DIPLOMA IN
TOOL
ENGINEERING &
DIGITAL
MANUFACTURING
CP01
SEMESTER 3
TOOL DESIGN DRAWING -WORK
INSTRUCTION
Manu George
SME: Mr. Guna Singh
Prepared by: Mr. Guna Singh
Verified by: Mr. Jayaraj B
Rev No : 0
Released Date: 02/01/2020
NTTF_DIPLOMA IN TOOL AND DIEMAKING_TOOL DESIGN DRAWING_SEM III_JUNE 2019
TABLE OF CONTENTS
1.0 DESIGN OF FIXTURES .............................................................................................................................. 2
1.1 Design of turning fixture ..................................................................................................................... 2
1.2 Design of milling fixture ...................................................................................................................... 3
1.3 Design of grinding fixture .................................................................................................................... 4
2.0 DESIGN OF JIGS ....................................................................................................................................... 5
2.1 Design of plate jig................................................................................................................................ 5
2.2 Design of box jig .................................................................................................................................. 6
2.3 Design of Angle Plate jig...................................................................................................................... 7
2.4 Design of indexing jig .......................................................................................................................... 8
3.0 DESIGN OF GUIDE PLATE TOOL ............................................................................................................ 10
3.1 Design of a single stage guide plate tool .......................................................................................... 11
3.2 Design of three stage guide plate tool .............................................................................................. 12
4.0 BLANKING TOOL WITH DIE SET ............................................................................................................ 13
4.1 Design of a 3 stage progressive tool with die set ............................................................................. 13
5.0 DESIGN OF PROGRESSIVE TOOL ........................................................................................................... 15
5.1 Progressive press tool design practice using 14 steps of press tool design ..................................... 15
5.2 Design of multi-stage progressive tool ............................................................................................. 16
5.2.1 .........................Design of multi-stage progressive tool incorporating one or more of the following
................................................................................................................................................................ 16
5.2.2 Design of multi-stage progressive tool incorporating one or more of the following features...... 17
5.2.3 ......... Design of multi-stage progressive tool incorporating one or more of the following features.
................................................................................................................................................................ 18
5.2.4 ......... Design of multi-stage progressive tool incorporating one or more of the following features.
................................................................................................................................................................ 19
NTTF_CP01 _TOOL DESIGN DRAWING_SEM III_JUNE 2020 Page 1
1.0 DESIGN OF FIXTURES
1.1 Design of turning fixture
Design a turning fixture for the component given below:
Objective:-
To design a turning fixture to perform the eccentric turning operation
Work instructions:-
1. Take a A3 size graph sheet (5mm square grid)
2. Study the part drawing carefully and get the necessary input about the machine; in
which the operation has to be performed
3. Decide proper location of the component inside the fixture; by arresting all possible
degrees of freedom
4. Check for any Poka-Yoke system that can be implemented
5. Design proper clamping methods/system which will suit the machining
6. Ensure the rigidity of clamps during machining
7. Provide necessary supporting features if required.
8. Design a base plate according to the required size.
9. Check whether the necessary design requirements for a turning fixture is met
10. Design a setting block for the fixture
11. Prepare the bill of material
12. Check the assembly using standard checklist if available
13. Make a solid model using Cad software in cad cam class.
NTTF_CP01 _TOOL DESIGN DRAWING_SEM III_JUNE 2020 Page 2
1.2 Design of milling fixture
Design a milling fixture for the component given below
Objective:-
To design a milling fixture to maintain the slot dimensions 10+0.018 as per the drawing
Work instructions:-
1. Take a A3 size graph sheet (5mm square grid)
2. Study the part drawing carefully and get the necessary input about the machine; in
which the operation has to be performed
3. Decide proper location of the component inside the fixture; by arresting all possible
degrees of freedom(DOF)
