Tool Engg Lab Manual

SHREE SHAKAR EDUCATION TRUST’S
SHREE DHANVANTARY COLLEGE OF

DIPLOMA ENGINEERING,
KIM-394110
LABORATORY MANUAL
TOOL ENGINEERING
(TE)
(3361902)
MECHANICAL ENGINEERING DEPARTMENT
:PREPARED BY:
Mr. NIRAV R. PATEL
2 TOOL ENGINEERING (3361902)

SHREE DHANVANTARY COLLEGE
OF DIPLOMA ENGINEERING, KIM-394110
EXPERIMENT LIST
SUBJECT: TOOL ENGINEERING SUBJECT CODE: 3361902
Sr. Experiment Title Page

No. No.
Preparatory Activity:
(a).To study about most commonly used limits, fits and tolerance values.
(b).To study about BIS designation and applications of most commonly used tool
1
materials.
(c).To study about machining processes and surface finish achieved.
(d).To study about models of / actual jigs, fixtures and progressive cutting dies.
2 To study about Cutting tools re-sharpening.
To study about design of Fixtures. (a).Sketch the component.

(b).Sketch location details.
3 (c). Sketch clamping details.
(d).Prepare production drawings of all parts of fixture(Details).
(e).Sketch assembly.
To study about design of Jigs.
(a).Sketch the component.
(b).Sketch location details.
4 (c).Sketch clamping details.
(d).Sketch tool guiding details.
(e).Prepare production drawings of all parts of jig
(f).Sketch assembly.
To study about design of Progressive dies.
(a).Sketch the component.
(b).Draw scrap strip layout.
5 (c).Calculate tonnage and center of pressure.
(d).Work out dimensions of punches and die.
(e).Production drawings of die block die shoe and stripper plate.
(f).Sketch assembly sketch of punches, die, die shoe and stripper plate.
SHREE DHANVNATARY COLLEGE OF DIPLOMA ENGINEERING MR. NIRAV R. PATEL


DIPLOMA ENGINEERING, KIM-394110
EXPERIMENT-1(A)
SUBJECT : TOOL ENGINEERING SEMESTER : 6th
SUBJECT CODE : 3361902 NAME OF FACULTY : Mr. N.R.Patel
AIM: To study about most commonly used limits, fits and tolerance values.
1. INTRODUCTION:
In manufacturing it is impossible to produce components to an exact size, even though they may be
classified as identical. Even in the most precise methods of production it would be extremely difficult and
costly to reproduce a diameter time after time so that it is always within 0.01 mm of a given basic size.
However, industry does demand that parts should be produced between a given basic size. The difference
between these sizes is called the “tolerance” which can be defined as “the amount of variation in size which
is tolerated”. A broad, generous tolerance is cheaper to produce and maintain than a narrow precise one.
Hence one of the golden rules of engineering design is “always specify as large a tolerance as is possible
without sacrificing quality”. There are a number of general definitions and terms which are used and these
are described and illustrated below.
2. SHAFT:
A shaft is defined as a member which fits into another member. It may be stationary or rotating. The
popular concept is a rotating shaft in a bearing. However, when speaking of tolerances, the term “shaft” can
also apply to member which has to fit into a space between two restrictions, for example a pulley wheel
which rotates between two side plates. In determine the clearance fit for the boss is regarded as the “shaft”.
3.HOLE:
A hole is defined as the member which houses or fits the shaft. It may be stationary or rotating, for
example, a bearing in which a shaft rotates is a “hole”. However, when speaking of tolerances, thee term
hole can be also apply to the space between two restrictions into which a member has to fit, for example the
space between two side plates in which a pulley rotates is regarded as a “hole”.
Fig.1.
4. BASIC SIZE:
This is the size about which the limits of particular fit are fixed. It is the same for both “shaft” and
“hole”. It is also called the “nominal size” (Fig 1).
5. TOLERANCE:
Tolerance is defined as the difference between maximum and minimum limits of size for a hole or
shaft. It is also the difference between the upper and lower deviations (Fig 1).
5.1 UNILATERAL SYSTEM OF TOLERANCE:
This tolerance allows variation in only one direction form the basic size. This method is
advantageous when a critical size is approached as material is removed during manufacturing, as in case of
close-fitting holes and shafts. A unilateral tolerance is always all plus or all minus; that is either the plus or
the minus value be zero.
5.2 BILATERAL SYSTEM OF TOLERANCE:
This tolerance allows variation in both directions from the basic size. Bilateral tolerances are usually
given with location dimensions or with any dimensions that can be allowed to vary in either direction. If it is
desired to specify an equal variation in both directions, the combined plus or minus symbol (±) is used with
a single value.
6.FIT:
A fit may be defined as the relative motion which can exist between a shaft and hole (as defined
above) resulting from the final sizes which achieved in their manufacture. There are three classes of fit in
common use: clearance, transition and interference.
6.1 CLEARANCE FIT:
This fit results when the shaft size is always less than the hole size for all possible combinations

