PRODUCT DESIGN AND PRODUCTION TOOLING (PDPT)

BY
DILIP KUMAR BAGAL
ASSISTANT PROFESSOR
DEPARTMENT OF MECHANICAL ENGINEERING
Government college of engineering, Kalahandi
Email: [email protected]
 SYLLABUS
Subject Code: PME6J001

Subject: PRODUCT DESIGN AND PRODUCTION TOOLING (PDPT)

MODULE – I (14 HOURS) Product Design-Product design considerations, product planning, product development, value analysis, product
specification. Role of computer in product design. Process Planning – selection of processes, machines and tools. Design of sequence of operations,
Time & cost estimation.

MODULE – II (14 HOURS) Forging design- allowances, die design for drop forging, design of flash and gutter, upset forging die design. Sheet metal
working- Design consideration for shearing, blanking piercing, deep drawing operation, Die design for sheet metal operations, progressive and
compound die, strippers, stops, strip layout.

MODULE – III (16 HOURS) Design of jigs and fixtures, principle of location and clamping, clamping methods, locating methods, Drill Jig bushing,
Indexing type drilling Jig. Design of single point cutting tool, broach and form tool. Tooling design for turret lathe and automats. Design of limit
gauges.

TEXT BOOKS:
1. Product Design & Manufacturing, A K Chitale, R C Gupta, Eastern Economy Edition, PHI.
2. Product Design & Development, Karl T Ulrich, Steven D Eppinger, Anita Goyal, Mc Graw Hill.
3. A Textbook of Production Engineering, P.C. Sharma, S. Chand & Co
REFERENCE BOOKS:
1. Fundamentals of Tool Engineering design, S.K. Basu, S.N. Mukherjee, R. Mishra, Oxford & IBH Publishing co.
2. Technology of Machine Tools, Krar, Gill, Smid, Tata Mc Graw Hill
3. Jigs & Fixture Design, Edwrd G Hoffman, Cengae Learning.
MODULE – III

➢ Jigs and fixtures are production tools used to accurately manufacture duplicate and interchangeable parts. Jigs and fixtures are specially
designed so that large numbers of components can be machined or assembled identically, and to ensure interchangeability of components.
Degree of Freedom is defined as
number of independent motion a
body has
3-2-1 Principle of Clamping Workpiece
It is principle of clamping widely used.
1) 3 Pin are used at Bottom
It will restrict 4 Rotational motion (X,Y Axis) and 1 Translation motion (-Z
Direction)
2) 2 Pin
It will Restrict 2 Rotational Motion (Z Axis) and 1 Translation motion in (+X
Direction)
3) 1 Pin
It will restrict 1 Translation Motion (+Y)
And Pin 3-2-1 combined will restrict 9 Motion
And Remaining 3 Motion is used to set work-piece at desired location and can
be restricted by Clamp.
(*Notation given i.e +X, -X . Changes according to views)
Some basic principles or rules need to be
followed while planning for locating blanks in
fixtures, such as
➢ One or more surfaces (preferably machined)
and / or drilled / bored hole(s) are to be taken for
reference
➢ The reference surfaces should be significant
and important feature(s) based on which most ofthe
dimensions are laid down
➢ Locating should be easy, quick and accurate
➢ In case of locating by pin, the pins and their
mounting and contact points should be strong, rigid and hard
➢ A minimum of three point must be used to
locate a horizontal flat surface
➢ The locating pins should be as far apart as feasible
➢ Vee block and cones should be used for self- locating solid and
hollow cylindrical jobs
➢ Sight location is applicable to first – operation location of blank
with irregular surfaces produced by casting, forging etc. when the
bracket is first located on two edges to machine the bottom
surface which will be used for subsequent locating.
➢ Adjustable locating pin(s) is to be used to accommodate limited
part size variation
Locating blanks for machining in lathes
In lathes, where the job rotates, the blanks are located by
✓ fitting into self centering chuck
✓ fitting into 4 –
independent jaw chuck and dead center
✓ in self – centering collets
✓ in between live and dead centers
✓ by using mandrel fitted into the head stock – spindle
✓ fitting in a separate fixture which is properly clamped on
a driving plate which is coaxially fitted into the lathe
spindle.
Locating for machining in other than
lathes