4. Check for any Poka-Yoke system can be implemented
5. Design proper clamping methods/system which will suit the machining
6. Ensure the rigidity of clamps during machining
7. Provide necessary supporting features if required
8. Decide proper base plate construction
9. Design a setting block for the fixture
10. Check whether the necessary design requirements for milling fixture is met
11. Prepare the bill of material
12. Prepare the necessary notes and machining details for each component
13. Check the assembly using standard checklist; if available
14. Submit the design for approval and necessary feed back
NTTF_CP01 _TOOL DESIGN DRAWING_SEM III_JUNE 2020 Page 3
15. Make a solid model using Cad software in cad cam class.
1.3 Design of grinding fixture
Design a grinding fixture for grinding 33˚ as per the component drawing given below
Objective:-
To design a grinding fixture maintaining dimensions as per the above drawing
Work instructions:-
1. Take a A3 size graph sheet (5mm square grid)
2. Study the part drawing carefully and get the necessary input about the machine; in
which the operation has to be performed
3. Decide an error proofing location of the component by arresting all DOF
4. Design proper clamping methods/system which will suit the machining
5. Ensure the rigidity of clamps during machining
6. Provide necessary supporting features if required
7. Decide proper base plate construction
8. Design also setting block for the fixture
9. Check whether the necessary design requirements for grinding fixture is met
10. Prepare the bill of material
11. Prepare the necessary notes and machining details for each component
12. Check the assembly using standard checklist; if available
13. Submit the design for approval and necessary feed back
14. Make a solid model using Cad software in cad cam class.
NTTF_CP01 _TOOL DESIGN DRAWING_SEM III_JUNE 2020 Page 4
2.0 DESIGN OF JIGS
2.1 Design of plate jig
Design a plate jig for drilling Ø5.0 (2X) as per the component drawing given below
Objective:-
To design a plate jig for drilling Ø5.0 (2X), maintaining dimensions as per given drawing
