BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI

WORK INTEGRATED LEARNING PROGRAMMES

Part A: Content Design

Course Title Tool and Fixture Design

Course No(s) MT* ZC433
Credit Units 3
Credit Model 303
Course Author Dr. Srinivasa Prakash Regalla
Version No Ver 1.1
Date 9th January 2016

Course Objectives

No

CO1 To train in the analysis, design, skilful standard data utilization and decision making
on the metal forming and machining tools

CO2 To train in the customized and economic design of jigs and fixtures as suitable for
the specific scenario to improve productivity of shopfloor manufacturing processes

CO3 To train in the efficient decision making in the deployment of most suitable gaging
and inspection methods of accurate quality control of engineering parts

Teaching methodology
Text Book(s)
TB1 Donaldson C., LeCain G. H., Goold V. C. and Ghose J., Tool Design, 4th Edition
(SIE), Tata McGraw Hill Education Private Ltd., New Delhi, 2012.

TB2 Boljanovic V., Sheet Metal Forming Processes and Die Design, Industrial Press,
2004, New York.

Reference Book(s) & other resources

RB1 Venkataraman K., Design of Jigs, Fixtures and Press Tools, 2nd Edition, 2016,
Wiley/Ane Books, New Delhi.

RB2 Joshi P. H., Press Tools Design and Construction, S.Chand & Company Ltd,
(1996), New Delhi.

RB3 Luqman M., Sheet Metal Press Tool Design and Making, CBS; First edition
(2015), New Delhi.
Modular Content Structure

(M=Module; SM=Sub-module)

M1. Gages and gage design

SM1.1. Introduction
SM 1.2. Fixed Gages
SM 1.3. Gage Tolerances
SM 1.4. Selection of materials for gages
SM 1.5. Indicating gages
SM 1.6. Automatic gages

M2. Locating and clamping methods

SM 2.1. Introduction
SM 2.2. The basic principles of location
SM 2.3. Locating methods and devices
SM 2.4. The basic principles of clamping

M3. The construction and classification of drill jigs

SM 3.1. Introduction
SM 3.2. Definition of a drill jig
SM 3.3. Types of drill jigs

M4. Design of drill jigs

SM 4.1. General considerations in the design of drill jigs
SM 4.2. Drill bushings
SM 4.3. Methods of construction
SM 4.4. Drill jigs and modern manufacturing

M5. Fixturing economics, classification of fixture and design of boring fixtures

SM5.1. Introduction
SM5.2. Fixturing economics
SM5.3. Types of fixtures
SM5.4. Boring fixtures

M6. Design of fixtures for other machining operations

SM6.1. Broaching fixtures
SM6.2.Lathe fixtures
SM6.3.Grinding fixtures

M7. Die construction for sheet metal blanking and piercing

SM 7.1. Introduction: Fundamentals of sheet metal forming processes revisited
SM.7.2. Basic die classifications and components
SM 7.3. Power press types and general press information
SM 7.4. Material handling equipment
SM 7.5. Die clearance
SM 7.6. Types of die construction

M8. Design of sheet metal blanking and piercing dies

SM 8.1. Die design fundamentals
SM 8.2. Design of blanking and punching dies
SM 8.3. Pilots
 SM 8.4. Strippers and pressure pads
SM 8.5. Presswork materials
SM 8.6. Strip layout
SM 8.7. Short run tooling for piercing

M9. Critical parameters of sheet metal bending and forming

SM 9.1. Fundamentals of bending and forming dies
SM 9.2. Variables affecting metal flowing deep drawing bending, LDR
SM 9.3. Determining blank size
SM 9.4. Drawing blank size

M10. Design of bending and deep drawing dies

SM 10.1. Estimation of drawing force
SM 10.2. Various forming dies, single-action and double-action drawing dies
SM 10.3. Tool and die materials
SM 10.4 Design of bending dies
SM 10.5. Design of deep drawing dies

M11. Using plastics as tooling materials

SM 11.1. Introduction
SM 11.2. Plastics commonly used as tooling materials
SM 11.3. Application of epoxy plastic tools
SM 11.4. Construction methods of plastic tooling
SM 11.5. Metal forming operations with urethane dies
SM 11.6. Calculating forces for urethane pressure pads

