Indicative contents

• Introduction: Introduction to cutting tool design, Basic requirements of cutting tools, Cutting element and mounting element, classification of cutting tools.
  
• Single point cutting tool: Geometry of single point cutting tool, Design of shank dimension using strength and rigidity consideration, selection of geometry for the cutting tool point, chip breakers, methods of chip braking, indexable inserts, tool holders for indexable inserts, Form tool design.
  
• Multi point cutting tool: Nomenclature of a twist drill, Design of basic elements of a drill, selection of geometry, drill shank design, profile sharpened milling cutters, design of profile sharpened plain milling cutter, design of form-relieved milling cutter, geometric elements of broach teeth, design of internal round and square broaches, design of taps and reamers, gear hobs and gear shaping cutter.
  
• Design of press working tools: Classification of presses, requirements of a press tool design, Shearing theory, clearance between punch and die, punch and die clearance after considering the elastic recovery of the material, cutting forces, rating of a press, shut height of a press, types of die construction, die design fundamentals, blanking and piercing die construction, pilots, strippers and pressure pads, strip layout, economic layout, Design problems on blanking and piercing die for simple components.
  
• Design of sheet metal bending and drawing dies: Theory of bending, bend allowance, bending methods, calculation of bending force, spring back, bending dies, single operation dies, compound dies, fundamentals of drawing, draw ratio, drawing pressure, presses for drawing, variables that affect metal flow during drawing, drawing dies and punches, effect punch and die ratio, punch and die clearance, redrawing, reverse redrawing. Design problems on bending and drawing dies for simple components.
  
• Jigs and fixtures: Principles of jigs and fixtures, principles of location, clamping, methods of clamping, location – different types of jigs-like Box jig, Leaf jig, plate jigs, etc. types of fixtures-like milling, turning, grinding, etc. Special types of jigs & fixturesTeaching and Learning This module is taught by a combination of Lectures, seminars, student participation and presentations. Student performance will be based on assignment and presentations which will endevaour to find out if the fundamentals have been assimilated.
  

Module Resources

• Essential reading
  1. Course notes
• Recommended Reading
  1. Rodin – Cutting Tool Design, MIR Publication
     
  2. ASTME – Die Design Handbook.
     
  3. Paguin – Die Design Fundamentals.
     
  4. Hinman – Press working of metals.
     
  5. NEE, John G. FUNDAMENTALS OF TOOL DESIGN 4th Edition 1998, 769 pp., ISBN: 0-87263-490-6 SME Published by Society of Manufacturing Engineers.
• Journals
• Magazines
• Internet Sites
• Multimedia CDs
• Laboratory