Work instructions:-
1. Take a A3 size graph sheet (5mm square grid).
2. Study the drawing carefully.
3. Decide an error proofing location of the component by arresting all DOF
4. Design proper clamping methods/system
5. Ensure the rigidity of clamps during drilling
6. Provide necessary supporting features if required
7. Check whether the necessary design requirements for drill jig is met
8. Prepare the bill of material (BOM)
9. Prepare the necessary notes and machining details for each component
10. Check the assembly using standard checklist; if available
11. Submit the design for approval and necessary feed back
12. Make a solid model using Cad software in cad cam class.
NTTF_CP01 _TOOL DESIGN DRAWING_SEM III_JUNE 2020 Page 5
2.2 Design of box jig
Design a box jig for drilling Ø5.0 (3X) as per the component drawing given below
Objective:-
To design a box jig for drilling 3 holes of Ø5.0 as per the given drawing
Work instructions:-
1 Take a A3 size graph sheet (5mm square grid).
2 Study the drawing carefully
3 Decide an error proofing location of the component by arresting all DOF
4 Check for easy loading and unloading of the component from jig
5 Design proper clamping system, ensure rigidity of clamps
6 Design provision for holding the jig
7 Provide feet to reduce the contact area to place on machine during drilling
8 Check the possibility of reducing the weight without affecting the strength
9 Check provision for chip removal
10 Loose components must be chained to the jig
11 Check whether the jig weight is balanced or not (min. over hanging)
12 Prepare the BOM and necessary notes and machining details
2 Submit the design for approval and necessary feed back
3 Make a solid model using Cad software in cad cam class.
NTTF_CP01 _TOOL DESIGN DRAWING_SEM III_JUNE 2020 Page 6
2.3 Design of Angle Plate jig
Design an Angle plate jig for drilling Ø8H8 as shown in the drawing
Objective:-
To design a Angle plate jig for drilling Ø8H8 hole as per the given drawing
Work instructions:-
1 Take a A3 size graph sheet (5mm square grid).
2 Study the drawing carefully
3 Decide an error proofing location of the component by arresting all DOF
4 Design the suitable locator to hold the component in position
5 Check for easy loading and unloading of the component from jig
6 Design proper clamping system, ensure rigidity of clamps
7 Design provision for holding the jig
8 Provide feet to reduce the contact area to place on machine during drilling
9 Check the possibility of reducing the weight without affecting the strength
10 Check provision for chip removal
11 Loose components must be chained to the jig
12 Check whether the jig weight is balanced or not (min. over hanging)
13 Check for other requirements for leaf jig as per the design check list
14 Prepare the BOM and necessary notes and machining details
2 Submit the design for approval and necessary feed back
3 Make a solid model using Cad software in cad cam class.
NTTF_CP01 _TOOL DESIGN DRAWING_SEM III_JUNE 2020 Page 7
2.4 Design of indexing jig
Design an indexing jig for drilling Ø12 (8X) as per the component drawing given below
Objective:-
To design an indexing jig for drilling Ø12 holes (8X) as per the given drawing
Work instructions:-
1 Take a A3 size graph sheet (5mm square grid).
2 Study the drawing carefully
3 Decide an error proofing location of the component by arresting all DOF
4 Design the suitable locator to hold the component in position
5 Check for easy loading and unloading of the component from jig
6 Design proper clamping system, ensure rigidity of clamps
7 Design provision for holding the jig using hand
8 Provide feet to reduce the contact area to place on machine during drilling
9 Check the possibility of reducing the weight without affecting the strength
10 Check provision for chip removal
11 Loose components must be chained to the jig
12 Check whether the jig weight is balanced or not (min. over hanging)
NTTF_CP01 _TOOL DESIGN DRAWING_SEM III_JUNE 2020 Page 8
13 Check for other requirements for indexing jig as per the design check list
14 Prepare the BOM and necessary notes and machining details
4 Submit the design for approval and necessary feed back
5 Make a solid model using Cad software in cad cam class.
NTTF_CP01 _TOOL DESIGN DRAWING_SEM III_JUNE 2020 Page 9
3.0 DESIGN OF GUIDE PLATE TOOL
Things to be considered while designing a press tool:-
Requirement of a Press Tool
Accuracy and finish
Productivity
Physical strength
Tensile strength
Compressive strength
Plate deflection
Wear resistance
Corrosion resistance
Error proofing or mistake proofing (Poka-Yoke)
Safety in operation
Maintenance & Interchangeability
Ease of installation in press machine
Reasonable tool cost
Technical terms in press working operations:
Shearing operations Non-shearing operations
Blanking Bending
Piercing Curling
Perforating Plunging or Flanging
Cutting off Embossing
Parting off Coining
Notching Bulging
Lancing Swaging or Necking
Louvering Drawing
Trimming
Shaving
NTTF_CP01 _TOOL DESIGN DRAWING_SEM III_JUNE 2020 Page 10
3.1 Design of a single stage guide plate tool
Design a single stage guide plate tool for the component given below
Objective:-
To design a guide plate tool for the given component
Work instructions:-
1 Study the drawing carefully
2 Draw in A3 Sheet minimum two strip layouts &calculate the economy factor
3 Choose the appropriate strip layout for starting the design (get the approval)
4 Calculate the clearance between punch & die.
5 Calculate the cutting force for the press tool
6 Calculate thickness for the die plate, determine length & width
7 Calculate thickness for other components (stripper plate, bottom plate etc)
8 Check for availability of suitable raw material sizes for each component
9 Design the punch and die profile incorporating the calculated clearance
10 Position the screw holes, dowel hole considering required strength of die plate
and punch
11 Design the stripper plate, bottom plate & shank
12 Prepare the assembly drawing and BOM
13 Check the drawing using design check list
14 Submit the drawing for approval
15 Update the necessary modifications and corrections
16 Make the detail of all individual components
17 Mention the necessary dimensional tolerance and machining symbols
18 Make a solid model using Cad software in cad cam class
NTTF_CP01 _TOOL DESIGN DRAWING_SEM III_JUNE 2020 Page 11
3.2 Design of three stage guide plate tool
Design a three stage progressive guide plate tool for the component given below
Objective:-
To design a 3 stage progressive guide plate tool for producing the component above