➢ In machine tools like drilling machine, boring

machine, milling machine, planning machine, broaching
machine and surface grinding machine the job remains
fixed on the bed or work table of those machine tools.
➢ Fixtures are mostly used in the aforesaid machine
tools and jig specially for drilling, reaming etc. for batch
production.
Locating by flat surfaces

b)
a)

c)
In several cases, workpieces are located by
premachined (drilled, bored or pierced) holes,
such as;
∗ Locating by two holes where one of the pins
has to be diamond shaped to accommodate
tolerance on the distance between the holes and
their diameters
∗ Locating by one hole and an external pin
which presents rotation of the blank around the
inner pin
∗ Locating by one hole and one Vee-block
 LOCATING ON MANDREL OR PLUG
Locating on mandrel or plug Ring or disc type work
pieces are conveniently located on mandrel or single
plug.
Supporting – principles and
methods
Workpiece has to be properly placed in the jig or
fixture not only for desired positioning and orientation but
also on strong and rigid support such that the blank does
not elastically deflect or deform under the actions of the
clamping forces, cutting forces and even its own weight.
Basic principles or rules to be followed
while designing or planning for supporting
• supporting should be provided at least at three points
• supporting elements and system have to be enough
strong and rigid to prevent deformation due to
clamping and cutting forces
• unsupported span should not be large to cause
sagging
• supporting should keep the blank in stable condition under the
forces
• for supporting large flat area proper recess is to be
provided, for better and stable support.
• round or cylindrical workpieces should be supported (along
with locating) on strong vee block of suitable size
• heavy workpieces with pre-machined bottom surface should
be supported on wide flat areas, otherwise on flat ended strong
pins or plugs.
• if more than three pins are required for supporting large
workpieces then the additional supporting pins are to be spring
loaded or adjustable
• additional adjustable supporting pins need to be
provided to compensate part size variation
∗ when the supporting surface is large and irregular
∗ when clamping and cutting forces are large
• ring or disc type jobs, specially requiring
indexing.
• Once workpiece is located, it is necessary to press it against locating
surfaces and hold it there against the force acting upon it.
• The tool designer refers to this action as clamping and the
mechanisms used for this action are known as clamps.

• Clamp should firmly hold the workpiece without distorting it.

• Should overcome the maximum possible force exerted on
workpiece by using minimum clamping force
• Easy to operate
• Vibrations should tighten the cams and wedges in the clamp
design (if any) and not loosen them.
• Mechanical Actuation Clamps
• Pneumatic and Hydraulic Clamps
• Vacuum Clamping
• Magnetic Clamping
• Electrostatic Clamping
• Non-Mechanical Clamping
• Special Clamping Operations
Clamping of workpiece in
fixtures
In jigs and fixtures the workpiece or blank has to be
strongly and rigidly clamped against the supporting
surfaces and also the locating features so that the blank
does not get displaced at all under the cutting forces
during machining.
While designing for clamping the
following factors essentially need to be
considered :
✓ Clamping need to be strong and rigid enough to hold the
blank firmly during machining
✓ Clamping should be easy, quick and
consistently adequate
✓ Clamping should be such that it is not affected by
vibration, chatter or heavy pressure
✓ Way of clamping and unclamping should not
hinder loading and unloading the blank in the jig or
fixture
✓ The clamp and clamping force must not damage or
 deform the workpiece
✓ Clamping operation should be very simple and
quick acting when the jig or fixture is to be used
more frequently and for large volume of work ο
clamps, which move by slide or slip or tend to do so
during applying clamping forces, should be avoided
✓ Clamping system should comprise of a smaller
number of parts for ease of design, operation and
maintenance
✓ The wearing parts should be hard or hardened
and also be easily replaceable
✓ Clamping force should act on heavy
part(s) and against supporting and locating
 surfaces
✓ Clamping force should be away from
the machining thrust forces
✓ Clamping method should be fool proof and safe
✓ Clamping must be reliable but also inexpensive
Clamping method and system are basically
of two categories:
(a) general type without much consideration on speed
of clamping operations
(b) quick acting type
Principles of Clamping
• Position
• Strength
• Productivity
• Operator fatigue
 Principles of Clamping
Position:
•Clamping system should be positioned at thick
sections of the workpiece.
•Clamping should be positioned to direct the
clamping force on a strong, supported part of
the workpiece.
• Clamping on unsupported part bends slender
workpieces, affects accuracy of operation.
Distortion of
unsupported
workpiece
• Clamping system should not
obstruct loading and unloading of
the workpiece.
• Clamping system should not obstruct the
paths of cutting tool.
• Operator should be able to operate
clamps easily and safely
• A vertical hole drilled in the bent workpiece
would become angular when the unclamped
workpiece springs back to its original shape.
 Principles of Clamping
• Clamping force shall be directed towards support /
locators.
 Principles of Clamping
• Clamp shall be directly in line with thesupport
 Principles of Clamping
• Clamping force shall be directed towards support /
locators.
 Principles of Clamping
• Clamps shall apply force against supported area of work
piece

