Tool Design Data Book PDF

TOOL DESIGN DATA BOOK
FOR
DIPLOMA IN MECHANICAL ENGINEERING (TOOL & DIE) COURSE CODE 1220
DIRECTORATE OF TECHNICAL EDUCATION GOVERNMENT OF TAMILNADU
DIRECTORATE OF TECHNICAL EDUCATION GUINDY, CHENNAI 25 TOOL DESIGN DATA BOOK
1. This book can be used for Board Examination by the Diploma in Mechanical Engineering (Tool & Die) students for the Tool Design subject. 2. The Use of this data book ( Institutional copy) Indian Standard specifications listed in Table 6.34 of this data book and any other related Indian standard specifications is permitted in the Board Examination for the subject 22254 - Tool Design and Drawing
Tool Design Data Book
Page 2
SL.NO
1. 2. 3.
CONTENTS TOPIC
Material Properties Sheet material SWG to mm & inch conversion Data for stamping dies Formulae Strip layout Die plate design data Stripper design data Punch design details Punch holder data Pilots Finger stops Automatic stops Fasteners - Screws & dowels Die set Press data Shut height Punch and die materials & Heat treatment Centre of Pressure Spring design data
PAGE NO.
1 2
3 4 5 10 12 15 16 17 18 21 23 27 28 29 34 36
Page 3
4. 5. 6.
Data for bending dies Data for drawing dies Data for gauge Design
ISO System of limits and fits tolerances & deviations Reference Indian standard specifications for gauge design
61 66
70 102
7.
Jigs & fixtures Guidelines for selection of locators and clamps Locating pins Clamps Jig feet & buttons Jig bushes Screws & nuts Pressure pads Spherical & C Washers Wing nuts 103 104 106 108 110 113 117 118 119 120
8.
Unit Conversion tables
Page 4
Table 1 - MATERIAL PROPERTIES
SHEAR STRENGTH S.No MATERIAL N/mm

2
ULTIMATE TENSILE STRENGTH N/mm2
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.
O T
L O
Stainless steel Steel 0.1% carbon ( soft) Steel 0.25%carbon ( mild) Steel 0.5% carbon Steel 0.75% carbon Steel 1% carbon Steel 1.2% carbon ( not tempered) Steel 1.25% carbon( tempered hot) Aluminium soft sheet Aluminium half hard sheet Aluminium hard sheet Brass soft sheet Brass half hard sheet Brass hard sheet Copper rolled Cupro nickel Duralumin soft sheet Duralumin treated and cold rolled Fibre hard Lead Leather Oak ( wood) Tin rolled sheet Tin coated steel sheet Zinc rolled sheet Zinc hard rolled Silver Paper using hollow dies
539.70 346.95 385.5 539.70
G I S E
616.8 655.35 724.7 1464.89 115.65 146.49 192.75 231.29 269.85 308.40 215.88 308.4 231.29 308.10 185.04 30.84 54 54 38.55 385.5 138 154.20 231.29 23.13
A T A
719.6 462.6 514 719.6
O O B
822.4 873.8 966.2 1953.18 154.2 195.32 257 308.38 359.8 411.20 287.84 411.20 308.39 410.80 246.72 41.12 72 72 51.4 514 184 205.6 308.38 30.84
Page 1
Table 2 - Sheet material SWG to mm & inch conversion
SWG 7/0 6/0 5/0 4/0 3/0 2/0 1/0 1 2 3 4 5 6 7
inches 0.500 0.464 0.432 0.400 0.372 0.348 0.324 0.300 0.276 0.252 0.232 0.212
Mm 12.700 11.79 10.97 10.16 9.45 8.84 8.23 7.62 7.01 6.40 5.89 5.39 4.88 4.47 4.06 3.66 3.25 2.95 2.64
SWG 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
inches 0.092 0.080 0.072 0.064 0.056 0.048 0.040 0.036 0.032 0.028 0.024 0.022 0.020 0.018 0.0164 0.0148 0.0136 0.0124 0.0116
Mm 2.34 2.03 1.83 1.63 1.42 1.22 1.02 0.91 0.81 0.71 0.61 0.56 0.51 0.46 0.42 0.38 0.35 0.31 0.30
SWG 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
inches 0.0108 0.0100 0.0092 0.0084 0.0076 0.0068 0.006
mm
0.27 0.25 0.23 0.21 0.19 0.17 0.15 0.13 0.12 0.11 0.10 0.09 0.08 0.07 0.06 0.05 0.04 0.03 0.02
O T
L O
8 9 10 11 12
D
0.176 0.160 0.144 0.128 0.116 0.104
0.192
S E
IG
A T A
0.0052 0.0048 0.0044 0.004 0.0036 0.0032 0.0028 0.0024 0.002 0.0016 0.0012 0.001
O O B
Page 2
DATA FOR STAMPING DIES FORMULAE: 1. Cutting force = Where S P T 2. 3. 4. 5. = = = S*P*T
Shear strength of the component material in N/mm2 Perimeter of the component in mm
Thickness of the component in mm = = = =

Area of Blank Area of Strip
Percentage of utilization Percentage of scrap Stripping Force
Press Capacities
6.Compressive force on punches = comp.stress of the punch matl. X area of cross section of punch 7.
WHERE
Buckling Forces
E= modulus of elasticity in GN/mm2 I=moment of inertia in mm4
O T
L O
8.
Lp=length of punch in mm Strip layout Margin (or) Bridge
G I S E
100 Percentage of utilization 10 to 20% of cutting force Cutting Force x 1.3
A T A
X 100
O O B
=2EI/LP2
= 1.5t where t is the sheet metal thickness in mm
The margin or the bridge thickness can also be selected from the following table
Page 3
Table - 3.1 - DATA FOR STRIP LAYOUT

Web length(l) in mm
Thickness of sheet metal in mm 0.5 0.75 1 1.25 1.5 1.75 2 2.25 2.5 3
Margin, (S), mm 1.5 2 3 3.5 4 4.5 1.2 1.7 2.4 2.9 3.4 3.9 1 1.75 2 2.5 3 3.5 1.4 1.9 2.4 2.9 3.4 3.9 1.5 2 2.5 3 3.5 4 1.8 2.2 2.7 3.2 3.7 4.2 2 2.5 3
10 50 100 150 250 350
O T
L O
G I S E
D
4 4.5
3.5
A T A
2 2 3 2 2.8 3.2 3.7 4.2 4.7 3.5 4 4 4.5 5 5
O O B
3.5 4 2.5 3.7 4.2 4.7 5.2 5.7 2.5 4 4.5 5 5.5 6
3.5
4.5
5.5
Page 4
DIE PLATE DESIGN DATA: Die block thickness =

3
F Where F is cutting force in Kg.
Die block thickness and other die dimensions may also be selected from the following table:
Strip Thickness
O T
L O
0 to 1.5
1.5 to 3.1 3.1 to 4.7 4.7 to 6.3 Over 6.3
G I S E
B
Die Block Height 24 29 35 42 48
N
27 33 39 47 54
A T A
O O B
C Minimum Distance Die Hole To Outside Edge 2 Inside Corners (1.5 B)

