· The process of designing and developing the tools, methods and techniques are necessary to improve the manufacturing efficiency and productivity.
· The design of cutting tool depends upon the function to be performed by the cutting tool.
· Metal cutting involves the interaction of four elements
Ø Work piece
Ø Cutting tool
Ø Work holder
Ø Tool holder
Tool design depends on the following factors;
v Over all shape and size of the part.
v Type and condition of the work piece.
v Degree of accuracy required.
v Number of components to be made.
v Locating and clamping elements.
Tool design objectives:
v To lower the manufacturing cost while maintaining quality of increased production.
v To provide simple and easy to operate the tools for maximum efficiency.
v To design the tools to make it fool proof and to prevent improper use.
v To select the metal which will give adequate tool life.
v To provide in the design of the tool for maximum safety of the operator.
Tool cost estimation:
v A tooling estimate includes the estimated cost of the tool and projected savings over alternative methods.
v The tool cost involves:
· Cost of tool material.
· Cost of labor (needed to fabricate the tool).
· Cost of designing the tool.
Safety as related to tool design:
Ø Tool should be safe to operate.
Ø Safety should be planned into every tool design details.
Ø Easy to load and unload.
Ø All sharp edges on the tool should be chamfered.
Ø Chip guards should be provided to protect operator.
Ø Tool clamping devices should not loosened during tool operation.
Ø Tool body (shank) should be rigid enough to resist all cutting forces.
The standard abbreviated form of a tool angle of a particular tool is known as tool signature.