M12. Tool design for numerically controlled machine tools

SM 12.1. Numerical control revisited
SM 12.2. Fixture design for NC machine tools
SM 12.3. Cutting tools for NC
SM 12.4. Tool holding methods for NC
SM 12.5. Automatic tool changers and tool positioners
SM 12.6. Tool presetting

M13. Design of lathe and milling cutting tools

SM 13.1. Revisit to mechanics of machining relevant to tool design
SM 13.2. Design of single point cutting tools for lathe
SM 13.3. Design of milling cutters

M14. Design of cutting tools for drilling and other processes

SM 14.1. Design of drills
SM 14.2. Design of reamers
SM 14.3. Design of taps
SM 14.4. Selection of carbide cutting tools
SM 14.5. Tooling for automatic screw machines with the example of Browne & Sharpe machine

Learning Outcomes:

No Learning Outcomes
 LO1 To become proficient in design, selection and deployment of gages for product
manufacturing inspection and measurement

LO2 To be able to design punch-die clearances and punch & die tolerances to enable high
productivity blanking and piercing operations

LO3 To characterize LDR for deep drawing operations and make decisions on number of passes
required for high quality deep drawn parts

LO4 To be able to design bending dies for high accuracy angle sheet metal parts with accurate
estimate of blank size

LO5 To be able to design, select and customize with quantitative economic estimations fixtures
and jigs for machining and forming processes

LO6 To be able to design and customize single and multi-point cutting tools for high
productivity machining applications

Experiential learning components

Lab work:

1 Design a milling fixture to mill the finished surface of the casting shown in Fig.1. This has to be first
meaningful operation on the rough casting. Holes are drilled after the surface is milled.
2 Design a broaching fixture to broach the slots in the V-block clamp as shown in Fig. 2.
Design a milling fixture to mill the 50 mm slot shown in the right angle clevis in Fig. 3. Assume that the
3 hole and 27 mm slot have been previously machined.
Design a milling fixture to mill the finished surface of the clevis shown in Fig-4. Holes will be drilled after
4 the surfaces have been machined.
Design a lathe boring fixture for holding the workpiece for boring the 45 mm hole as shown in Fig-5.
5 Introduce at least one additional feature in the workpiece and then design the fixture.
 Part B: Course Handout

Academic Term Semester II 2015-16

Course Title Tool and Fixture Design
Course No MT* ZC433
Lead Instructor Dr. Srinivasa Prakash Regalla

Contact Session 1
Module Title: M1. Gages and gage design
Type Content Topic Title Study/HW
Ref. Resource
Reference

Pre CH Self-study of tool design methods, tool making TB1-

practices, tool materials and heat treatment Chapters 1 to
3

During CH SM1.1 Introduction to gages

SM1.2 Fixed Gages
SM1.3 Gage Tolerances TB1 Chapter
SM1.4 Selection of materials for gages 5
SM1.5 Indicating gages
SM1.6 Automatic gages

Post CH Design a single gauge to measure 3 different Design

angles on a part exercises to
Quiz-1 questions provided by instructor be
recommende
d by
instructor
Contact session 2
Module Title: M2. Locating and clamping methods
Type Content Topic Title Study/HW
Ref. Resource
Reference

Pre CH SM 2.1. Introduction TB1 Chapter

6

During SM 2.2 to The basic principles of location TB1 Chapter

CH SM 2.4 Locating methods and devices 6
The basic principles of clamping

Post CH Assignment-1 given by instructor

Contact session 3
Module Title: The construction and classification of drill jigs
Type Content Topic Title Study/HW
Ref. Resource
Reference

Pre CH SM 3.1. Introduction TB Chapter 7

During SM 3.2. to Definition of a drill jig

CH SM 3.3 Types of drill jigs
TB Chapter 7

Post CH Modeling some known drill jigs in CREO to be provided

(Pro/Engineer): assignment for practice by instructor

Contact session 4
Module Title: M4. Design of drill jigs
Type Content Topic Title Study/HW
Ref. Resource
Reference