within their tolerance ranges. Relative motion between shaft and hole is always possible. The minimum
clearance occurs at the maximum shaft size and the minimum hole size. The maximum clearance occurs at
the minimum shaft size and the maximum hole size.
6.2 TRANSITION FIT:
A pure transition fit occurs when the shaft and hole are exactly the same size. This fit is theoretically
the boundary between clearance and interference and is practically impossible to achieve, but by selective
assembly or careful machining methods, it can be approached within very fine limits. Practical transition fits
result when the tolerance are such that the largest hole is greater than the smallest shaft and the largest shaft
is greater than the smallest hole.
6.3 INTERFERENCE FIT:
This is a fit which always results in the minimum shaft size being larger than the maximum hole size
for all possible combinations within their tolerance ranges. Relative motion between the shaft and hole is
impossible. The minimum interference occurs at the minimum shaft size and maximum hole size. The
maximum interference occurs at the maximum shaft size and minimum hole size.


EXPERIMENT-1(B)
Aim: To study about BIS designation and applications of most commonly used tool materials.
Requirements:
The cutting tool materials must possess a number of important properties to avoid excessive wear,
fracture failure and high temperatures in cutting, The following characteristics are essential for cutting
materials to withstand the heavy conditions of the cutting process and to produce high quality and
economical parts:
 Hardness: At elevated temperatures (so-called hot hardness) so that hardness and strength of the tool
edge are maintained in high cutting temperatures:
Hot hardness for different tool materials:
 Toughness: ability of the material to absorb energy without failing. Cutting if often accompanied by
impact forces especially if cutting is interrupted, and cutting tool may fail very soon if it is not strong
enough.
 Wear resistance: although there is a strong correlation between hot hardness and wear resistance,
later depends on more than just hot hardness. Other important characteristics include surface finish
on the tool, chemical inertness of the tool material with respect to the work material, and thermal
conductivity of the tool material, which affects the maximum value of the cutting temperature at
tool-chip interface.
Cutting tool materials:
Carbon Steels:
It is the oldest of tool material. The carbon content is 0.6~1.5% with small quantities of silicon,
chromium, manganese, and vanadium to refine grain size. Maximum hardness is about HRC 62. This
material has low wear resistance and low hot hardness. The use of these materials now is very limited.
High-speed steel (HSS):
First produced in 1900s. They are highly alloyed with vanadium, cobalt, molybdenum, tungsten and
chromium added to increase hot hardness and wear resistance. Can be hardened to various depths by
appropriate heat treating up to cold hardness in the range of HRC 63-65. The cobalt component give the
material a hot hardness value much greater than carbon steels. The high toughness and good wear resistance
make HSS suitable for all type of cutting tools with complex shapes for relatively low to medium cutting
speeds. The most widely used tool material today for taps, drills, reamers, gear tools, end cutters, slitting,
broaches, etc.
Cemented Carbides:
Introduced in the 1930s. These are the most important tool materials today because of their high hot
hardness and wear resistance. The main disadvantage of cemented carbides is their low toughness. These
materials are produced by powder metallurgy methods, sintering grains of tungsten carbide (WC) in a cobalt
(Co) matrix (it provides toughness). There may be other carbides in the mixture, such as titanium carbide
(TiC) and/or tantalum carbide (TaC) in addition to WC.
QUESTIONS:
1.Classify different machining process.