36 44 53 63 72
1 Smooth Die Hole Contour (1.125 B)
3 Sharp Inside Corners

(2 B) 48 58 70 84 96
Table 3.2 - Recommended minimum C distance for various die hole contour and die block heights B
Page 5
Table 3.3 - Tabulation of suggested standard die block sizes
O T
L O
D
76.2 76.2 101.6 101.6 101.6 127 127
G I S E
B C D E 88.9 127 15.8 44.4 44.4 69.8 69.8 69.8 88.9 88.9 57.1 95.2 69.8 95.2 120.6 88.9 114.3 15.8 15.8 15.8 15.8 19 19 101.6 127 152.4 127 152.4
N
F 23.8 23.8 23.8 23.8 23.8 23.8 23.8
A T A
G
O O B
M8 TAPPED THROUGH HOLE M8 TAPPED THROUGH HOLE M8 TAPPED THROUGH HOLE M8 TAPPED THROUGH HOLE M10 TAPPED THROUGH HOLE M10 TAPPED THROUGH HOLE M10 TAPPED THROUGH HOLE
Page 6
Table 3.4 - Tabulation of suggested standard medium size die block sizes:
A 101.6 101.6 127
B 177.8
O T
L O
127 152.4 152.4 177.8
D
203.2 254 203.2 254 279.4
203.2
S E
C D 19 19 19 19 19 19 19 63.5 63.5 88.9 88.9 114.3 114.3 139.7
139.7 165.1 165.1 215.9 165.1 215.9 241.3
IG
E F 69.8 82.5 82.5 82.5
A T A
G 28.5 28.5 28.5 28.5 28.5 28.5 28.5
O O B
M10 TAPPED THROUGH HOLE M10 TAPPED THROUGH HOLE M10 TAPPED THROUGH HOLE M10 TAPPED THROUGH HOLE M10 TAPPED THROUGH HOLE M10 TAPPED THROUGH HOLE M10 TAPPED THROUGH HOLE
107.9
107.9 120.6
Page 7
Die land:Die land varies depending upon the no. of regrinding requirements (die life expectancy). But in general die land is given as 3 to 5 mm.
Angular clearance: - Generally 1/4o to 1o angular clearance is provided. Increased die clearance weakens the die. Angular clearance may also be selected from the following table:
Table 3.5 Anglular clearance data

Strip thickness in mm
Soft materials require greater angular clearance than hard materials.
O T
L O
G I S E
1.5875 to 4.76 4.76 to 7.9 Over 7.9
0 to 1.5875
Angular clearance per side 1/4o 1/20 3/40 10
A T A
O O B
Page 8
Die clearance:Clearance per side = C *T * (max/10) Where C= constant = 0.005 for very accurate components =0.01 for normal component. T= Sheet thickness in mm. max = Shear strength of sheet material in N/mm2
Clearance per side can also be selected from the table given below:
Table 3.6 Die clearance

Material Mild steel Aluminum Brass
Die clearance per side in percentage of sheet thickness 2.5%-5% 1.5%-3%
O T
L O
G I S E
1.5%-3%
A T A
O O B
Page 9
STRIPPER DESIGN STRIPPER PLATE THICKNESS = A = (W/30) +2t Where A = Stripper plate thickness in mm W= Width of strip in mm t= Thickness of sheet metal in mm.
The stripper plate thickness can also be selected from the following table:
Table 3.7 Stripper plate thickness

STRIP (thicknes s* width) 1.6x75 1.6x150 1.6x225 1.6x300 3.2x75 3.2x150 3.2x225 3.2x300 4.8x75 4.8x150 4.8x225 4.8x300 6.35x75 6.35x150 6.35x225 6.35x300 7.8x75 7.8x150 7.8x225 7.8x300 Stripper Plate thicknes s (A) in mm 6 8 10 14 10 12 14 16 12 15 18 20
O T
L O
D
16 18 20 22 18 22 24 26
G I S E
A T A
O O B
Note:For design and manufacturing simplicity, the width and length of stripper is assumed same as that of the die plate
Page 10
Table 3.8 Clearance between Strip and Strip gudie

Strip thickness in mm clearance for hand feed in mm Clearance for automatic feed in mm
0-1.587
1.587-3.175 3.175-4.762 4.762-6.35
O T
L O
6.35-7.937
G I S E
A T A
0.8 0.8 0.8 0.8 0.8
O O B
1.6 2.4 3.2 4.0 4.8
Page 11
PUNCH DESIGN DETAILS Table 3.9 - Stepped Round Punch Table 3.10 Round Punch
O T
L O
G I S E
A T A
O O B
Page 12
Table 3.11 Square Punch
Table 3.12 Quick change punch
O T
L O
G I S E
A T A
O O B
Page 13
Table 3.13 Punch Chamfered head
Table 3.14 Stepped Punch
Table 3.15 Square Punch with shedder
O T
L O
G I S E
A T A
O O B
Page 14
Table 3.16 - COMMONLY USED PUNCH PL ATE SIZES:-
Table 3.17 - COMMONLY USED PUNCH PLATE SIZES
O T
L O
G I S E
A 50 50 75 75 75 100 100 100 125 125 125 150 150 150 150 175 175 175
A T A
B 12.7 15.8 19 22.2 25.4 28.5 31.7 34.9 38.1
B 50 75 75 100 125 100 125 150 125 150 175 150 175 200 250 175 225 275
O O B
A 0 to 7.9 7.9 to 11 11 to 12.7 12.7 to 15.8 15.8 to 17.4 17.4 to 19 19 to 22.2 22.2 to 23.8 23.8 to 25.4
Page 15
Table 3.18 - PILOTS ACORN TYPE PILOT B C D E MAT 3.1 0.7 3.9 2.3 D.R. 4.7 1.19 4.7 3.1 D.R. 6.3 1.5 7.1 4.7 D.R. 7.9 1.98 9.5 6.3 D.R. 9.5 2.3 11.1 7.1 D.R. 11.1 2.77 12.7 7.9 D.R. 12.7 3.1 14.2 9.5 D.R. 14.2 3.57 15.8 11.1 D.R. 15.8 3.9 17.4 11.9 D.R. 17.4 4.3 19 12.7 D.R. 19 4.7 22.2 14.2 D.R. FLATTENED POINT TYPE B C D E MAT 20.6 12.7 23.8 15.8 Tool Steel 22.2 13.4 25.4 17.4 T.S 23.8 14.2 28.5 19 T.S 25.4 15.8 31.7 20.6 T.S 26.9 16.6 33.3 22.2 T.S 28.5 17.4 36.5 23.8 T.S 30.1 18.2 38.1 25.4 T.S 31.7 19 41.2 26.9 T.S 33.3 20.6 42.8 28.5 T.S 34.9 21.4 44.4 30.1 T.S 38.1 23.8 47.6 31.7 T.S
A 3.1 4.7 6.3 7.9 9.5 11.1 12.7 14.2 15.8 17.4 19 A 20.6 22.2 23.8 25.4 26.9 28.5 30.1 31.7 33.3 34.9 38.1
O T
L O
G I S E
A T A
O O B
Page 16
FINGER STOPS
Table 3.19 - FINGER STOPS

