Tooling

Factors that affect the TOOL DESIGN:

● Position And Profile of the engineering assembly.

● Sequence of the engineering parts loading and fixing.(Assembly build

sequence).
● Tolerances of the engineering. Tool tolerance will be 1/3 of
engineering.
● Manufacturability of the TOOL parts and Assembly.

● Ed- Edge distances of holes.

● Indexing area or feature of engineering.

Considerations:

● Edge Distances Will be 1- 1.5D it may vary at high amount of load

acting areas.
● Try to design the Tool Which contain the Components like L-Angles,
Plates, Shafts, gussets plates, rectangular pipes,
● Thickness of these will be 8-12mm for smaller tools for larger once it
may vary from 8mm to 30mm.
PROCESS (Design gates):

● ICR , FDR, DDR, FRD, DCR.

 ● ICR- Initial concept review
in this Review basic concept of Tool 3D model will be made and
Reviewed in the presence of Manufacturing & Production teams.
● FDR-Functional design review.
In FDR Freeze the Design and finalize the 3D Model.
● DDR-Detail design review
Drawing will be reviewed here
● FRD-Fabrication ready design review
Design will be checked for fabrication Challenges.

● DCR-Design completion Release.

Final check for the entire Design & drawing before Releasing for
Manufacturing.

TOOL CODES: ()

DJ- drill jig

LJ- Locating jig
RF-Routing fixture
HF-Holding fixture
FME-Floor mounting equipment
ME-mechanical equipment
JDT-jig drill template
OHME-Over head mechanical equipment.
PME-portable mechanical equipment

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MIT-Miscellaneous tool.
FAJ-Final Assembly jig.
HF-Holding fixture.
CF-Check fixture
MDT- Marking drill template
JDT- Jig drill template

Indexing :

● Identify the index surface as per

● This should be tightly controlled on engineering because it will directly

affect the final hole position on engineering which we are drilling with
our tool.
● Indexing area or feature can be:
Tooling hole -TH
Coordinate pilot hole-CPH
Pilot hole if it is tightly controlled on engineering
Engineering part surface. If it is tightly controlled.

● In case of using engineering part surface as indexing it should be

tightly controlled.
● Our tool should index with only one engineering part surface.

● If it is indexing on two different engineering part surfaces there may

be ups and downs in the engineering assy after manufacturing(With in
the tolerance) so our tool will not fit properly.
● U can index at two different areas of a same engineering part surface.

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 ● Try to controls the tool with engineering drawing dimension ref.

Standard Tooling parts:

Pins
Clamps
C-clamps
Toggle clamps

Cleco
Side grip clamps
Super side grip clamps.
Bushes
Spoon bushes
Clevis
Bullet nose pin
Nut Plate Jigs
www.Carrlane.com

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www.McMaster.com
In.misumi
Www.skf bearing. Com

These websites will provide the information about these standard parts.
Removable Set up:

● As name suggest the Set up will be Removable. Every time when we

load and remove the tool this setup will be removed from the whole
tool Assy.
● In this two L-Pins And Two Screws will be used for joining the
components.
● Instead of L-pins some cases Bullet nose pins can also be used.

● In this case the L-pin holes will be transferred on assy of tool.

● On top L-angle shown below image two clearance holes will be there,
where the screws will be used.
● On bottom plates threaded holes need to be tapped.

● Screws will hold two parts together and L-Pins align the parts at same
position every time when we assemble the components together.

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 ● L-pins Available in Misumi website

● Hexagon Socket head cap screws catalog

● Liner bushes carrlane

Fixed setup:

● Set up will be fixed in this case we are not going to disassemble the set
up every time when loading and removing the Tool.
● In this two dowel pins And Two Screws will be used for joining the
components.
● Dowel holes will be transferred on assembly of tool.

● On top L-angle shown below image two clearance holes will be there,
where the screws will be used.
● On bottom plates threaded holes need to be tapped.

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 ● Screws will hold two parts together and dowels align the parts at same
position every time when we assemble the components together.
● Tools will be inspected for every six months may be at that time they
will disassemble the parts.

Dowels – Catalog

● Dowels should be located on Extreme ends always.

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Why we need to use two screws and two dowels why not four screws or
four dowels:

● While using the screws, on bottom plate threaded hole will be Tapped
and on top plate clearance hole will be drilled so there may be
chances to movement of top plate with in that clearance that leads to
the shifting of holes which we need to drill on engineering parts.
● If we use all four dowels for fixed set up or four L- pins for removable
set up, Alignment of the parts will be good but there is nothing to hold
the parts together, so there are chances of getting disassemble the
components while using.

