LECTURE PRESENTATION

Reading Assignment:

• FTD Chapter 1

Optional Reading

• Ergonomics and Safety in Tool Design
• Photos: Examples of Tooling
• micron mm to atoms
• Cable Bracket Die (DWG)

Outline

Objectives

• Reduce overall cost to manufacture a product
• Increase production rate
• Maintain quality
• Reduce cost of tooling (cost effective)
• Design safe and easy to use tools

Areas of Knowledge

• Cutting tools, tool holders, cutting fluids
• Machine tools
• Jigs and fixtures
• Gages and measuring instruments
• Dies for sheet-metal cutting and forming
• Dies for forging, upsetting, cold finishing, and extrusion
• Fixtures and accessories for welding, riveting, and mechanical fastening

The Design Process

• Statement of the problem
• Analysis of requirements
• Development of initial ideas
• Development of design alternatives
• Finalization of design ideas
• Evaluate

Requirements

• Functions
• Precision
• Costs
• Lead time
• Safety
• Adaptability, compatibility, standardization
• Working life

Economics of Design

• Remember to think lean
• Combined operations
• Process cost comparisons
  • Break even point (1-1)
  • Total unit cost for a particular method (1-2a)
  • Break even point, W&S method (1-3)
  • ELS (1-4)

Break-Even Analysis

Tool Drawings

• UM Valve
  • Fulcrum (pdf)
  • End Plate (pdf)
• “Real world” drawing
  • Cable Bracket Die (pdf)
  • Cable Bracket Die (dwg)

Consider who will be making the tool

• Do not crowd views
• Analyze each cut
• Use standard values
• Use only the views necessary to define the part
• Realistic, thoughtful tolerances
• Shaft easier to change than hole
• Use stock sizes if possible
• Notes may be necessary

Tooling Layout

• Lay out the part (red is suggested)
• Lay out cutting tools and holders
• Indicate locating requirements
• 3-2-1 locating planes
• Indicate clamping requirements
• Use full scale if possible
• Indicate standard fixture parts
• Identify each item with balloons and leaders

Safety

• Design out hazards if possible
• Always break sharp edges
• Rigidity
• Fool proofing (poke-yoke)
• Make drill jigs large enough to hold without spinning
• Use guards if possible
• Punch Presses
• Limit Switches
• Feed Mechanisms
• Electrical Equipment
• Lockout provisions
• Other Provisions

1. Straight wrists
2. Avoid static muscle loading
3. Avoid stress concentrations in soft tissue of hand
4. Reduce grip force requirements
5. Maintain optimal grip span
6. Avoid sharp edges, pinch points, and awkward movements
7. Avoid repetitive finger trigger actions
8. Protect hands from heat and cold
9. Avoid excessive vibration
10. Use gloves that fit
11. Note: There may be ANSI or other standards associated with a particular type of tool. For example:

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