2.Classify different surface finish process.
3.Explain milling process with neat sketch.


EXPERIMENT-1(C)
Aim: Demonstration of actual Jigs, Fixtures and Progressive cutting dies.
STUDENT ACTIVITY:
Students will have to prepare PPTs/models of Jigs, Fixtures and Progressive cutting dies


EXPERIMENT-2(A)
Aim: To study about single point cutting tool with nomenclature for re-sharpening.
Nomenclature of single point cutting tool
Shank:
The shank is which part of the tool on one of the end of which the tool point is formed or the tip or bit is
supported.
Base:
The base is the surface of the shank which bears against the support and takes the tangential pressure of the
cut.
Heel:
The heel is the edge between the base and the flank immediately below the face.
Point or Tool Tip:
The point is end of the tool, which is shaped to produce the cutting edges and face.

Cutting Edge:
The portion of the tool edge along which the chip is separated from the work. The cutting edge usually
comprises the nose radius, the side cutting edge, and the end cutting edge.
The Side (Primary) Cutting Edge:
This is the edge formed by intersection of the tool face and side flank. It is mainly responsible for shearing
of the work material during cutting.
The End (Auxiliary) Cutting Edge:
This is the edge formed by joining the side-cutting and end-cutting edges.
Flank:
The flank is the surface or surfaces below and adjacent to the cutting edge. These are the surfaces of the tool
facing the work.


EXPERIMENT-2(B)
Aim: To study about Cutting tools re-sharpening.
Re-sharpen any one cutting tool following:
1.Drill.
2.Side and face milling cutter
3.Centre drill, type A
[1] Drill re-sharpening:
Before re-sharpening a worn or broken drill it is advisable to study a new drill. With a protractor,
measure the angle of the cutting edge. It will be 59°. This angle, combined with the helix angle(the spiral) of
28° or up to 30°on standard jobber drills, creates the straight cutting edges that do the work. This is about
the same top rake that lathe tools have for general machining. The point with the included angle of 118° like
the bow of a ship, helps keep the drill on track. A drill that has been sharpened with an almost flat point
wobbles all over the place. Also, if the included angle of the drill point is less than 118° the cutting edge will
be convex. If the included angle of the drill point is more than 118°the cutting edge will be concave. The
aim is to get a straight cutting edge for 100 percent efficiency.

Besides re-grinding the angle correctly, you have to have each of the two cutting edges the same
length. To allow the drill to penetrate the metal, the body of the drill behind the cutting edges must be
backed off at an angle of between 12° and 15°.For small drills 3mm and below you can back off up to 18°.
Too much and the edge will soon fail; too little and the “heel” will rub and the drill will not cut.


EXPERIMENT-3
AIM: To study about design of Fixtures.
Designing of jigs and fixtures depends upon so many factors. These factors are analyzed to get
design inputs for jigs and fixtures.
The list of such factors is mentioned below:
a) Study of work piece and finished component size and geometry.

