Standard

Posted: 08/24/05

AEP 110 - Tool Design II

Course Description

Continues the development of the knowledge and skills required for tool design. Topics include: single point cutting tools, design of a blanking die, blank pierce dies, solid die design, combination dies, and progressive dies.

Competency Areas	Hours
Single Point Cutting Tools	Class	6
Design of a Blanking Die	D. Lab	4
Blank Pierce Dies	P. Lab/O.B.I.	0
Solid Form Die Design	Credit	8
Combination Dies
Progressive Dies

Prerequisite:	AEP 109
Corequisite:

Course Guide

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

SINGLE POINT CUTTING TOOLS		8	4	0
Chip formation	Identify the elements of machine chip formation.
	Describe the effects of tool geometry, speeds and feeds, and tool materials on tool use and life.
Tool geometry	Draw the body of a tool in three views.
Side rake angle	Draw a side rake angle.
End relief angle	Draw an end relief angle.
Side relief angle	Draw a side relief angle.
End cutting edge angle	Draw an end cutting edge angle.
Lead an angle	Draw a lead angle.
Back rake angle	Draw a back rake angle.
Chip grooves	Draw chip grooves.
Nose radius	Draw a nose radius.
DESIGN OF A BLANKING DIE		20	10	0
Die layout	Describe the basic steps in laying out a simple blanking die.
Plan view	Draw the plan view of the part.
Lower die shoe	Design and draw the lower die shoe.
Punch and upper die set	Design and draw the punch and upper die set.
Stock stop and support	Design and draw the stock stop and support including the stripper.
Front elevation	Design and draw the front elevation view.
General calculations	Calculate blanking and stripping pressure and heat treatment information.
List of materials	Complete the list of materials.
Title block	Complete the title block.
BLANK PIERCE DIES		6	0	0
Die assembly, front view	Identify the stripper, guide, punch, punch plate, and die shoe.
Stripper and shoulder bolt	Identify and describe the use of the shoulder and stripper bolts.
Selecting materials	Select the proper metals.
	Identify appropriate heat treatment information.
	Make a list of materials and general notes.
SOLID FORM DIE DESIGN		16	16	0
Blank	Compute the length of the blank.
	Locate the approximate position of the front view on a drawing sheet with the part shown in its fully developed length.
Formed position	Show the part in the formed position.
Punch and die steel	Design the punch and die steel around the formed part.
Corner shoe	Embed the steel die member in a corner shoe.
Gage	Draw the gage for the blank.
Spring knock-out pin	Design a spring knock-out pin.
Top view	Design the top view as a half plan of the die and punch.
Screws and dowels	Show screws and dowels in all views.
General notes	Complete general notes showing blanking pressure and heat treatment calculations.
Materials	Complete the list of materials and title block.
COMBINATION DIES		4	4	0
Diameter	Determine the approximate diameter of the blank for a combination die.
Representation	Determine how the part is to be represented.
	Select a standard sized sheet.
	Identify and describe the part in red both as a blank and a formed part in all views.
Outside cutting dies	Determine the dimensions of the outside cutting die.
Lower forming steel	Show the lower forming steel under the formed sheet.
Spring pressure die button	Identify the spring pressure die button.
Spring loaded pins	Recognize spring loaded pins which keeps the part from sticking in the die.
Upper and lower die shoes	Recognize upper and lower die shoes.
Screws and dowels	Identify screws and dowels and their dimensions.
General notes	Make general notes with blanking and stripping pressure calculations and heat treatment information.
PROGRESSIVE DIES		6	6	0
Views	Describe the views of the die and punch.
	Describe the front view of a section.
	Describe a sectional view through one preliminary gage.
	Describe a sectional view through a spring pilot.
Stock strip	Describe the stock strip in both plan views.
Holes	Identify the holes to be pierced in the first and second stages.
Last stage blank	Show the last stage outline in red.
End stop	Show the end stop beyond the blanking stage.
Stock	Identify the stock shown in the front view.
Stop strip	Identify the stop strip in the three views.
Partial die shoes	Describe partial die shoes shown in each view.
Spring view	Show a sectional view of a spring view.
Preliminary gage	Identify a preliminary gage sectional view.
Screws and dowels	Recognize screw and dowel dimensions and detail numbers.
General notes	Make general notes with blanking and stripping pressure and heat treatment information.

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.