1 SMOOTH DIE HOLE CONTOUR FRONT FINGER SPACER STOP WIDTH No. 2 INSIDE CORNERS FRONT SPACER WIDTH FINGER STOP No.
A STRIP THICKNESS 0 to 1.5 1.5 to 3.1 3.1 to 4.7 4.7 to 6.3 Over 6.3 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 A 3.2 4.8 6.4 8.0 9.5 3.2 4.8 6.4 8.0 9.5 B 6.3 7.9 9.5 11.1 12.7 9.5 11.1 12.7 14.2 15.8 9.5 11.1 12.7 14.2 15.8
3 SHARP CORNERS FRONT SPACER WIDTH
25 32 38 45 50 C 16.6 20.6 24.6 28.5 32.5 23.8 27.7 31.7 35.7 39.6 36. 40.4 44.4 48.4 52.3
1 2 3 4 5 D 37.3 44.4 51.5 58.7 65.8 50.8 57.9 65 72.2 79.3 63.5 70.6 73.5 81.3 88.4
O T
L O
.3.2 4.8 6.4 8.0 9.5
G I S E
38 45 50 58 64 6 7 8 9 10 E 1.6 2.4 3.2 4.0 4.8 1.6 2.4 3.2 4.0 4.8 1.6 2.4 3.2 4.0 4.8 F 46.22 57.37 66.92 76.50 86.05 61.31 70.86 80.41 89.99 99.56 74.01 83.56 93.11 102.69 112.26
50 56 63 70 75
FINGER STOP No.
A T A
O O B
11 12 13 14 15
AUTOMATIC STOPS
Page 17
Table 3.20- AUTOMATIC STOPS NO 1 2 3 4 5 6 A 101.6 477.5 965.2 1442.7 2092.9 127 B 6.3 6.3 6.3 7.9 7.9 7.9
O T
L O
NO 1 2 3 4 5 6
M 4.8Drill 9.5 depth 45 csk 4.8Drill 9.5 depth 45 csk 4.8Drill 9.5 depth 45 csk 4.8Drill 9.5 depth 45 csk 4.8Drill 9.5 depth 45 csk 4.8Drill 9.5 depth 45 csk
G I S E
1.6 deep 1.6 deep 1.6 deep 1.6 deep 1.6 deep 1.6 deep
C 19.8 23.8 58.4 160 302.2 441.9
D 8.7 9.5 10.3 11.1 11.9 12.7
E 6.3 6.3 6.3 7.9 7.9 7.9
N
F 119.3 160 241.3 302.2 340.3 401.3
G 241.3 281.9 360.6 441.9 523.2 604.5
D
P 12.7R. 12.7R. 12.7R. 12.7R. 12.7R. 12.7R.
A T A
I 2.3 3.1 3.1 4.7 4.7 4.7 J 3.1 3.9 3.9 5.5 5.5 5.5 K 7.1R. 7.1R. 7.1R. 8.7R. 10.3R. 11.1R. Q 30 30 30 30 30 30 R 1.1R. 1.1R. 1.1R. 1.1R. 1.1R. 1.1R. S 3.1R. 3.1R. 3.1R. 3.1R. 3.1R. 3.1R. T 1.5 1.9 2.3 2.7 3.1 3.9
O O B
L 4.7 6.3 6.3 7.1 7.9 9.5
H 4.7 6.3 7.9 9.5 11.1 12.7
N 6 6 6 6 7 7
O 1.5 R. 1.9 R. 1.9 R. 2.3 R. 2.3 R. 2.3 R.
U 16.6 20.6 24.6 78.7 183 281.9
Page 18
Table 3.21- AUTOMATIC STOPS
NO 1 2 3 4 5 6
A 6.3 9.5 12.7 15.8 19 22.2
B 16.6 20.6 24.6 78.7 180.3 281.9
NO 1 2 3 4 5 6
O 33 33 33 33 33 33
O T
L O
NO 1 2 3 4 5 6
A 37.30 39.68 43.65 47.62 50.80 54.76
P 5.5 6.7 6.7 7.9 8.7 9.5
Q 3.1 4.7 6.3 7.9 9.5 11.1
G I S E
R 0.8 X 45 0.8 X 45 0.8 X 45 0.8 X 45 0.8 X 45 0.8 X 45. S 2.3 3.1 3.1 4.7 4.7 4.7 C 25.4 78.7 160 241.3 322.5 401.3 D 7.9 7.9 8.7 10.3 10.3 11.1 E 19 20.6 23 24.6 58.4 99
C 25.4 78.7 160 241.3 322.5 401.3
D 50.8 157.4 320 645.1 1127.7 76.2
E 25.4 78.7 160 241.3 322.5 401.3
F 12.7 14.2 15.8 17.4 19 20.6
T 6.75dr 10.31 c bore 6.35 deep 6.75dr 10.31 c bore 6.35 deep 8.33dr 11.90 c bore 7.93 deep 8.33dr 11.31 c bore 7.93deep 9.92dr 15.08 c bore14.28deep 9.92dr 15.08c bore 14.28deep
G 19 20.6 23 24.6 58.4 99
D
H 322.5 78.7 523.2 119.3 238.7 401.3
I 3.1 3.1 3.1 3.9 3.9 3.9
A T A
J 3.1 3.1 3.1 3.9 3.9 3.9 K 6.3 6.3 6.3 7.9 7.9 7.9 L 7.9 8.7 8.7 10.3 11.9 12.7
O O B
M 9.1 10.3 11.1 12.7 14.2 15.8 N 7.9 8.7 9.5 11.1 11.9 13.4
U 4.8 drill 2.4 deep 45 csk 1.19 deep 4.8 drill 2.4 deep 45 csk 1.19 deep 4.8 drill 2.4 deep 45 csk 1.19 deep 4.8 drill 2.4 deep 45 csk 1.19 deep 4.8 drill 2.4 deep 45 csk 1.19 deep 4.8 drill 2.4 deep 45 csk 1.19 deep
B 34.93 37.30 41.67 44.84 48.02 52.38
F 322.5 401.3 523.2 604.5 238.7 401.3
G M6 TAP M6 TAP M8TAP M8TAP M10 TAP M10 TAP
Page 19
Table 3.22- AUTOMATIC STOPS
STOP NO. 1 2 3 4 5 6
A 28.5 30.1 31.7 33.3 34.9 36.5
STOP NO. 1 2 2-A 3 3-A 3-B 4 4-A 4-B 4-C 5 5-A 5-B 5-C 6 6-A 6-B
A 19.8 23.8 25.4 27.7 29.3 30.9 31.75 33.33 34.92 36.51 37.3 38.89 40.48 42.06 42.86 44.45 46.03
Table 3.23 - FULCRUM PIN DIMENSIONS
O T
L O
STOP NO 1 2 3 4 5 6
G I S E
B 2.40 3.175 3.175 4.80 4.80 4.80
A T A
O O B
A 22.22 25.40 28.575 31.75 34.925 38.10
Page 20
APPLICATION OF FASTENERS SCREWS:
Heat treated socket head cap screws can withstand double the load permissible for commercial hexagonal head bolts and nuts. S = design stress for socket head cap screw ranges from 80 to 120 N/mm2. Root area for the metric screws can be found from the following formula A = 0.7854 (D 1.227P)2 Where D = Diameter. Of screw in mm P = Pitch of screw in mm Load (N) = A x S
DOWELS:
Dowels are subjected to shear stress due to horizontal force resulting from die clearance. S = Dowels are rarely stressed beyond 50 to 80 N/mm2 Horizontal Force Stripping Load Load/Dowel Area
= Load/Dowels S
Dowel diameter = (Area/0.7854)
If Dowel size becomes too big more number of smaller dowels having same total sectional
O T
L O
area can be used. As area of dowel varies according to square of dowel diameter it is better to use two big dowels instead of a no. of smaller dowels.
G I S E
= Die clearance x Stripping Load = 10% of vertical Force = Horizontal Force / No. of Dowels
A T A
O O B
Page 21
Table 3.24 - NO OF SCREWS BASED ON STRIPPING FORCE STRIPPING FORCE IN TON N 0.2 1992.8to2491.0 0.4 3985.6 0.63 6277.3 0.8to1.0 7971.2to9964.02 1.25 12455.0 1.60 15942.4 2.5 24910.0 4.0 39856.0 M6 2 3 4 6 8 * * * M8 * 2 2 3 4 5 8 * M10 M12 * * * 2 3 3 5 8 * * * 2 2 2 4 6 M16 * * * * * 2 3 3
M20 * * * * * * * 2
SCREWS AND DOWELL COMBINATIONS

