number, date of publication)

TITLE OF TOPIC (Short, Description) Lesson No: 02-B

1. Understand the method of clamping __________________________

Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch

2. Quick acting net (clamps)

Special Assignment:- (Usually home work)

Tools Material & Aids:-

Reference:- (Author, title, publisher, page or chapter number, date of publication)

TITLE OF TOPIC (Short, Description) Lesson No: 02-B

SPECIFIC OBJECTIVES:- Expected Entry behaviors

1. Understand the different parts __________________________

Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch

Different types of stand parts.

Types of Jigs & fixtures. Plate type, template type.

Swinging leaf jig.

Special Assignment:- (Usually home work)

Tools Material & Aids:-

Reference:- (Author, title, publisher, page or chapter number, date of publication)

TITLE OF TOPIC (Short, Description) Lesson No:

SPECIFIC OBJECTIVES:- Expected Entry behaviors

Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch

Vise fixtures. Holding record:

Special Assignment:- (Usually home work)

Tools Material & Aids:-

Reference:- (Author, title, publisher, page or chapter number, date of publication)

TITLE OF TOPIC (Short, Description) Lesson No: 03

1. Understand the Properties of Material __________________________

Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch

Introduction about the material

H.S.S. Die steel, Die steel,

 Dill bushes – carbon steel

Special Assignment:- (Usually home work)

Tools Material & Aids:-

Reference:- (Author, title, publisher, page or chapter number, date of publication)

TITLE OF TOPIC (Short, Description) Lesson No:

1. Understand the movement of work piec __________________________

Time TOPICS,NOTES (Brief) Key points/Reminders/Sketch

Principles of locations When we want to stop the movements

Xx, yy, zz – 6 movements. Rotation of

Explain 3:2:1 Location Stop the movement of horizontal plan xx