b) Type and capacity of the machine, its extent of automation.
c) Provision of locating devices in the machine.
d) Available clamping arrangements in the machine.
e) Available indexing devices, their accuracy.
f) Evaluation of variability in the performance results of the machine.
g) Rigidity and of the machine tool under consideration.
h) Study of ejecting devices, safety devices, etc.
Classification of fixture:
a) Turning fixtures
b) Milling fixtures
c) Fixture for grinding
d) Fixture for broaching
e) Fixture for boring/drilling
f) Tapping fixture
g) Fixture for welding
h) Assembling fixture
Milling Fixtures:
Fixtures used to perform different types of milling operations are called milling fixtures. The fixture
is probably located on the table of the machine and secured in position by means of bolts and nuts. The
workpiece located on the base of fixture and clamped. The fixture and associated jigs holds the workpiece
and direct the tool to right position by avoiding frequent measurement and marking. The experience of
varying forces by the workpiece are also overcome by the concerning fixtures and jigs. Proper locations of
the fixture on the machine table is usually achieved with the help of two tons provided under the fixture
base. These tons enter a T-slot of the table to provide the required location. The fixture base can then be
secured to the table by means of T-bolts and nuts. The fixtures for milling operations are designed and
described on the basis of milling operations, milling techniques and clamping power techniques.

a) On the basis of types of operations, the milling fixture may be of different types are listed below:
These are straddle milling fixture, face milling, slot milling, plain milling, side milling, form milling
and gang milling fixtures.
b) On the basis on technique of milling machining, milling fixtures are named as single piece milling
fixture, string milling, reciprocal milling, index milling and abreast milling fixture.
c) On the basis of clamping power and clamping method milling fixtures are named as fixture with
mechanical clamping, hydraulic clamping, pneumatic clamping, automatic clamping and vice jaw
clamping fixture.
CASE STUDY:
1.Design a suitable fixture to mill a slot of 5 x 5 mm. for a component shown in fig-2


EXPERIMENT-4
Aim: To study about design of Jigs.
INTRODUCTION:
Jigs are specifically designated machine parts, which can be manufactured by any of the following methods:
(a) Machining, (b) Forging, (c) Casting and (d) Complicated.
Jigs are fabricated in different pieces and joined together by welding.
Normally jigs are made of hardened steel, which are wear resistant, corrosion resistant, and thermally in
sensitive. Their dimensional accuracy directly influences the accuracy of performance of the operations
where these are used.
DIFFERENT TYPES OF JIGS:
Drilling Jigs:
Drilling jigs are used for large number of operations. Different types of drilling jigs are described below.
Template Jig:

This is a simple plate of metal or wood which carries correct locations of holes to be made in the
workpiece. Size of template jig should be same as that of the workpiece. It is overlapped with the workpiece
and drilling is done quickly. Use of this jig avoids the marking operation completely.
Plate Type Jig:
If the work is to be done on very large scale, an improvement can be made to template jig that is
plate type jig. This uses a plate having drill pushes and suitable means to hold and locate the works that it
can be clamped to the plate and holds drilled directly through the bushes in correct positions.
Open Type Jig:
In this jig the top is kept open and workpiece is placed on the base of the jig and the drill plate.
Carrying the drill bushes is placed on the top to guide the tool. After the operation is over, the drill plate is
removed and workpiece is replaced. It is shown in Figure.

Swinging Leaf Type Jig:
This type of jig carries a leaf or plate, arranged at the top or on one side, which is capable of
swinging about a fulcrum. It is normally the drill plate itself which is pivoted about a point at its one end. A
swinging leaf type jig is shown in Figure 4.15. The work is loaded and unloaded with the help of swinging
bolt.
Box Type Jig:
When the holes are to drill more than one plane of the work piece, the jig has to be provided with
equivalent number of bush plates. For positioning jig on the machine table feet have to be provided opposite
each drilling bush plate. One side of the jig will be provided with a swinging leaf for loading and unloading
the work piece, such a jig would take the form of a box. Such a jig should be as light as possible. Since it
will have lifted again and again. Typical figure of box type jig is shown.

CASE STUDY:
1. Design a suitable Drill Jig to drill 10 mm dia. hole for a component shown in fig.Draw the drill jig and
its elements with all necessary dimensions.


