Tool Design, MET 3331 (3-0-3)

Prerequisites: MET 2322, MET 3131

Course Syllabus

Professor:        Simin Nasseri

Office:             Q231 (office hours)

Phone:             678- 915- 7420

Email:              snasseri@spsu.edu

Web Page:             http://met.spsu.edu/snasseri/

Please send emails for making appointments at other times rather than specified.

 

·         Course Description

·         Course Texts

·         Course Objectives

·         Procedure and Grading Policy

·         Course Content

·         All the Materials for this Course  

·         Quizzes/ Tests

·         Homework Assignments

·         Projects

·         Websites/Documents to Use for the Projects

 

Image from: http://www.aerocaddesign.com/machining.htm

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Course description:

Jigs and fixtures for production machining processes are covered. Specific subjects include methods of gaging work pieces, ease and simplicity of operation, assembly methods, capital evaluation, and techniques for locating and holding work pieces, time studies, tool steels, bending allowances, and reverse engineering techniques. The course is design project oriented. Projects include calculations of tooling forces and costs as well as complete production drawings of the tool design.

 

 

Course texts:

 

1- Fundamentals of tool design, 5th Edition, SME (by David Spitler (Contributor, Editor), Society of Manufacturing Engineers (Contributor, Corporate Author), Jeff Lantrip (Editor, Translator), John G. Nee (Editor, Translator), David A. Smith (Editor, Translator)) ISBN-10: 087263650X

 

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About the book

This revised edition contains new material from leading industry experts on topics such as rapid prototyping, design of pressworking tools, bending, forming and drawing, forging dies, inspection and gaging, CAD applications, and more. It is more searchable and "user-friendly" than the previous version. As before, the book outlines all the factors that impact tool success, showing how and why tools work in relation to the manufacturing processes for which they are being designed. Each chapter details the "nuts & bolts" of tool design-- such as material science, tool layout, cost analysis, calculating economical lot sizes, safety, and more.

Check the content of this book here.

 

 

2- Jig and fixture design, 5th Edition, Hoffman, ISBN: 9781401811075

 

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About the book

By emphasizing similarities among types and styles, Jig and Fixture Design, 5E speeds readers to a complete understanding of the why's and how's of designing and building a variety of different workholders for manufacturing. From simple template and plate-type jigs to complex channel and box-type tooling, this newly revised edition features more than 500 illustrations of tools and applications to spur readers to success. All-new sections on assembly tools, handling tools, and catalog reading enable readers to develop important skills. Specific examples of various jigs and commercially available fixtures also appear to guide readers in developing their understanding of how design principles, as well as the latest design and manufacturing technologies, are being applied in the construction of jigs and fixtures today. As in past editions, heavy emphasis is placed on the economics of jigs and fixtures, including methods and formulas for use in estimating workholder costs. A solid background in industrial processes, as well as machine shop technology, is assumed.

 

3.      Materials on the Internet:

 

·         3 first chapters of Carr Lane (Internet link)

·         Carr Lane Man. Co.

·         The fabricator tool and die articles

·         Tooling university

·         Society of Manufacturing Engineers Website

 

The following texts are also used for developing this course:

 

1.      Jig and Fixture Handbook, Carr Lane Mfg. Co.,  ISBN-10: 0962207918

2.      Jigs and Fixtures Design Manual, 2nd Edition, by Prakash Hiralal Joshi, ISBN-10: 0071405569

3.      Handbook of Die Design, SME, by Ivana Suchy (Author), ISBN-10: 0070666717

4.      Tool and Manufacturing Engineers Handbook, Vol 2 Forming CD-ROM, Wick et al, SME

5.      Die Design Fundamentals, Third Edition, By Vukota Boljanovic, J.R. Paquin and R.E. Crowley, 2005, ISBN-10:0-8311-3119-5

6.      Sheet Metal Forming Processes and Die Design, Vukota Boljanovic, 2004, ISBN-10:0-8311-3182-9

7.      Sheet Metal Forming Knowledge Base, CD, SME, AFFT

8.      Fundamentals of Modern Manufacturing; Materials, Processes and Systems, by Groover

 

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Course Objectives:

Students completing this course will be able to:

·         Design a jig.

·         Provide the engineering calculations for the design of a fixture for a CNC machining center.

·         Design and automate a fixture.

·         Calculate the forces on a fixture using 3D Statics

·         Estimate the cost of tooling.

·         Determine metal cutting forces and clamping forces for engineering jigs and fixtures.

·         Produce ANSI standard design drawings utilizing 3 D modeling software and online databases for a milling fixture.

·         Design a modular tooling fixture demonstrating basic locating and holding principles.

·         Design a gage.

·         Determine the forces on a press.

·         Provide the engineering calculations for designing a die.  

Students completing this course will know:

·         The importance of team work in the work place.

·         The value of associating with engineers through professional societies like SME.

·         The importance of safety in designing jigs, fixtures, and other tooling.

·         The importance of professional certifications.

·         The design process for manufacturing tools in general.

·         How to organize, schedule, and control a project.

·         How to research the procedures to do the engineering required for, planking, punching, bending and forming.

·         Research and assemble the tools for engineering and designing tools.

·         The fundamental locating and holding principles for jigs and fixtures.

·         How to write an engineering calculation procedure.

·         How to compare the advantages of fixed tooling, modular tooling, automated tooling and shuttle tooling.

 

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Procedures:

Your grade in this course will be determined from your performance on:

o   In-class participation/ Homework Assignments

o   Projects (including presentations),

o   Quizzes and tests.

 

Attendance is mandatory and points will be taken off final grade in case of illegitimate absence. There are many in-class projects for which the students should attend the class.

 

Homework Assignments will be given periodically.

