AKTU Tool Design (BME604) Syllabus PDF – B.Tech 3rd Year

Course Outcomes

Unit‐1 Cutting Tools (8-Hours) 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.

Unit‐2 Jigs and Fixtures (8-Hours) 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.

Unit‐3 Sheet Metal, Bending and Drawing (8-Hours) 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. Unit‐4 Die Casting Dies and Injection Moulding (8-Hours) 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.

Unit 5: Control, drives and structure (8-Hours)

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.

Text Books

1. Machine Tool Design and Numerical Control by N.K. Mehta, McGraw Hill

Reference Books

1. Principles of Machine Tools by G.C. Sen and A. Bhattacharya, Central Book Agency
2. Design of Machine Tools by D. K Pal and S. K. Basu, Allied Publishers
3. Machine Tool Design, Vol. I, II, III and IV, N. S. Acherkhan, Mir Publishers
4. Jigs and Fixtures, by Joshi, Tata McGraw Hill, New Delhi.
5. Theory and Application of Metal Cutting, by Juneja, Wiley Eastern Ltd
6. Basic Die Making & Advance Die Making by D. Eugene Ostergaard, McGraw Hill
7. Injection Mould Design by R.G.WPye, Longman Scientific & Technical Publishers BME 652 - CAD/CAM Lab Total Eight Experiments are to carried out. FOUR Experiments each from CAD and CAM. A. CAD Experiments
8. Line Drawing or Circle Drawing experiment: Writing and validation of computer program.
9. Geometric Transformation algorithm experiment for translation/rotation/scaling: Writing and validation of computer program.
10. Design of machine component or other system experiment: Writing and validation of computer program.
11. Understanding and use of any 3-D Modeling Software commands.
12. Pro/E/Idea etc. Experiment: Solid modeling of a machine component
13. Writing a small program for FEM for 2 spring system and validation of program or using a FEM Package
14. Root findings or curve fitting experiment: Writing and validation of computer program.
15. Numerical differentiation or numerical integration experiment: Writing and validation of computer program. B. CAM Experiments
16. To study the characteristic features of CNC machine
17. Part Programming (in word address format) experiment for turning operation (including operations such as grooving and threading) and running on CNC machine
18. Part Programming (in word address format or ATP) experiment for drilling operation (point to point) and running on CNC machine
19. Part Programming (in word address format or ATP) experiment for milling operation (contouring) and running on CNC machine
20. Experiment on Robot and programs
21. Experiment on Transfer line/Material handling
22. Experiment on difference between ordinary and NC machine, study or retrofitting
23. Experiment on study of system devices such as motors and feed back devices
24. Experiment on Mechatronics and controls