EXPERIMENT-5
Aim: To study about design of Progressive dies.
Introduction:
Press working may be defined as chip less manufacturing process by which various component are
made from large are applied by press for shout time interval Following are the shearing operation by press
tool:
Blanking:
Punching or Piercing:
Lancing:
Perforating:
Notching:

Framing:
Cutting:
Slitting:
While following are the bending drawing:

 Drawing
 Bending
 Deep drawing
 Forming
 Bulging
 Embossing
 Cooling
 Strength forming
 Knurling
 Swaging
 Automation parts of electronic equipment etc.
Classification of Die:
1) According to the types operation performed

 Shearing
 Blanking
 Piercing
 Punching
 Performing machine
2) According to specification of construction

 Cutting die
 Forming die
 Multi operation
 Compound die
 Progressive die
 Combination die
Difference between:
Compound die Progressive die

1. more than one shearing operation are 1. more than one shearing are perform on different station
performed station
2. medium size press is used 2. press size according to our need
3. die design is complication 3. die design is simple
Tonnage:
It indicates the maximum pressure at which the press designed to safety performed the cutting or
forming operation. It is a maximum capacity press. The capacity of must should like width the same. Hence
a job required that must power and number more should be assigned the press some times.

Calculation of tonnage of press: There force required penetrate of share the stroke material the punch is
cutting force of tom age is cutting force of tom age
F = P*T*Fs
Where:
F = cutting
P =perimeter in mm
T = thickness
Fs = shearing strength
Now parameter for diameter
Π * d for having small diameter
Π * [D*d]
Shut height of press
It is the distance from the shoe to the of punch holder when die is closed shoe position in another
works we can say that shut height as the distance from top of table or bottom of side
General aspects of design:

 The general aspects satisfy die given below
 Die shut give maximum production & minimum maintenance expense with maximum cost
 Modern method of press working
 Production quality dimension strength & finishing should be maintained to complete in market
Rule of method for block design = the method is based on experience for a die block made of tool
18 mm for perimeter < 75 mm

25 mm for perimeter < 250 mm
They should be minimum 30 mm margin the opening in the die block for regrinding the die block to
the die holder
 Analytical method
 Practical method
 Graphical method
Design of punch:
The punch is made member of the die set the die of punch determine by producing clearance
between punch & die
If, D= punch diameter

f = stroke thickness

F = shear strength
T = compressive strength
L = π/5 *d*d/f*fs
Percentage scrap = [18*51.25*45 / 18*51] * 100 = 26.47 %
Bending method:
V-Bending: A wedge shaped punch the sheet metal of strip into a wedge shap die capacity this method
produce a bend having 90.
 Analytical method
 Graphical method
 Practical method
Design of Die method Rate of the method Stress method
Stroke Stops are:

 Pin stop
 Automation stop
 Starting stop
 Figure stop
 Power stop
 Shoulder stop
Die sets are:

 Various styles
 Three part
 Four part
 Round part
Die wear is the negative allowance
Edge bending: A slat punch force the stroke against the force of die as illustrated in the bed axis is pearled
to the stroke is subjected to cantilever loading
Bonding die:
It is an assembly of different parts is the man parts are given below
 Punch holder
 Die block
 Punch
 Wear strip
 Die holder
 Pressure below
 Hill
 Stop power
Points to remember:
 Working is chip less manufacturing process in which large to force
 Press tool are classified as to

 Types of operation performed
 Specify construction
 Punch a claimer punch holder plate die tonnage indicated the safety maximum pressure by press
CASE STUDY:
1.Design a suitable die assembly for a component shown in fig -3. Sketches the disassembly & its element
&dimension also show your necessary calculation & scrap strip layout.

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SHREE SHAKAR EDUCATION TRUST’S

SHREE DHANVANTARY COLLEGE OF

SHREE SHAKAR EDUCATION TRUST’S

Sr. Experiment Title Page

2 To study about Cutting tools re-sharpening.

To study about design of Fixtures. (a).Sketch the component.