 

Projects will be assigned after certain modules are covered. Projects are related to locating and clamping, jigs, fixtures, gages and dies.

 

Tests are either in the form of multiple choices or problem solving and are given at the beginning of the classes. These tests cover the course materials which were taught in the previous session (or sessions).

 

 

Grading policy:

 

  • In-class participation & HW assignments       10%
  • Quizzes/ Tests:                                                35%
  • Projects:                                                          55%

Total:                                                               100%

 

[90 - 100% = A,   80 - 89% = B   70 - 79% = C   60 - 69% = D   Below 60% = F]

 

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Course content- Topic coverage:

 

·         Tool Design

·         Tooling Cost

·         Tool Materials

·         Cutting Tool Design

·         Locating and Workholding Principles

·         Jig Design

·         Fixture Design

·         Modular and Automated Tool Handling

·         Presses and Dies

·         Metal Cutting, Forming and Drawing

·         Tool design for Inspection and Gaging

·         Tool Design for Joining Processes

 

 

ADA/504 Compliance

Students with disabilities who believe that they may need accommodations in this class are encouraged to contact the ATTIC counselor working with disabilities at (678) 915-7361 as soon as possible to better ensure that such accommodations are implemented in a timely fashion.

 

 

Student Conduct

Academic dishonesty and non-academic misconduct, in any form, is not tolerated in the classroom.  This includes, but is not limited to, cheating, plagiarism, and disorderly conduct.  Please refer to sections in the Undergraduate Catalog on “A Disruptive Behavior and Academic Dishonesty”.

 

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All the Materials for this course (Chapters Summaries and Solved Problems):

 

Any use of these materials on any other website or networked computer environment for any purpose is prohibited. The materials on this website are copyrighted and any unauthorized use of any materials may violate copyright and other laws.

 

Part1:

1.      Review of Engineering Graphics (Hand sketching, Projections, Classification of fits)

·         More on classification of fits

2.      Review of Geometric Dimensioning & Tolerancing (GD & T)

·         GD&T one page summary

3.      Review of Statics (Calculating the forces on clamps/ fixtures)

4.      Design Elements- Part 1

5.      Design Elements- Part 2

6.      Cutting Tools – Part 1: Tool Materials, Tool Geometry

·         Cutting tool materials/ Tool life (SME video)

7.      Cutting Tools - Part 2: Cutting Tool Design

8.      Cutting Tools – Part 3: Tool Life, Cutting Fluids

9.      Cutting Tools – Part 4: Machinability – Tooling cost

·         Tooling Cost Solved Problems

·         Charts of Machinability

 

Part 2:

10.  Workholding Principles – Part 1: Locating, 3-2-1 Method

11.  Workholding Principles – Part 2: Locating Rules

12.  Workholding Principles – Part 3: Locator Types (with “Cool design”  section)

13.  Workholding Principles – Part 4: Clamping (with “Cool design”  section)

14.  Workholding Principles – Part 5: Machining Forces

·         Clamping Force Solved Problems

15.  Jigs and Fixtures – Introduction

16.  Jigs- Part 1 - Types and Functions

17.  Jigs- Part 2 - Design Considerations

18.  Jigs- Part 3 – Design Examples (with “Cool design” section)

 

Part 3:

19.  Fixtures- Part 1 – Types and Functions

20.  Fixtures- Part 2 – Classifications

21.  Fixtures- Part 3 – Modular Fixtures (Completed)

·         Modular Fixturing- Video 1 (5:40 min)

·         Modular Fixturing- Video 2 (5:11 min)

·         Modular Fixturing- Video 3 (5:54 min)

·         Building a Milling Fixture

22.  Fixtures- Part 4 – Design Fundamentals

23.  Fixtures- Part 5 – Tooling Cost

Design of Pressworking Tools:

24.  Dies – Part 1- Types & Components

25.  Dies – Part 2 – Cutting Operations (with “Cool design”  section)

·         Die Cutting Problems

26.  Dies – Part 3 – Forming Operation- Designing a forming die (Completed with “Cool design”  section)

27.  Dies – Part 4- Bending Dies (with “Cool design”  section)

·         Die Bending and Forming Problems

28.  Dies – Part 5 (Designing a draw die, completed with “Cool design” section)

    

 

        MMAG00343_0000[1] Check the tentative schedule here

   MMAG00343_0000[1]

Tool Design Weblog

 

 

Vocabulary 1

Vocabulary 2

 

 

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Quizzes/ Tests

 

TBA

 

 

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Homework Assignments

 

1.      HW # 1: Solve the problems related to Dimensional Tolerancing (Except the last two pages: Terms to understand). These will be handed out in class.

 

 

 

Reading Assignments:

 

1.      Trigonometry tables and handy references for engineers

2.      Mechanics of materials (interactive multimedia tool)

3.      Mechanics of elastic bodies

4.      Engineering drawing and sketching

5.      GT&D one page summary

6.      Materials

7.      Hand-tools design

8.      Materials of Engineering

9.      Metallurgy of Steel (by Verhoeven, Iowa State University), Page 151 (Tool steel)

10.  Pneumatic System

11.  Hydraulic System

 

 

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Projects

 

TBA

 

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Use these papers for your projects (if you wish):

 

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Websites/ Documents to use:

 

·         Carrlane (1)

·         Carrlane (2)

·         Valtra Inc

·         Jergens Inc.

·         Engineer Edge

·         AME (on fixtures)

·         Stevens Engineering: On modular fixturing

·         Sheet Metal Design (Technical Help)

·         Clamps (from various sites)

·         Gages

 

Danly Die set catalogue (Canada):

·         Danly IEM

·         Air Presses

·         Aluminum Die Set

·         Ball Bearing Die Set

·         Bend GER

·         IEM Cams

·         Aerial and Die Mount Cams

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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