-
The diameter of the screws and dowels is also determined by the size of the component. Generally 10mm screws are used on die components up to 150 mm2. Heavy die components are usually secured with 12 to 16mm diameter screws. Dowel diameter should be same as that of the cap screws. Dowel should be located diagonally across from each other and as apart as possible to increase the locational accuracy.
All screws and dowels should be located from 1.5 to 2 times their diameter from the component edge.
O T
L O
G I S E
A T A
O O B
Page 22
Table 3.25 - DIE SET DETAILS

S. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 X 60 100 150 100 95 120 120 150 150 160 160 160 D 52 52 52 75 100 100 120 140 170 120 145 135 160 180 160 180 160 180 185 120 120 210 235 230 210 235 165 165 260 255 Y 130 100 INCH SIZE 04 X 04 04 X 06 04 X 08 05 X 05 05 X 06 06 X 06 06 X 07 06 X 09 06 X 12 07 X 07 07 X 08 08 X 08 08 X 09 08 X 10 08 X 12 08 X 13 09 X 09 09 X 10 10 X 10 10 X 10 10 X 10 10 X 11 10 X 12 10 X 15 11 X 11 12 X 12 12 X 12 12 X 12 12 X 13 13 X 13 L 100 150 200 130 125 150 150 230 305 180 180 200 200 205 200 200 230 230 254 254 254 254 254 254 280 305 305 305 305 330 W 100 100 100 130 150 150 180 150 T 20 20 25 20 22 22 25 20 30 25 25 30 30 30 30 30 30 30 30 30 30 30 30 35 30 30 30 30 30 35 B 22 22 30 25 25 25 30 20 35 30 30 35 35 35 35 35 35 35 35 35 35 35 35 40 35 35 35 35 35 40 Pillar (OD) 16 20 20 20 20 20 25 20 28 25 25 28 28 28 32 32 28 28 28 28 28 32 32 32 32 32 32 28 32 36
O T
L O
D
21 22 23 24 25 26 27 28 29 30
20
S E
200 200 200 200 200 230 255 255 280
IG
170 170 200 200 200 255 255 -
D
180 200 205 230 254 305 330 230 250 254 254 254 280 305 380 280 305 305 305 330 330
150
A T A
O O B
TYPE Back Pillar Back Pillar Back Pillar Back Pillar Back Pillar Back Pillar Back Pillar Blister Cen Cent Pillar Back Pillar Back Pillar Back Pillar Back Pillar Back Pillar Cent Pillar Cent Pillar Back Pillar Back Pillar Back Pillar Diago. Pillar Four Pillar Back Pillar Back Pillar Cent Pillar Back Pillar Back Pillar Diago. Pillar Four Pillar Back Pillar Back Pillar
Page 23
BALL BEARING CAGES
Table 3.26 - Ball Bearing Cages Standard bearing Al./Brass No. 1 2 3 4 5 6 7 I.D.X. 20 25 28 32 32 36 40 O.D.X 26 31 36 40 40 44 48 Length X 65 70 80 80 95 90 90 Ball 3 3 No.
Table 3.27 Ball Bearing Cages
Non Standard bearing Al./Brass I.D.X. 15 16 19 24 18 30 32 36 38 40 48 50 60 O.D.X. 21 22 25 30 24 38 40 44 46 48 58 60 70 Length X 70 70 70 70 70 80 100 105 105, 125 105, 125 105, 125 105, 125 125
O T
L O
S E
IG
4 4 4 4
N
2 3 4 5 6 7 8 9 10 11 12 13
A T A
O O B
3 3 3 3 3 4 4 4 4 4 5 5 5
Ball
Page 24
Table 3.28 - SLEEVE BUSH FOR DIE SETS
Sleeve Bush Standard Bush

