Standard

Posted: 08/24/05

AEP 109 - Tool Design I

Course Description

Introduces the basic concepts and procedures involved in tool design. Topics include: introduction to tool design, drill jigs, mill fixtures, hydraulic and pneumatic devices, and lathe fixtures.

Competency Areas	Hours
Introduction to tool Design.	Class	6
Drill Jigs	D. Lab	4
Mill Fixtures	P. Lab/O.B.I.	0
Hydraulic and Pneumatic Tooling Devices	Credit	8
Lathe Fixtures

Prerequisite:	AEP 102, AEP 104
Corequisite:

Course Guide

Competency	After completing this section, the student will:	Hours
		Class	D.Lab	P.Lab/ O.B.I.

INTRODUCTION TO TOOL DESIGN		10	0	0
Tooling	Identify major uses of tooling in manufacaturing
Tool materials	Describe different types of tool materials.
Production team	Describe the function of each member of a production team.
Basic manufacturing processes	Describe manufacturing processes used to produce different sizes and shapes of workpieces.
Supporting and locating principles	Explain basic clamping and workholding principles
Manuals	Locate reference information on a specified topic in a tool design manual.
Job opportunities	Identify job opportunities in tool design.
DRILL JIGS		16	14	0
Open and closed drill jigs	Design and draw open and closed drill jigs.
	Select correct views of the workpiece.
Locators	Choose correct size and type locator to fit the workpiece configuration.
	Place locators to contact the correct surface of the workpiece and maintain dimension control.
Clamp	Select the correct size and type of clamp and place clamps in their correct location on a tool drawing.
Bushings	Select the correct bushing sizes and types from a standard bushing catalog.
Bushing plate	Select the correct material and thickness for the bushing plate.
	Space the bushing plate at a proper distance from the workpiece.
Drill jig body	Select correct steel and thickness of plates using stock sizes to complete the body of a drill jig.
	Space each plate at an adequate distance from the workpiece surfaces to allow for proper functioning of clamps and locators.
Dimensioning	Dimension a drill jig drawing according to tool design dimensioning and tolerancing standards.
MILL FIXTURES		12	14	0
	Design a mill fixture with set block to include the following:
Preliminary procedures	Use standard preliminary procedures (see drill jigs) for drawing workpiece, locators, and clamps.
Standard parts	Select standard mill fixture locators and clamps to withstand the force of milling operations.
Clamps	Place clamps close enough to the edge of the workpiece surface being machined to prevent vibration and deflection.
Clearance	Select clamps and locators that will clear the cuter and arbor and be easily accessible to the machine operator.
Set block	Design the set block using proper steel and heat treatment.
	Position the set block with the desired setback distance from the feeler surface to the edge of the workpiece being machined.
	Locate the set block far enough from the clamps to eliminate clamping interference.
	Ensure that the drawing calls for the feeler thickness to be stamped on a non-feeler surface.
Base	Select the correct steel for the base using stock thickness and width large enough to prevent deflection or vibration during milling operations.
	Provide slots in each end of the base for the correct T-bolt size.
	Place two fixture lays in the base that will fit the T-slots in a mill bed.
Analysis	Analyze a vise-held fixture’s features and uses for a milling operation.
HYDRAULIC AND PNEUMATIC TOOLING DEVICES		8	0	0
Multiple clamping	Identify and describe self-contained hydraulic units for multiple clamping during machinery operations.
Drill jigs	Identify and describe air operated drill jigs and drilling machines.
Special machine	Describe Hydrocheck type units for controlled feed on high production drilling and lathe operations.
	Describe air operated drill press controlled feed units for automatic high production drilling operations.
LATHE FIXTURES		14	12	0
	Design and draw a lathe fixture to include the following:
Standard procedures	Draw workpiece, locators, and clamps according to the standard procedures.
Base	Design a base that is large enough to fit the workpiece and tooling accessories.
	Make allowances for the attachment of the base to the lathe.
Center	Design the base to include a method for indicating center.
Balancing	Indicate in the general notes some instructions for balancing the lathe fixture.
Chuck Jaws	Note special chuck jaws for simple parts that may be used as a fixture.

Suggested Resources

Books

Altintas, Yusuf. (2000). Manufacturing Automation: Metal Cutting Mechanics, Machine Tool Vibrations, and CNC Design. New York, NY: Cambridge University Press.

Henriksen, Erik Karl. (1974). Jig and Fixture Design Manual. (1^st ed.). New York, NY: Industrial Press.

Hilton, Peter D. (2000). Rapid Tooling: Technologies and Industrial Applications. New York, NY: Marcel Dekker.

Hoffman, Edward. (2003) Jig and Fixture Design, 5E (1st ed.) Independence, KY: Thomson Delmar Learning.

Joshi, Prakash Hiralal. (2002) Jigs and Fixtures Manual. (2^nd ed.) New York: McGraw-Hill.

Schertz, Karen. (2001). Design Tools for Engineering Teams: An Integrated Approach. (1^st ed.). Independence, KY: Thomson Delmar Learning.

Society of Manufacturing Engineers. (2003) Fundamentals of Tool Design (5^th ed.). Princeton, NJ: Prentice Hall.

NOTE: Henriksen’s book “Jig and Fixture Design Manual” is textbook used by Scott McKinley for the Aerospace Tool Design Specialist Technical Certificate of Credit program.