GOOD BAD
Clamping method and system are basically of
two categories:
1. General type without much consideration of the speed
of clampingoperations.
2. Quick acting clamping method / quick
action clamps.
 Strap / Plate / BridgeClamps
• It is very simple and reliable clamping device.
• The clamping force is applied by spring loaded nut.
Strap/ Plate / BridgeClamps
• These are made of rectangular plates and act like levers.
• The clamps are tightened by rotating a hexagonal nut on
a clamping screw.
• One end of the clamp presses against the workpiece and
the other end on the heel pin.
• The toe i.e. clamping face of the clamp is curved and the
pressure face of the heel pin is made spherical to take
care of any variations in the workpiece.
• Spherical washers permits the clamp to tilt with respect
to the screw and the nut.
•Strap clamps are provided with a washer and
spring below the clamp.
• The spring lifts the clamp as the nut is
loosened and workpiece becomes free.
•The Spring holds the clamp in a raised position
during loading and unloading of the
workpiece.
• Washer prevents the entry of the spring in the
hole of the clamp.
•Clamp is rotated about the stud to release the
workpiece.
 Strap Clamp:Workpiece Variation
• The clamp is prevented from rotating during
clamping by providing pin at the heel-end.
• The clamp stud is usually at least 10 mm in diameter and
nearer to the toe-end than heel-end of the clamp.
 Strap Clamp:Workpiece Variation
• The heel pin engages the clamp plate to prevent it from
rotating during clamping.
Strap/ Plate / Bridge Clamp
Retractable Strap Clamp
 “U” Clamp
• U Clamp can be removed altogether to facilitate
loading and unloading of the workpiece.
 TwoPoint Clamp
• It is used to clamp two workpieces or to clamp
a single workpiece at two locations.
Swinging Strap Clamp
• This type of clamp can be rotated by 90o to clear the passagefor loading and
unloading the workpiece.
• The clamp is swung to the position shown by the chain dotted line during
loading and unloading of the workpieces.

Swinging Strap Clamp

 SpecialStrap Clamp
• The clamp shape can be changed to suit the workpiece and the operation.

Spider Clamp or Three-point Clamp

• Circular and symmetrical workpieces can be clamped well with a spider
clamp
having three clamping points, no heel pin is necessary.
 StrapClamp
• Gooseneck Clamp can reduce the clamp height with respect to the
work piece height.

Gooseneck Clamp
Strap Clamp
• Strap Clamp clamping two workpieces

Strap Clamp
Strap Clamp:Workpiece Variation

Universal Clamp withcylindrical washer

 Edge Strap Clamp
• Edge Clamps are used for clamping workpieces on the
edges during facing operations or when only horizontal
surface is to be machined.
• Tightening of the hexagonal nut wedges the clamp
between the workpiece and the angular heel surface.

Edge Strap Clamp

 Edge JawClamp
• Edge jaw clamp slides down the inclined
heel as the hexagonal nut istightened.
• Tightening of the hexagonal nut pushes the
jaw against the workpiece to clampitsedge.