D-2 I.D D-3 O.D. D-4 Stap O.D. 40 46 54 56 62 65 40 46 54 56 60 62 65 Length L-1 Length L
Sleeve Bush Non Standard Bush
No
No
1 2 3 4 5 6 7 8 9 10
20 25 28 32 36 40 26
36 42 50 52 58 60 36 42 50 52 56 58 60
20 23 28 28 30 30 20 23 28 28 30 30 30
O T
L O
11 12 13
D
36 40 40 44 48
31
G I S E
N
60 70 80 80 90 90 60 70 80 80 90 90 90
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
D
D-2 I.D. 21 22 25 30 38 46 30 25 15 16 31 36 20 26 33
A T A
D-3 D-4 Stap O.D. O.D. 32 32 36 42 50 60 44 38 32 32 42 50 36 36 42 36 36 40 46 54 65 50 42 36 36 46 54 46
O O B
Length L
60 60 70 70 80 90 110 90 60 60 110 110 75 80 90
Page 25
PILLAR PINS FOR DIE SETS
Table 3.29 - Standard Pillar S. No 1 2 3 4 5 6 7 D 20 25 28 30 32 36 L
125, 150
S. No 1
O T
L O
D
3 4 5 6 7 8 9 10 11 12
G I S E
40 D 15 16 19 20 24 25 28 30 32 36 40 50
Table 3.30 - Non Standard Pillar L 90, 100 90, 100 125, 150 100, 180 140, 160, 180, 200, 225 200, 250, 300 150, 225, 250, 300 150, 200, 225, 250 300, 250, 350 225, 275, 300, 350 225, 275, 300, 350, 400 200, 225, 255, 270, 300, 350
140, 160, 180 180, 200 180, 190
150, 180, 200, 230 170, 200, 250 200, 250
A T A
O O B
Page 26
SELECTION OF PRESS (TON)
Press capacity required =Cutting Force x 1.3 ( Select nearest higher capacity press from the data given below)
Table 3.31 - Preferred capacities of Mechanical and Hydraulic presses( as per IS 7469-1974):Capacity in (Tonnes) (1) (1.6) (2.5) (4.0) (6.3) (10) (16) (25) (40) (63) Capacity in (Tonnes)
KN 10 16 25 40 63 100 160 250 400 630
KN *2000 2500 *3150
*800
O T
L O
1000
*1250 1600
S E
(80)
IG
4000
*5500 6300
A T A
(200) (250) ( 315) ( 400) ( 550) (630) (800) (1000) (1250) (1600) (2000) (2500) (3150) (4000)
O O B
*8000 10000 12500 16000 20000 25000 31500 40000
(100) (125) (160)
Note capacities marked with asterisk(*) are optional in the range.
Page 27
Using the same principle, die shut height for stamping dies, bendingdies, and formingdies can also be calculated
O T
L O
Standard shut height of press as per IS 10644-1983:100, 125 ,160 ,200,250 ,315, 355, 400, 450, 500, 560, 630, 710, 800, 900, 1000,
G I S E
A T A
O O B
The shut height of the tool must be kept according to the available press shut heights.
Page 28
Table 3.32 - PUNCH AND DIE MATERIAL SELECTION AND HEAT TREATMENT
O T
L O
G I S E
A T A
O O B
Page 29
O T
L O
G I S E
A T A
O O B
Page 30
O T
L O
G I S E
A T A
O O B
Page 31
O T
L O
G I S E
A T A
O O B
Table 3.33 - SELECTION OF STEEL FOR DIFFERENT APPLICATIONS
Page 32
O T
L O
G I S E
A T A
O O B
Page 33
CALCULATION OF CENTER OF PRESSURE:When the shape of blank to be cut is irregular, the summation of shear forces about the centre line of press ram may not be symmetrical. Due to this bending moments will be introduced in the press ram, producing misalignment and undesirable
deflections. To avoid this the centre of pressure of the shearing action of the die must be found and while laying out the punch position on the punch holder, it should be ensured
that the centre line of the press ram passes exactly through the centre of pressure of the
blank. This centre of pressure is the centroid of the line perimeter of the blank. It should
be noted that it is not the centroid of the area of the blank. The centre of pressure can be found out by the following formula:
= (l1x1+l2x2+l3x3+)/l1+l2+l3+. = lx/l
= (l1y1+l2y2+l3y3+)/l1+l2+l3+. = ly/l Where = x distance from centre of pressure
= y distance from centre of pressure l1,l2,l3. = length of line elements
x1,x2,x3..= x distance of the centroids of line elements l1,l2,l3 respectively. y1,y2,y3..= y distance of the centroids of line elements l1,l2,l3 respectively.
O T
L O
G I S E
A T A
O O B
Page 34
O T
L O
G I S E
A T A
O O B
Page 35
SPRING DESIGN DATA 1. DATA FOR DESIGN OF CONVENTIONAL COIL SPRINGS SPRING SELECTION: - If the diameter and length are known then directly the spring dimensions can be selected from the tables given in page no to . Select springs with desired total load. - If diameter and length are not known, use the following spring selection steps and refer to the rate column of the dimension table for spring selection. - Step 1:- Estimate the level of production required of the die short run, constant production etc.,
Step 2: - Determine compressed spring length H an operating travel T from the die layout
Step 3:-
O T
L O
Determine free length C as follows: o Decide which load classification the spring should be selected from light, medium, heavy or extra heavy load. Then chose the figure nearest the compressed length H required by the die design from the appropriate charts below . read corresponding c free length.
G I S E
A T A
O O B
Step 4:Estimate total initial spring load L required for all springs when springs are compressed X in mm Step 5:Tool Design Data Book Page 36
- Determine X initial compression by using the following formula:
X=C-H-T
Step 6:Determine R ( total rate for all springs in N/mm) by using the following formula
R=L/X
Step 7:- Select springs from the table given below as follows: o The free length C must comply with length determined in step 3. o Divide R in step 6 by the number of spring to be used ( if known) in order to get the rate per spring. Then refer to the following pages for the catalogue number of springs having the desired rate. If the number of springs is not known, divide R from step6 by the rate of the spring you select for the correct number of springs.
O T
L O
Table 3.34 Spring Compressed length to free length conversion chart
G I S E
A T A
O O B
Page 37
O T
L O
G I S E
A T A
O O B
Page 38
Table 3.35 Rectangular spring light load
O T
L O
G I S E
A T A
O O B
Page 39
Table 3.35 Contd
O T
L O
G I S E
A T A
O O B
Page 40
Table 3.36 Rectangular spring Medium load
O T
L O
G I S E
A T A
O O B
Page 41
Table 3.36 Contd
O T
L O
G I S E
A T A
O O B
Page 42
Table 3.37 Rectangular spring Heavy load
O T
L O
G I S E
A T A
O O B
Page 43
Table 3.37 Contd.
O T
L O
G I S E
A T A
O O B
Page 44
Table 3.38 - Rectangular spring Extra Heavy load
O T
L O
G I S E
A T A
O O B
Page 45
Table 3.38 Contd
O T
L O
G I S E
A T A
O O B
Page 46
Table 3.39 - Rectangular spring Ultra Heavy load
O T
L O
G I S E
A T A
O O B
Page 47
Table 3.40 - Circular spring Light load
O T
L O
G I S E
A T A
O O B
Page 48
Table 3.41 - Circular spring Medium load
O T
L O
G I S E
A T A
O O B
Page 49
Table 3.42- Circular spring Heavy load
O T
L O
G I S E
A T A
O O B
Page 50
Table 3.43- Circular spring
O T
L O
G I S E
A T A
O O B
Page 51
Table 3.43 Contd.
O T
L O
G I S E
A T A
O O B
Page 52
Table 3.43 Contd
O T
L O
G I S E
A T A
O O B
Page 53
Table 3.44 Spring retainer
O T
L O
G I S E
A T A
O O B
Page 54
Table 3.45 - RUBBER SPRINGS
O T
L O
G I S E
A T A
O O B
Page 55
O T
L O
G I S E
A T A
O O B
Page 56
O T
L O
G I S E
A T A
O O B
Page 57
O T
L O
G I S E
A T A
O O B
Page 58
O T
L O
G I S E
A T A
O O B
Page 59
Table 3.50 RUBBER SPRINGS
Stripping Pressure (N) at Deflection of D L 44 54 10 64 74 44 54 13 64 74 44 54 16 64 74 44 54 20 64 74 44 25 54 64 74 44 54 32 64 74 44 54 40 64 3mm 978 734 703 670 1566 1357 1081 811 2433 1779 1526 1490 3002 2580 2046 1939 4737 3425 3291 3158 6383 5693 4480 3469 8562 6583 5804 6mm 1401 1290 1060 1020 2647 2180 1780 1707 3513 2958 2736 2650 4359 3936 3424 3180 6605 5515 5070 4781 9185 8674 6961 9mm 1512 1268 1220 2469 2158 2139 3692 3202 3182 4581 4226 3980 6672 6205 5887 25 32 38 40 40 50 60 60 43 55 65 65 7 7 8 8 D 10 13 16 20 d 18 23 28 33 d1 23 26 31 36 t 6 6 6 7 d2 1.6
O T
L O
S E
12521 10497 9563
6491
IG
10008 8118 7570 12744 11453
A T A
O O B
3.0
Page 60
BENDING TOOL DESIGN DATA Bending Allowance(L): L = ( / 180) x A x (R + 0.5T) When R 2T L = ( / 180) x A x (R + 0.33T) When R < 2T Where A = angle of bend in degrees R = bend inside radius T = sheet thickness Developed Length = Straight arm + Bend allowance
On bends, the short length should be minimum of 2.5 x stock thickness+ radius
O T
L O
G I S E
A T A
O O B
Page 61
Minimum hole (and short slot) to bend distance should be 2.5 x the stock thickness + Bend radius.
For long slots, the distance should be 4 x the stock thickness + bend radius.
O T
L O
G I S E
A T A
O O B
Page 62
V Bending: Bending Force = (1.33LST2) / W L = length of the bent part in mm T = thickness of blank in mm S= Tensile strength of blank material in N/mm2 W = width of V at top W should not be less than 6 times blank thickness; preferred range is 8 to 10
Edge radius RE = (2 to 6)t
Where, = thickness of material
Punch Radius RP = Radius of component
Die Radius, RD = Punch radius + thickness of material
O T
L O
G I S E
A T A
O O B
Page 63
U Bending or channel bending:
Bending Force, F = [(0.67LST2) / W] Span, W = RE + C +RP
Edge Radius, RE = (2 to 6)t for non moving edge Punch Radius, RP = Part radius C = Die clearance Die radius, RD = RP+ (1.2 to 1.25) t s T =Thickness of blank in mm L =Length of bent part.
O T
L O
S = ultimate tensile strength in N/mm2
G I S E
A T A
O O B
Page 64
WIPING DIES:
Bending Force, F = [(0.333LST )/W] Span, W = RD + C + RP Die radius, RD = Part radius C = Die Radius, RP = 3 to 8T
SPRING BACK:
For low carbon and for soft non ferrous material 0 to 2 For 0.40 to 0.5 carbon steel and half hard material 3 to 5 Spring back may be high in hardened material 10 to 15 Bend radius Tensile strength 600N/mm2 7 12 400N/mm2 4 6
O T
L O
Table 4.1 Spring back data
R=T
R = 5T
G I S E
A T A
O O B
Page 65
DRAWING DIES Type of operation:
h / d 0.5 shallow drawing h / d > 0.5 deep drawing Where, h = shell height d = shell diameter Estimation of blank Diameter (Theoretical): D = (d2 + 4dh) D = (d2+4dh 0.5r) D = (d2+4dh r) D = [(d 2r)2+4d(h- r) + 2r(d 0.7r)] Where, D Blank diameter in mm d Shell outer diameter in mm h Shell Height in mm
when d / r 20 or more
when d / r is between15&20 when d / r is between10&15
r Corner radius of punch Considering Trim allowance:
Trim allowance = 0.05mm for every 10 mm diameter. Of drawn cup Where,
O T
L O
Initial diameter of blank (D1) = D (Theoretical diameter.) + Trim allowance
G I S E
when d / r is below 10
A T A
O O B
Page 66
t / D Consideration: t / D decides the severity of wrinkling t / D Percentage
Wrinkling is a severe and compressive load must be reduced. Upto 0.5 Blank holder must be used, so a double action press is preferable Above 0.5 upto 1.5 Above 1.5 upto 2.5 Wrinkling is moderate and low blank holding forces are permitted
Wrinkling is very light so, single action press is enough
Table 5.1 -
No wrinkling so blank holder is Over 2.5 unnecessary even with high compressive load Selection of percentage reduction for 1st Draw using t / D ratio: (t / D) x 100
Single action 1.5 2.0 2.5
Where,
D1 = Blank diameter. After adding trim allowance D2 = Diameter. Of 1st Draw
O T
L O
Table 5.2 - Allowable percentage reduction for successive draws First draw Second draw Third draw Fourth draw (t / D) % 25% 15% 10 %
G I S E
Double action 0.15 0.2 0.3 0.4 0.5
A T A
O O B
% reduction for 1 st Draw [(D1 D2) / D1] x 100 30 35 40 45 47.5
Page 67
Table 5.3 - No. Of Draws according to h / d ratio No. of First draw Draws Up to 0.75 1 40 0.75 1.5 2 40 1.5 - 3 3 40 3 4.5 4 40 Percentage of reduction P= 100(1-d/D) Where d= ID of drawn shell D= OD of blank Estimation of drawing pressure: Drawing pressure, p = x d x t x S x ((D / d) C) Where, P = Drawing force in kgf d = Shell outer diameter D = Blank diameter t = thickness of sheet in mm h / d ratio Second draw -25 25 25 Third draw --15 15 Fourth draw ---10
S = Ultimate tensile strength in N/mm2
C = constant to cover friction and bending (0.6 to 0.7 for ductile material) Blank holding pressure:
Blank holding pressure = 1/3rd of drawing pressure Press capacity:
O T
L O
Press capacity = (Drawing pressure + Blank holding pressure) x 1.3
G I S E
A T A
O O B
Page 68
Table 5.4 - Drawing speed Material Steel Stainless steel Aluminum Aluminum alloys Copper Brass Single action drawing Ft / Min M / Sec 60 0.3048 180 0.9144 150 0.762 200 1.016 Double action drawing Ft / Min M / Sec 35 55 0.1778-0.27 20 30 0.1016-0.1524 100 0.508 30 40 0.1524 0.2032 85 0.4318 100 0.508
Table 5.5 - Draw die clearance Blank thickness(t) 1st Draw
Upto 0.38 1.07t 1.09t 0.4 1.27 1.08t 1.1t 1.28 3.18 1.1t 1.12t 3.5 and above 1.12t 1.14t t is the thickness of the original blank Punch radius:
2nd draw/ Intermittent draw 1.08t 1.1t 1.09t 1.12t 1.12t 1.14t 1.15t 1.2t
Punch radius = 4t to 10t (or) Radius on product drawing Where, t = sheet thickness
Draw radius (or) die radius: R = 6t to 8t (or) R = 0.8[(D - d)t] Tolerance:
Tolerance = 0.005 (or) 0.127 Table 5.6 - Draw die material:
O T
L O
Rate of production Less than 1000 Around 1000 Nos. Above 10000 Nos. Above 10,00,000
G I S E
A T A
Sizing draw
O O B
1.04t 1.05t 1.05t 1.06t 1.07t 1.09t 1.08t 1.1t
Die material Plastic (or) zinc C.I Tool Steel Carbide Punches & die
Page 69
6. DATA FOR GAUGE DESIGN:-
O T
L O
G I S E
A T A
O O B
Page 70
O T
L O
G I S E
A T A
O O B
Page 71
O T
L O
G I S E
A T A
O O B
Page 72
O T
L O
G I S E
A T A
O O B
Page 73
O T
L O
G I S E
A T A
O O B
Page 74
O T
L O
G I S E
A T A
O O B
Page 75
O T
L O
G I S E
A T A
O O B
Page 76
O T
L O
G I S E
A T A
O O B
Page 77
O T
L O
G I S E
A T A
O O B
Page 78
O T
L O
G I S E
A T A
O O B
Page 79
O T
L O
G I S E
A T A
O O B
Page 80
O T
L O
G I S E
A T A
O O B
Page 81
O T
L O
G I S E
A T A
O O B
Page 82
O T
L O
G I S E
A T A
O O B
Page 83
O T
L O
G I S E
A T A
O O B
Page 84
O T
L O
G I S E
A T A
O O B
Page 85
O T
L O
G I S E
A T A
O O B
Page 86
O T
L O
G I S E
A T A
O O B
Page 87
O T
L O
G I S E
A T A
O O B
Page 88
O T
L O
G I S E
A T A
O O B
Page 89
O T
L O
G I S E
A T A
O O B
Page 90
O T
L O
G I S E
A T A
O O B
Page 91
O T
L O
G I S E
A T A
O O B
Page 92
O T
L O
G I S E
A T A
O O B
Page 93
O T
L O
G I S E
A T A
O O B
Page 94
O T
L O
G I S E
A T A
O O B
Page 95
O T
L O
G I S E
A T A
O O B
Page 96
O T
L O
G I S E
A T A
O O B
Page 97
O T
L O
G I S E
A T A
O O B
Page 98
O T
L O
G I S E
A T A
O O B
Page 99
O T
L O
G I S E
A T A
O O B
Page 100
O T
L O
G I S E
A T A
O O B
Page 101
Table 6.34 - REFERENCE INDIAN STANDARDS FOR GAUGE DESIGN:IS NO. IS: 3455 1971 INDIAN STANDARD SPECIFICATION FOR Gauging practice for Plain work pieces Gauging members for Plain plug gauges, GO and NO GO members IS: 6137 1983 (Size range from 1 upto and including 40mm)
Gauging members for Plain plug gauges, GO and NO GO members IS: 6244- 1980 (Size range above 40 to 120 mm)
Gauging members for Plain plug gauges, GO and NO GO members IS: 6246 1980 (Size range above 120 up to and including 250 mm) IS: 7018 (Part 1) 1983
Technical supply conditions for gauges Part 1 General
Technical supply conditions for gauges Part 2 - Assembly and IS: 7018 (Part 2) 1983 including 250 mm) inspection Plain Plug gauges ( Size range from 1 mm upto and
Technical supply conditions for gauges Part 3- Assembly and IS: 7018 (Part 3) 1983
IS: 5388 1983 IS: 3477 1973 IS: 3485 - 1966
O T
L O
Note:- Use of Institute copies of all the above Indian Standards and any other related Indian standards is permitted in the Tool Design and Drawing examination for the D.M.E ( Tool & Die) course.
G I S E
Plain ring gauges
identification of screw plug gauges for ISO metric screw threads ( Size range from M1 upto and including M200) Hexagon handles for Plain and Threaded Plug gauges GO and NO GO Snap Gauges for size range 3 to 250 mm
A T A
O O B
Page 102
JIGS & FIXTURES