Work instructions:-
1 Study the drawing carefully
2 Draw in A3Sheet minimum three strip layouts and calculate the economy factor
3 Choose the most appropriate layout for starting the design
4 Calculate the clearance between punch & die
5 Calculate the cutting force for the press tool
6 Calculate thickness for the die plate, determine length & width
7 Calculate thickness for other components (stripper plate, bottom plate etc)
8 Design the punch and die profile incorporating the calculated clearance
9 Position the screw holes, dowel hole & stopper pin locations
10 Design the stripper plate, bottom plate, finger stopper, punch holder, top plate,
shank etc
11 Prepare the assembly drawing and BOM
12 Prepares necessary notes & details of machining if required
13 Check the drawing using design check list
14 Submit for approval& update the necessary modifications & corrections
15 Make the detail of all individual components, provide necessary GD&T, mention the
necessary dimensional tolerance and machining symbols
16 Make a solid model using Cad software in cad cam class.
NTTF_CP01 _TOOL DESIGN DRAWING_SEM III_JUNE 2020 Page 12
4.0BLANKING TOOL WITH DIE SET
4.1 Design of a 3 stage progressive tool with die set
Design a 3 stage progressive tool with die set, for the given component
Objective:-
To design a 3 stage progressive tool with die set for producing the component given
Work instructions:-
1 Study the drawing carefully
2 Draw minimum three strip layouts in A3 Sheet &calculate the economy factor
3 Study the specifications of the press machine and calculate shut height.
4 Choose the most appropriate strip layout for starting the design
5 Calculate the clearance between punch & die
6 Calculate the cutting force for the press tool
7 Calculate thickness for the die plate, determine length & width
8 Calculate thickness for other components (stripper plate, bottom plate etc)
9 Check for availability of suitable raw material sizes for each component
10 Design the punch and die profile incorporating the calculated clearance
11 Position the screw holes, dowel hole & stopper pin locations
12 Design the progressive tool with die set incorporating all standard elements
13 Prepare the assembly drawing and BOM
14 Prepares necessary notes & details of machining if required
15 Submit for approval& update the necessary modifications & corrections
16 Make the detail of all individual components, provide necessary GD&T, and mention
the necessary dimensional tolerance and machining symbols.
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17 Make a solid model using Cad software in cad cam class.
NTTF_CP01 _TOOL DESIGN DRAWING_SEM III_JUNE 2020 Page 14
5.0 DESIGN OF PROGRESSIVE TOOL
5.1 Progressive press tool design practice using 14 steps of press tool
design
Design a progressive press tool using 14 steps of press tool design:
Objective:-
To design a progressive press tool using 14 steps of die design
Work instructions:-
1 Study the drawing carefully
2 Prepare a Strip layout using A3 size graph sheet.
3 Draw minimum of three strip layouts to calculate the economy factor
4 Follow the 14 different steps involved in the press tool design.
5 Make a Assembly model in a A3 sheet.
6 Prepare Bill of materials and Check the drawing using design check list.
7 Draw detailed drawings of all individual elements, provide necessary GD&T, and
mention the necessary dimensional tolerance and machining symbols.
8 Check the drawing using design check list.
9 Submit for approval& update the necessary modifications & corrections
10 Prepare solid model of the tool in 3d software in cad cam class
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5.2 Design of multi-stage progressive tool
5.2.1 Design of multi-stage progressive tool incorporating one or more
of the following
Traveling Stripper with split dies
Cut –off punches with side cutter
Parting – off punches
Fixed stop / Trigger stop / Auxiliary stop
Objective:-
To design a multi-stage progressive press tool
Work instructions:-
1 Study the drawing carefully
2 Draw the strip layout in A3 size graph sheet and calculate the economy factor
3 Study the specifications of press machine
4 Calculate the cutting clearance, cutting force etc.
5 Calculate the thickness of different tool elements starting from die plate
6 Check the availability of raw material size with the calculated dimensions
7 Design the split die plate, cutting & non-cutting punches, pilots considering the
necessary clearance between die plate profile.
8 Design all the other elements including a travelling stripper.
9 Complete the design, prepare BOM and necessary notes if required
10 Verify the design using the press tool design check list
11 Submit the drawing for verification and get the necessary feed back
NTTF_CP01 _TOOL DESIGN DRAWING_SEM III_JUNE 2020 Page 16
12 Update the necessary corrections and prepare the raw material list
13 Make an Assembly Solid model in CAD Software in cad cam class.
5.2.2 Design of multi-stage progressive tool incorporating one or more
of the following features.
