Tool Design

• Single point Cutting Tools: Requirements of a tool designer, general tool design procedure, Definition and geometry of single point cutting tool, design of single point lathe tool: design of shank dimension using strength and rigidity considerations for rectangular, square and round cross section and selection of tool geometry; solid type tool, brazed tip tool, long index able insert, throwaway index able insert types and chip breakers.
• Multi Point Cutting Tool: Geometry of drill tool, end and face mill cutter; Drill bit design of elements like back taper, web thickness, land width, margin, flute length and cross section and selection of tool geometry; design of milling cutter: design of elements like number of teeth and height circular pitch, body thickness, chamfer width, fillet radius and selection of tool geometry.

Jigs & Fixtures: Tooling, die-punch, mould, work holding and fixturing; Introduction to tooling design; procedure of designing; role of Tolerance and clearance; economic considerations and calculations; principle of location of the work piece, degrees of freedom, references surfaces, resting components, fixture elements for surface concentric and radial locations; clamping of the work‐piece; review of cutting forces, principles and methods of clamping; quick clamping devices, standards; guiding elements for tools, gauge for cutter, jig bushes, indexing methods, design of jigs/fixtures/accessories for drilling, milling, turning, broaching, grinding, and welding.

• Design of dies: Simple piercing and blanking process, design of inverted die, compound die, progressive dies, rules for developing stock, strip layouts for progressive dies, types of progressive dies, load centre, analytical and graphical method to determine load centre (i.e. centre of pressure), miscellaneous dies, shaving, horn, cam actuated and precision lamination dies, fine blanking dies, principles ‐ design considerations.
• Bending dies: Theory of bending, blank development, spring back effect, spring back factor, methods of correction to overcome spring back, types of bending dies, pressure pad dies, forces in bending, construction and working principles, press brake tooling, curling, flanging principles of stretch forming – stretch forming dies.

• Design of dies for metal casting : Casting dies, terminology applicable to process, terminology applicable to dies, alignment of metal flow in hot chamber, horizontal cold chamber and vertical cold chamber machines, modification for casting of deep core or with limitations of stroke, design for
• various elements, effect of off‐centre cavity layout, necessity of balancing, types of dies, parameters influencing the runner and gate design, ejection mechanism, ejection elements and various locations, die locking mechanism, trimming , types of trim dies and alloys suitable for die making.
• Injection Moulding: Injection moulding machine and its elements, general configuration of a mould, 2‐ plate and 3‐plate mould, gate, runner, parting surface, ejection system, core and cooling system; introduction to compression die, transfer die, blow moulding dies, extrusion dies, forming and calendaring dies.

• Introduction to kinematics of machine tools, motion transmission, design of hydrostatic, hydrodynamic and antifriction guideways, design of spindles, design of speed gear boxes and feed box, feed drives, stepped and stepless regulations of speed, feed diagram, ray diagrams and design considerations.
• Vibration in machine tools, lubrication, rigidity, and reliability in machine tools.