Table 7.1 - GUIDELINES FOR SELECTION OF LOCATORS
SI.NO LOCATING DEVICE 1 Six point locator(3-2-1) pin and button locators 2 V-block 3 Nesting locator
APPLICATION Locating flat surfaces
5 6
V-block, horizontal (one side is fixed and other end is adjustable or cam operated) V-locator. Jack pin locator Eccentric locators
Table 7.2 - GUIDELINES FOR SELECTION OF CLAMPS CLAMPS SITUATIONS Strap clamp Swinging strap clamp Cam operated clamp Toggle clamp Screw clamp
Equalizing clamp
Hydraulic and pneumatic clamp
O T
L O
Hydraulic clamp with rack and pinion Spider clamp Edge clamp
S E
IG
Commonly used for rectangular work pieces. For easy loading and un loading. Effective and fast, but should be used. Adapted for many types of fixtures. Components are to grip on. Exerting equal pressure to hold. Faster, uniform and effective. Circular rod in V-block Circular and symmetrical workpiece clamping. Used during facing operation.
A T A
Locating round circular flat Locating cylindrical profile in vertical position. Locating elliptical and irregular surfaces.
O O B
Locating a rough work piece. Variation in work piece size.
Page 103
Table 7.3 - LOCATING PINS (ROUND) - IS 5093
D g6 10 12 16 20 25
d 9.5 11.5 15 19 24
d1 p6 8 10 12 16 20
d2 7.5 9.5 11.5 15.5 19.5
h1 8 10 14 18 22
h2 16 18 22 25 32
32
31
25
24.5
25
Table 7.4 - END LOCTING PLUGS - IS 5095 D d h6 16
O T
L O
S E
IG
20
D
15 19 24 31 39
A T A
d1 p6 d2 12 11.5 16 15.5 20 19.5 25 24.5 32 31.5
O O B
36 h2 16 25 40 20 32 45 25 40 60 40 63 50
h1
12
15
25
18
32
22
40
25
80
Page 104
Table 7.5 - DIAMOND LOCATING PINS - IS 5094 D d1 d d2 e8 p6 12 11 8 7.5
b 4
h1 8
h2 12
14
13
10
9.5
10
18
17
12
11.5
14
22
21
16
28
27
20
36
35
Table 7.6 - ROUND LOCATING STUDS - IS 5096
O T
L O
G I S E
N
D g6 1 2 1 8 2 0 2 5 3 2
D
25
d1 p6 1 0 1 4 1 6 2 0 2 5
A T A
15.5 8 19.5 10 24.5 12
d2 d3 d4 s7 5 h 4 0 5 5 6 2 7 0 8 5 M6 M8 M1 0 M1 2 M1 6 6 8 1 0 1 2
18
O O B
14 18 21 28 32
h1 h2 1 0 1 6 1 8 2 2 2 5 1 2 1 8 2 0 2 5 2 8
22
25
11. 5 17
9.5 13. 5 15. 5 19. 5 24. 5
19
24
31
Table 7.7 - V-Locator L1 l2 l3 b1 b2 b3 d
Page 105
25
20
35
15
32
15
36 50 Table 7.8 - V-Block
25 32
50 60 a 50 63 80 100
20 22 b 40 50 63 80
45 55 c 40 50 63 80
25 30 dmax 40 50 63 83 200 300
200 200 300 300 Table 7.8 - SWING CLAMP - IS 5250 d