Edge JawClamp
 Pivoted StrapClamp
• Clamps are often pivoted at the centre to simplify
their operation.
• Knurled headed screw is used to loosen and
tighten the clamp.
 Pivoted Edge Clamp
• Pivot pin is nearer to the clampingpoint.
• Screw is shifted to the end opposite theclamping
point.
• Clamping screw becomes more accessible to the
operator.
 Pivoted Two-wayClamp
•Pivot action can be used for two-way clamping of the
workpiece.
• Tightening of the screw makes the curved surface of the clamp
touch the workpiece and further tightening of the screw clamps
the workpiece vertically and horizontally.
•Two-way clamp also pushes the workpiece against two
locators.
Pivoted Two-way Clamp
Hinged Clamp
Hinged Clamp
•Hinged clamp provides rapid clearance of the passage for loading
and unloading.
•It is clamped with swinging eyebolt. The clamp has open slot
through which the eyebolt can be swung into position.
•Tightening of the hexagonalnut clamps the workpiece.
•For loading and unloading the workpiece, the hexagonal nut is
loosened half-a-turn and the eyebolt is swung out of the open slot
to free the hinged plate.
 Hinged Two-way Clamp
•Workpiece is pushed against the location pins by the pivoted edge
clamp which also houses the swinging eyebolt.
• Knurled nut is used to clamp the workpiece against the
locationpins.
•Workpiece is clamped in two direction by the edge clamp and the
pad in the hinge.
•For loading and unloading the workpiece, the knurled nut is
loosened half-a-turn and the eyebolt is swung out of the open slot
to free the hinged plate.
Hinged Two-way Clamp
CWasher
• Strap clamp with an open slot.
• Simple and quick in operation.
• Slot permits quick removal of C Washer after a slight
loosening of the hexagonal nut.
• C washer is often chained to the fixture or pivoted
around a shoulder screw to prevent its loss.
• Pivot shoulder screw makes the Cwasher captive.
 Swinging Clamps
• Thesesclamps are swung to the position.
• They rotate in the plane of the plate.
• Figure depict the swinging
clamp pivoted about the
shoulderscrew.
• Workpiece is clamped by
knurled head screw.
 Swinging Clamps
• Swinging latch with an open slot at one end. The latch is swung around pivot Pat the
other end.
• Shoulder screw Sinters the open slot during operation. The workpiece is clamped by
knurled head screw.
 Swinging Clamps
• Types of latches and their methods
of operation.
• Chain-dotted line shows the
latches in their clear loading
and unloading position.
• Shoulder screws are often used as
pivots for thrust pads.
• The shoulder diameter must
be bigger than the thrust
diameter so that the
shoulder face acts as a stop
when the screw is tightened.
 SwingingClamps
• Swinging clamp with CWasher
 Toggle Clamp
• They provide considerable
distancefor loading and unloading of the workpiece.
• The Cframe clamp can be
swung to the chain
dotted position during
loading and unloading.
 Toggle Clamp
• The pusher-type toggle clamp withdraws backwardsduring unclamping.
• Toggle clamps are provided with clamping screws to accommodate
workpiece variations.
Toggle Clamp
 QuickTurnScrew/ ThumbScrew
• It is used to clamp hinged jig plates and
latches within a quarter turn.
• In unclamped position head of the thumb
screw can pass through the slot provided in
the jig/latch plate.
• The plate can swung clear of the thumb
screw head.

• For clamping, the thumb screw is turned 90o

so its head is right angles to the slot in the
plate.
• The mating surface of the thumb screw head
must be filed for properclamping.
• Quarter-turn screws are suitable for light
loadsonly.
• For heavy loads, swingingeyebolt and knob
combination is used.
 Quick Action HandNut
• They are available with the manufacturers ofs tandard parts.
• Casthand nuts are more convenient and less expensive than the turnednuts

CastHand Nut
 Cam
• Quick clamping by cam is very effective and very simple in operation.
• The cam type clamping system is used for clamping through some interior
parts
where other simple system will not haveaccess.
 Cam
• Cam shifts its mating surfaces to clamp orunclamp the workpieces.
 Double Clamping
• Twoworkpieces with limited variation can be clamped by a single strap clamp.
• Thesphericalwashersare provided between the nut and the clamp which allow
the clamp to tilt slightly to suit the variation in the two workpieces.
 Screw operated strap
clamps
The clamping end of the strap is
pressed against a spring which
enables quick unclamping
✓ Drilling jigs are used to machine holes in mechanical products. To obtain positional
accuracy of the holes, hardened drill bushes or, jog bushes are used to locate and guide
drills, reamers etc. in relation to the workpiece. The portion of the jig into which the
hardened bushes are fitted is called bush plate.
✓ Drilling jigs are either clamped to the workpiece in which holes are to be drilled or, the
workpiece is housed and clamped in the jig body. If more than one hole is to be drilled, the
drill jig is made to slide on the table of the drilling machine.
✓ Drilling jigs make feasible the drilling of holes at higher speed, with greater accuracy and
with less skilled workers than is possible when the holes are laid out and drilled by hand.
Jig bushings eliminate the elastic spring back in machining and easily locate the tool relative to
the work.