Traveling stripper with split dies
Cut –off punches with side cutter
Parting – off punches
Fixed stop / Trigger stop / Auxiliary stop
Objective:-
To design a multi-stage progressive press tool
Work instructions:-
1 Study the drawing carefully
2 Draw the strip layout in A3 size graph sheet and calculate the economy factor
3 Study the specifications of press machine
4 Calculate the cutting clearance, cutting force etc.
5 Calculate the thickness of different tool elements starting from die plate
6 Check the availability of raw material size with the calculated dimensions
7 Design the split die plate, cutting & non-cutting punches, pilots considering the
necessary clearance between die plate profiles.
8 Design all the other elements including a travelling stripper.
9 Complete the design, prepare BOM and necessary notes if required
10 Verify the design using the press tool design check list
11 Submit the drawing for verification and get the necessary feed back
NTTF_CP01 _TOOL DESIGN DRAWING_SEM III_JUNE 2020 Page 17
12 Update the necessary corrections and prepare the raw material list
13 Make an Assembly Solid model in CAD Software in cad cam class.
5.2.3 Design of multi-stage progressive tool incorporating one or more
of the following features.
Traveling Stripper with split dies
Cut –off punches with side cutter
Parting – off punches
Fixed stop / Trigger stop / Auxiliary stop
Objective:-
To design a multi-stage progressive press tool
Work instructions:-
1 Study the drawing carefully
2 Draw the strip layout in A3 size graph sheet and calculate the economy factor
3 Study the specifications of press machine
4 Calculate the cutting clearance, cutting force etc.
5 Calculate the thickness of different tool elements starting from die plate
6 Check the availability of raw material size with the calculated dimensions
7 Design the split die plate, cutting & non-cutting punches, pilots considering the
necessary clearance between die plate profile.
8 Design all the other elements including a travelling stripper.
9 Complete the design, prepare BOM and necessary notes if required
10 Verify the design using the press tool design check list
11 Submit the drawing for verification and get the necessary feed back
12 Update the necessary corrections and prepare the raw material list
NTTF_CP01 _TOOL DESIGN DRAWING_SEM III_JUNE 2020 Page 18
13 Make an Assembly Solid model in CAD Software in cad cam class.
5.2.4 Design of multi-stage progressive tool incorporating one or more
of the following features.
Traveling Stripper with split dies
Cut –off punches with side cutter
Parting – off punches
Fixed stop / Trigger stop / Auxiliary stop
Objective:-
To design a multi-stage progressive press tool
Work instructions:-
1 Study the drawing carefully
2 Draw the strip layout in A3 size graph sheet and calculate the economy factor
3 Study the specifications of press machine
4 Calculate the cutting clearance, cutting force etc.
5 Calculate the thickness of different tool elements starting from die plate
6 Check the availability of raw material size with the calculated dimensions
7 Design the split die plate, cutting & non-cutting punches, pilots considering the
necessary clearance between die plate profile.
8 Design all the other elements including a travelling stripper.
9 Complete the design, prepare BOM and necessary notes if required
10 Verify the design using the press tool design check list
11 Submit the drawing for verification and get the necessary feed back
NTTF_CP01 _TOOL DESIGN DRAWING_SEM III_JUNE 2020 Page 19
12 Update the necessary corrections and prepare the raw material list
13 Make an Assembly Solid model in CAD Software in cad cam class.
Exercises:-
Draw different strip layouts for the given components and calculate economy factor
Economy factor (E) in % =
NTTF_CP01 _TOOL DESIGN DRAWING_SEM III_JUNE 2020 Page 20
NTTF_CP01 _TOOL DESIGN DRAWING_SEM III_JUNE 2020 Page 21
Objectives:-
1 To understand the importance of proper strip layout in press tool design
2 To improve the knowledge in utilization of CAD software for making complex
part geometries
References
Youtube video links:-
[Link]
[Link]
[Link]
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