6.6 9
w W1
20 25 30 35 45 50
t
12 14 16 20 25 30
O T
L O
Table 7.9 - STRAP CLAMP IS 4292 d

7 10 12 15 19 24
G I S E
11 14 18 22
N
7 9 11 15 18 23
D
L
52 60 70 80 90 100
A T A
200 300 L1 L2 L3 a
20 22 24 26 32 38 25 30 35 40 45 50 14 18 20 22 28 32 4 5 6 7 9 11
O O B
11 dmin 5 5 7 7 10 12
Size of screw
M6 M8 M10 M12 M16 M20
12 14 16 20 25 30
l1
50 60 80 100(125) 125(160) 160(200)
a
10 13 15 21 26 30
b
20 22 30 40(50) 45(65) 60(80)
c
8 10 12 14 18 22
h
10 12 15 20 25 30
s
20 25 30 40 50 60
For screw size

M6 M8 M10 M12 M16 M20 Page 106
28 35 42 45
200(250) 250(315) 315(350) 350(400)
35 45 48 53
80(105) 100(130) 125(150) 150(180)
26 34 40 45
30(40) 70 40(50) 80 45(55) 90 55(60) 100
M24 M30 M36 M39
Table 7.10 - SWING C WASHER- IS 4298 d H13

6.6 9.0 11 14 18 22 26 30
d1
8.5 8.5 8.5 10.5 10.5 10.5 12.5 12.5
R R1
18 21 24 27 33 38 42 45 8 8 8 10 10 10 12 12
R2
21.3 25.5 29.5 34.0 42.0 49.0 55.0 60.0
R3
14.7 16.5 18.5 20.0 24.0 27.0 29.0 30.0
R4
10.0 13.0 16.0 20.0 25.0 30.0 32.5 35.0
For bolt t or Nom screw size

6 6 6 8 8 8 M6 M8 M10 M12 M16 M20 M24 M27
O T
L O
G I S E
A T A
2.0 2.5 2.5 3.0 3.0 3.0 4.0 4.0
O O B
10 10
Page 107
Table 7.11 - JIG BUTTON (IS 4294) MATERIAL: C45 RC d1