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While creating Drawing for these:

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 ● In all the cases alignment holes Should be transferred on Assembly.

Dowel and L-pin Alignment holes need to drill in Assembly both the parts or
we can drill in one part at detail level.

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Step Drilling of holes :
Drilling the final size hole by using spoon Bush of different sizes from under
size (USDA) to final size (FSDA). For every 0.05” increase in diameter need to
have step while drilling.
0.098 -0.103" (#40)
0.159-0.165”
0.190-0.196”
0.218-0.229”
0.250-0.254”
Why we need to go for Step Drilling:

● Material removable rate & Applied Force will be less So final hole will
be with good finishing.
● If we are going for the final size directly there may be chances of
damaging engineering parts by applying unnecessary force to drill.
● Factors need to consider:
a. Thickness need to be drill Through(Stack
up)
b. Material
c. Location
d. Hole count

Spoon bush:

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EX: need to drill .247-.250 Hole
Hole will be drilled to the MMC Size So hole need to be enlarged to .247”
need to select from standard drill size chart.
For under sizes spoon bushes will be made in Local Shop Floor Design is in
Above picture.

● Steps need to be considered like.

● Standard Drill size chart will be available on Google We can select the
Steps From chart.
● If incase the steps need to be drill are more we can avoid few steps by
considering the production department comments.

#10 - .1935
15/64 - .2344
customized - .247 (Reaming)
Final size :
● .247 will be drilled with the Standard Spoon bushes which are bought
from Carrlane or UDB(united drill bushings) because these are very
hard and preside so wear and tear problem will be less.
● Final size will like finishing operation so material removal rate will be
0.015 not more than that.

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 ● For .247 size standard drill size not available so drill bit will be
customized Locally in these type of cases.

Drilling we can jump up to .06”

Reaming material removal rate .015-.025

UDB United drill bushes:

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 ● For example we have to drill the hole size .191

● Go to the above chart it will come in the range of .1250-.1935 length u

can select from the 5/16 to 1” if incase we need more length we can
go to the carrlane there more than 1” length bushes are available.
● OD of our Spoon bush will be 5/16

● So this OD Will be the ID of our bush which we are inserting in the Drill
Plate.

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Drill template:
Just a plate with drill bushes.
These plates will locate w.r.t the CPH holes on engineering. And transfer the
holes.

● For the templates indexing area will be contour Split. Protrusion of the
bushes will not be allowed on that side.
● All bushes will be press fitted into The drill plate so that it will not
come out when we are using the tool.

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● For locating of templates need to use the CPH Holes on Engineering so
provide one Slotted bush and one Collar bush with the size of CPH Hole
on template.
● One side slotted bush provided because to avoid misalignments while
loading the tools.

Flatness value to controls

Perpendicularity value
JIGS & FIXTURES
OTP POINTS
TOOLS ASSEMBLY

https://mrotools.com/

Cleco:
Temporary fasteners used to hold the parts mainly in Assembly line.

● Cleco Fasteners are color coded for easy identification.

● Grip length will vary.

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 Colour PIN Diameter
Brass #10 3/16
Black #20 5/32
Black #21 5/32
Copper #30 1/8
Purple Zinc , Silver #40 3/32

Plier Operated Cleco Fasteners:

● spring-loaded and steel bodied fasteners are dedicated to light

clamping forces. (No more than 25lbs.) 
● alternative to competitive fasteners.

● are a simple, plier-actuated, inexpensive.

● Required to add more because of less Clamping Force

Wing Nut Cleco Fasteners:

Cylindrical Body Cleco Fasteners:

The double lead thread design further enhances overall installation
and removal efficiency.

Side grip Clamps:

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Super Side grip Clamps:
The Super Side Grip® with a closed force of 55 pounds and a
maximum force over 100 pounds, provides 70% more clamping power
than conventional side grip clamps

Nut plate Jigs:

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Tool identification spec
Tool design document
Paint
–chem mill spec
– Signal blue
– Yellow
These colors are used to Differentiate the LH & RH (FOOL PROOFING)
ECCN- Export control classification number.
EAR – Export administration regulations.
NLR-No license required.
Standard notes-

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details numbering
drawing code symbols
material listing ordering
table contents and index.

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