Pre CH SM 4.1. General considerations in the design of drill jigs TB Chapter 7

During SM 4.2. Drill bushings TB Chapter 7

CH SM 4.3. Methods of construction
SM 4.4. Drill jigs and modern manufacturing

Post CH Drill jig design assignment in CREO Problem

 announced by
the instructor

Contact session 5
Module Title: Fixturing economics, classification of fixture and design of boring fixtures
Type Content Topic Title Study/HW
Ref. Resource
Reference

Pre CH SM5.1. Introduction TB1 Chapter

8

During SM5.2. Fixturing economics TB1 Chapter

CH SM5.3. Types of fixtures 8
SM5.4. Boring fixtures

Post CH Design of fixtures for machining and forming Problems

processes hinted by the
instructor

Contact session 6
Module Title: Design of fixtures for other machining operations
Type Content Topic Title Study/HW
Ref. Resource
Reference

Pre CH Review of lathe, broaching and grinding processes Any standard

textbook on
machining
such as that
of Boothroyd
& Knight &
online

During SM6.1. Broaching fixtures TB1 Chapter

CH SM6.2. Lathe fixtures 9
SM6.3. Grinding fixtures

Post CH Design of fixtures for broaching, lathe and Problems

grinding processes suggested by
instructor
Contact session 7
Module Title: Die construction for sheet metal blanking and piercing

Type Content Study/HW

Ref. Resource
Reference

Pre CH SM7.1 Introduction: Fundamentals of sheet metal forming TB1 Chapter

processes revisited 10 & TB2
Chapter 1-7

During SM.7.2. Basic die classifications and components

CH SM 7.3. Power press types and general press
SM 7.4. information T1 Chapter 7
SM 7.5. Material handling equipment
SM 7.6. Die clearance
Types of die construction

Post CH Creo modeling of some of the existing blanking

dies

Review Session-1
Session Title: Mid-semester Review
Type Content Topic Title Study/HW
Ref. Resource
Reference

Pre CH Review all classes Previous

Classes

During CH Review: complete syllabus

Post CH

Contact session 8
Module Title: Design of sheet metal blanking and piercing dies

Type Content Topic Title Study/HW

Ref. Resource
Reference

Pre CH SM 8.1. Die design fundamentals TB1-Chapter

9
 &
TB2-Chapter
8

During SM 8.2. Design of blanking and punching dies

CH SM 8.3. Pilots T TB1-
SM 8.4. Strippers and pressure pads Chapter 9
SM 8.5. Presswork materials &
SM 8.6. Strip layout TB2-Chapter
SM 8.7. Short run tooling for piercing 8

Post CH Design of blanking and punching dies Suggested by

instructor

Contact session 9
Module Title: Critical parameters of sheet metal bending and forming

Type Content Topic Title Study/HW

Ref. Resource
Reference

Pre CH SM 9.1. Fundamentals of bending and forming dies TB1-Chapter

10 & TB2-
Chapters 10
and 11

During SM 9.2. Variables affecting metal flowing deep drawing

CH SM 9.3. bending, LDR
SM 9.4. Determining blank size TB1-Chapter
Drawing blank size 10 & TB2-
Chapters 10
and 11

Post CH Term paper on students exposure and observation Activity by

of current problems faced in bending and forming students
dies in his company or another company or supervised
literature by instructor
Contact session 10
Module Title: Design of bending and deep drawing dies
Type Content Topic Title Study/HW
Ref. Resource
Reference

Pre CH SM 10.1. Estimation of drawing force TB1-Chapter

10 & TB2-
Chapters 10
and 11

During CH SM 10.2. Various forming dies, single-action and double- TB1-Chapter

SM 10.3. action drawing dies 10 & TB2-
SM 10.4 Tool and die materials Chapters 10
SM 10.5. Design of bending dies and 11
Design of deep drawing dies