SHREE DHANVNATARY COLLEGE OF DIPLOMA ENGINEERING MR. NIRAV R. PATEL

SHREE SHAKAR EDUCATION TRUST’S

“hole”. It is also called the “nominal size” (Fig 1).

5.1 UNILATERAL SYSTEM OF TOLERANCE:

5.2 BILATERAL SYSTEM OF TOLERANCE:

6.1 CLEARANCE FIT:

SHREE DHANVNATARY COLLEGE OF DIPLOMA ENGINEERING MR. NIRAV R. PATEL

6.2 TRANSITION FIT:

6.3 INTERFERENCE FIT:

SHREE DHANVNATARY COLLEGE OF DIPLOMA ENGINEERING MR. NIRAV R. PATEL

SHREE SHAKAR EDUCATION TRUST’S

Hot hardness for different tool materials:

High-speed steel (HSS):

1.Classify different machining process.

SHREE DHANVNATARY COLLEGE OF DIPLOMA ENGINEERING MR. NIRAV R. PATEL

SHREE SHAKAR EDUCATION TRUST’S

Aim: Demonstration of actual Jigs, Fixtures and Progressive cutting dies.

SHREE DHANVNATARY COLLEGE OF DIPLOMA ENGINEERING MR. NIRAV R. PATEL

SHREE SHAKAR EDUCATION TRUST’S

Nomenclature of single point cutting tool

Point or Tool Tip:

SHREE DHANVNATARY COLLEGE OF DIPLOMA ENGINEERING MR. NIRAV R. PATEL

The Side (Primary) Cutting Edge:

The End (Auxiliary) Cutting Edge:

SHREE DHANVNATARY COLLEGE OF DIPLOMA ENGINEERING MR. NIRAV R. PATEL

SHREE SHAKAR EDUCATION TRUST’S

Aim: To study about Cutting tools re-sharpening.

Re-sharpen any one cutting tool following:

[1] Drill re-sharpening:

SHREE DHANVNATARY COLLEGE OF DIPLOMA ENGINEERING MR. NIRAV R. PATEL

SHREE DHANVNATARY COLLEGE OF DIPLOMA ENGINEERING MR. NIRAV R. PATEL

SHREE SHAKAR EDUCATION TRUST’S

AIM: To study about design of Fixtures.

The list of such factors is mentioned below:

a) Study of work piece and finished component size and geometry.

SHREE DHANVNATARY COLLEGE OF DIPLOMA ENGINEERING MR. NIRAV R. PATEL

SHREE DHANVNATARY COLLEGE OF DIPLOMA ENGINEERING MR. NIRAV R. PATEL

SHREE SHAKAR EDUCATION TRUST’S

Aim: To study about design of Jigs.

Jigs are fabricated in different pieces and joined together by welding.

DIFFERENT TYPES OF JIGS:

SHREE DHANVNATARY COLLEGE OF DIPLOMA ENGINEERING MR. NIRAV R. PATEL

Plate Type Jig:

Open Type Jig:

SHREE DHANVNATARY COLLEGE OF DIPLOMA ENGINEERING MR. NIRAV R. PATEL

Swinging Leaf Type Jig:

Box Type Jig:

SHREE DHANVNATARY COLLEGE OF DIPLOMA ENGINEERING MR. NIRAV R. PATEL

SHREE DHANVNATARY COLLEGE OF DIPLOMA ENGINEERING MR. NIRAV R. PATEL

SHREE SHAKAR EDUCATION TRUST’S

Aim: To study about design of Progressive dies.

SHREE DHANVNATARY COLLEGE OF DIPLOMA ENGINEERING MR. NIRAV R. PATEL

Percentage scrap = [1851.2545 / 1851] 100 = 26.47 %