Jigs and Fixtures Test 1

Tool Design

The process of designing and developing the tools, methods, and techniques
necessary to improve the manufacturing efficiency and productivity

3 Main Objectives of Tool Design

• lower manufacturing cost
• Maintaining quality and
• Increase production.

Concurrent Engineering

A process that allows the design team to be involved in a plan for a product design and production. It allows the tool design team member(s) to be involved in product design and production where their
knowledge of fixtures and manufacturing process will result in fewer design errors.

Tool Designer within the Chain of Command

Falls between product design and production/manufacturing.

Production Plan

A description of how core assets are to be used to develop a product in a production line

Design Process

A way of devising innovative solutions to problems that will result in new products or systems

Successful Design Requirements

• Functional

• Desirable

• Producible at a reasonable cost

• Attractive / appealing

System Design

Deals with the design of large systems such as heating/HVAC, electrical, traffic control, drainage, etc.

Product Design

Involves the design of a “product” or device such as a tool, appliance, automobile, airplane, ship, computer, etc.

Design Process Steps

• Define the problem

• Analyze needs

• Set objectives

• Create alternatives

• Check for feasibility

• Select the solution

• Draw the Design

Design Loop

Step 1. Identifying Problems and Opportunities: Analyzing Real -World Situations
Step 2. Framing a Design Brief: Problem Clarification and Specification
Step 3. Research and Investigation: Information Gathering
Step 4. Generation of Alternative Solutions
Step 5. Choosing the Best Solution
Step 6. Developmental Work
Step 7. Modeling and Prototyping: Construction
Step 8. Testing and Evaluating
Step 9. Redesigning and Improving

Product attributes to consider

Power, speed, cost, reliability, safety, functionality, ease of use, aesthetics, ethics & social impact, maintainability, testability, and manufacturability

Empirical Design

Based on past experience or successful designs. For example the designer uses a pattern wall thickness known to work well with the material and size of the finished casting.

Scientific Design

Based on the laws and principles of physics, mathematics, chemistry, mechanics, etc. For example a material separator using the principle of centrifugal force.

End Use Requirements

• Anticipate conditions of use

• Performance requirements

• Consideration for environment, load, speed of production, life expectancy, optimum size, maintenance, shape, color, and strength.

Requirements a part must meet

• Material for construction of the part

• Method of fabrication

• Dimensions

• Color

• Surface finish

• Packaging

• Every other detail of production

Attachment considerations on assemblies

Permanent, semi-permanent, quick detachable

Design

The formal process of creating products and systems to satisfy a set of requirements using available resources.

Tool Drawings

Transfer the needed details from the tool designer to the tool maker. Simple tool drawings are usually done in the assembly format. Large complicated tool drawings require detail and assembly drawings.

Types of Tool Drawings

• Assembly

• Detail

• Simple and large/complicated

General Notes

Notes in the top left corner of the drawing sheet

Local Notes

Attached to a leader

Flag Notes

Comes with a triangle with an identifier (number). References to general notes. Applies to a specific area or thing.

Words on a Drawing

Saves hours of time, but should not complicate drawing.

Standard/Bought Parts

Can be described by name rather than drawing the entire detail

Methods of Dimensioning

Limit dimension and basic size

Basic Size Dimensions

Shows the basic size and the allowable variation in the
form of a tolerance.
Two types:
-Unilateral: tolerance applied in one direction only
-Bilateral: tolerance applied in both directions

Dual Dimensioning

Shows both inch and metric dimensions. Primary system is shown on top for vertical and on the left for horizontal dimensions. Less confusion, no calculations, normally get parts in metric and use inch tools. Although it can make the drawing become cluttered.

Cross-Reference Drawing

Provides a conversion table off to the side to convert all dimensions between systems without cluttering the drawing.

SI (Metric) Drawing Rules

-All dimensions are expressed in millimeters
-The (mm) abbreviation is omitted
-Those dimensions less than 1 millimeter must be preceded by a zero.
-No commas or spaces for values over 1000.
-Omit meaningless zeros. Example: 0.5 not 0.500.
-Still use the degree symbol in angular measurements.
-Keep English thread unit as English units, do not convert to metric.

0.5

metric units

.50

inch units