Post CH Numerical design exercises on bending and deep To be

drawing dies, punches and blank holders prescribed by
the instructor

Contact session 11
Module Title: Using plastics as tooling materials

Type Content Topic Title Study/HW

Ref. Resource
Reference

Pre CH SM 11.1. Introduction TB1-Chapter

11

During CH SM 11.2. Plastics commonly used as tooling materials TB1-Chapter

SM 11.3. Application of epoxy plastic tools 11
SM 11.4. Construction methods of plastic tooling
SM 11.5. Metal forming operations with urethane dies
SM 11.6. Calculating forces for urethane pressure pads

Post CH Term paper on current scenario of using plastic Online and

tooling in automotive and allied manufacturing other
industries resources
Contact session 12
Module Title: Tool design for numerically controlled machine tools

Type Content Topic Title Study/HW

Ref. Resource
Reference

Pre CH SM 12.1. Numerical control revisited TB1-Chapter

12

During CH SM 12.2. Fixture design for NC machine tools TB1-Chapter

SM 12.3. Cutting tools for NC 12
SM 12.4. Tool holding methods for NC
SM 12.5. Automatic tool changers and tool positioners
SM 12.6. Tool presetting

Post CH Term paper on how the tooling for CNC machines Online
differs from that for conventional machines resources and
other sources

Contact session 13
Module Title: Design of lathe and milling cutting tools
Type Content Topic Title Study/HW
Ref. Resource
Reference

Pre CH SM 13.1. Revisit to mechanics of machining relevant to tool TB1-Chapter

design 4

During CH SM 13.2. Design of single point cutting tools for lathe TB1-Chapter
SM 13.3. Design of milling cutters 4

Post CH Design exercises using Creo on lathe and milling As

cutter design recommende
d by the
instructor

Contact session 14
Module Title: Design of cutting tools for drilling and other processes
Type Content Topic Title Study/HW
Ref. Resource
Reference

Pre CH Revisit to mechanics of machining relevant to tool TB1-Chapter

design 4
 During CH SM 14.1. Design of drills TB1-Chapter
SM 14.2. Design of reamers 4
SM 14.3. Design of taps
SM 14.4. Selection of carbide cutting tools
SM 14.5. Tooling for automatic screw machines with the
example of Browne & Sharpe machine

Post CH Design exercises using Creo on cutters for drilling As

and other processes recommende
d by the
instructor

Review session-2
Session Title: Comprehensive Review
Type Content Topic Title Study/HW
Ref. Resource
Reference

Pre CH Review all classes

During CH Review: complete syllabus

Post CH Doubt clarifying through email/telephone or in

person

Detailed Plan for Lab work/Design work

Lab Lab Objective Lab Sheet Content

No Access URL Reference

1 Design a milling fixture to mill the finished surface of the casting Textbooks &
shown in Fig.1. This has to be first meaningful operation on the Reference
rough casting. Holes are drilled after the surface is milled.
Books
2 Design a broaching fixture to broach the slots in the V-block
clamp as shown in Fig. 2.

3 Design a milling fixture to mill the 50 mm slot shown in the right

angle clevis in Fig. 3. Assume that the hole and 27 mm slot have
been previously machined.

4 Design a milling fixture to mill the finished surface of the clevis

shown in Fig-4. Holes will be drilled after the surfaces have been
machined.

5 Design a lathe boring fixture for holding the workpiece for boring
the 45 mm hole as shown in Fig-5. Introduce at least one
additional feature in the workpiece and then design the fixture.
Evaluation Scheme

Evaluation Name Type Weight Duration Day, Date,

Component (Quiz, Lab, Project, Mid (Open book, Session,
term exam, End semester Closed book, Time
exam, etc) Online, etc.)

EC - 1 Tool design assignments 20

and quizzes if any

EC - 2 Mid-semester Closed Book 30

Examination

EC - 3 Comprehensive Open Book 50

Examination

Guidelines: The tool design exercises mentioned in the experiential learning section may be suitably
modified based on the interest and background of the certain companys working professionals.
It is recommended that the tool design is exercised first on paper and then results are to be
documented in CREO and presentation of the same be mandatory for relevance to best practices in
industry.

Important Information: