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
- Straight wrists
- Avoid static muscle loading
- Avoid stress concentrations in soft tissue of hand
- Reduce grip force requirements
- Maintain optimal grip span
- Avoid sharp edges, pinch points, and awkward movements
- Avoid repetitive finger trigger actions
- Protect hands from heat and cold
- Avoid excessive vibration
- Use gloves that fit
- Note: There may be ANSI or other standards associated with a particular type of tool. For example:
| ANSI B173.1 | NAIL HAMMERS – SAFETY REQUIREMENTS |
| ANSI B173.2 | FOR HAND TOOLS – BALL PEEN HAMMERS – SAFETY REQUIREMENTS |
| ANSI B173.3 | HAND TOOLS- HEAVY STRIKING TOOLS – SAFETY REQUIREMENTS |
| ANSI B173.4 | FOR HAND TOOLS – AXES – SAFETY REQUIREMENTS |