6 10 16 25 40
HARDNESS: 45 50 d2
4 6 8 12 20
h
5 8 5/13 8/20 13/32
a
1.2 1.6 2.0 2.5 3.2
l
6 8 10 14 20
Under cut
A2 X 0.2 B2 X 0.2 B2 X 0.2 B2 X 0.2 B2 X 0.2
Table 7.12 - JIG FEET MATERIAL: FREE CUTTING STEEL HARDNESS:56 2RC
H 10 20 15 30 20 40 25 50 30 60 40 80 d M6 M8 M1 0 M1 2 M1 6 M2 0 b 11 13 16 20 24 29 d1 6 9 12 15 20 26 d2 8 10 12 15 19 24 e1 12.7 16.2 19.6 25.4 31.2 36.9 K 5 6 8 10 12 16 l 21 31 28 43 36 56 45 70 54 84 r1 0.5 0.5 r2 1 1 S X
O T
L O
G I S E
69 109
D
0.5 0.5 1.0 1.0
A T A
11 14 17 22 27 32 2.0 2.5 2.5 3.0 3.0 4.0 1.5 1.5 2 2
34 13 22 9 18 7 20 8 18 7 13 5
O O B
Page 108
Table 7.13 - FEET BOLT Basic size M10 M10 M10 M10 M12 M12 M12 M12 M12 M12 M12 Table 7.14 - FEET NUTS A 50 65 75 90 75 90 100 112 125 140 B 28 28 28 28 35 35 35 35 35 C 12 12 12 12 18 18 18 18 18 18 18 D 12-20 12-20 12-20 12-20 20-25 20-25 20-25 20-25 20-25 20-25 20-25 E 10 10 10 10 12 12 12 12 12 12 12 F 20 20 20 20 25 25 25 25 25 25 25
Basic size
M10 20 20
O T
L O
B
M10 25 20
G I S E
M10 36 20 M10 50 20
N
M12 25 25
150
D
35 35
M12 36 25
A T A
M12 50 25 M12 62 25
O O B
M12 20 25
M12 75 25
M12 87 25
Page 109
Table 7.15 - JIG BUSH FIXED BUSH
d1 Upto 1 1.0-1.8 1.8-2.6 2.6-3.3 3.3-4.0 4.0-5.0 5.0-6.0 6.0-8.0 8.0-10 10-12 12-15 15-18 18-22 22-26 26-30 30-35 35-42 42-48 48-55 55-63
Short l1 l2 6 6 6 8 8 8 10 10 12 12 16 16 20 20 20 25 25 32 32 36 4 4 4 6 6 6 7 7 8 8 12 12 15 15 15 20 20 25 25 30
Long l1 l2 9 9 9 12 12 12 16 16 20 20 28 28 36 36 36 45 45 56 56 72 7 7 7 9 9 9 13 13 16 16 24 24 31 31 31 40 40 50 50 66
d2 3 4 5 6 7 8 10 12 16 18 25 25 30 36 42 48 56 63 70 80
d3 6 7 8 10 11 12 14 16 20 22 26 30 35 41 47 55 63 70 77 87
O T
L O
G I S E
A T A
d4 r1 10 13 16 20 24 28 33 40 46 52 59 67 75 1.2 1.2 1.2 1.6 1.6 2.0 2.0 2.0 2.5 2.5 4.0 4.0 6.0 6.0 6.0 8.0 8.0 8.0 8.0 8.0
r2
O O B
Z 0.005 0.005 0.005 0.005 0.005 0.005 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.02 0.02 0.02 0.02 0.02 0.02 0.02
0.2 0.2 0.3 0.3 0.4 0.4 0.4 0.6 0.8 0.8 0.8 0.8 1.0 1.0 1.0 1.0 1.0 1.6 1.6 1.6
Page 110
Table 7.16 - LINER BUSH Short Long d1 Upto 1 1.0-1.8 1.8-2.6 2.6-3.3 3.3-4.0 4.0-5.0 5.0-6.0 6.0-8.0 8.0-10 10-12 12-15 15-18 18-22 22-26 26-30 30-35 35-42 42-48 48-55 55-63 6 6 6 8 8 8 10 10 12 12 16 16 20 20 20 25 25 30 30 36 9 9 9 12 12 12 16 16 20 20 28 28 36 36 36 45 45 56 56 70
d2 3 4 5 6 7 8 10 12 16 18 22 25 30 36 42 48 56 63 70 80
r1 1.2 1.2 1.2 1.6 1.6 2.0 2.0 2.0 2.5 2.5 4.0 4.0 6.0 6.0 6.0 8.0 8.0 8.0 8.0 8.0
r2 0.2 0.2 0.3 0.3 0.4 0.4 0.4 0.6 0.8 0.8 0.8 0.8 0.8 1.0 1.0 1.0 1.0 1.6 1.6 1.6
z 0.005 0.005 0.005 0.005 0.005 0.005 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.02 0.02 0.02 0.02 0.02 0.02 0.02
O T
L O
G I S E
A T A
O O B
Page 111
Table 7.17 - SLIP BUSH
d1 Upto 4 4-6 6-8 8-10 10-12 12-15 15-18 18-22 22-26 26-30 30-35 35-42 42-48
d2 8 10 12 16 18 22 25 30 36 42 48 56 63
d3 16 19 22 26 30 35 40 47 56 62 69 78 85
d4 11 14 17 21 24 29 35 41 47 54 61 69 78
d5 2.5 2.5 2.5 3.0 3.0 5.0 5.0 5.0 6.0 6.0 6.0 6.0 6.0
l1 20 22 25 28
l2 10 12 12 16 16 20 20 20 25 25 32 32 36
l3 1 1 1 1 1 1 1 1 2 2 2 2 2
O T
L O
G I S E
28 36 36 36 45 45 50 50 56
A T A
a b 4 4 4 5 3 3 3 4 4 5 5 5 6 6 6 6 6 5 7 7 7 8 8 11 11 14
r1 3 3 4 5 5 5 5 6 6 6 8 8 8
O O B
z X 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.02 0.02 0.02 0.02 0.02 14 12 10 12 10 12 8 0 0 0 0 0 0
Page 112
Table 7.18 - LOCKING SCREWS
d6 d7 d8 l4 l5 l6 h d6 m6 * l m n t r2 c M5 2.5 X 14 10 15 M5 2.5 X 14 12 16 M5 10 5 6 6 15 2 2.5 X 14 12 1.6 2.0 0.6 18 M5 3.0 X 14 16 20 M5 3.0 X 14 16 22 M6 5 X 20 20 26 M6 13 6 8 8 20 2 5 X 20 20 2.0 2.5 1.0 29 M6 5 X 20 20 33 M8 6 X 24 25 38 M8 6 X 24 25 41 M8 16 8 10 10 25 2.5 6 X 24 30 2.5 3.0 1.6 45 M8 6 X 24 30 48 M8 6 X 28 35 55 TOMMY NUT (Material C 45) Basic size A B
O T
L O
G I S E
A T A
M10 25 M12 25
O O B
28
35
M16
32
38
Page 113
Table 7.19 - KNURLED THUMB NUT (Material C 45) Basic size A B 16 M6 20 M8 M10 M12 M16 Table 7.20 - THUMB NUT (Material C 45) d1 M6 M8 M10 M12 M16 Table 7.21 Hand nut 22 25 28 35 20 22 25 28
C 10 12 12 14 16
D 1.5 1.5 3 3 3
O T
L O
A 41 54 58 64 70 80
D
B 32 38 41 45 50 56
G I S E
C 23 27 30 32 38 45 D M12 M16 M20 M22 M24 M30
N
F 8 13 13 17 17 19
A T A
d2 7 9 11 13 18 b 28 32 36 45 54
H 6 8 8 10 10 11 J 3 5 5 6 6 8
h 12 14 16 18 22
O O B
e 12 14 16 18 22
E 14 17 17 19 21 25
G 3 5 5 5 6 8
K 25 35 35 41 44 52
HAND NUT (Material C 45)
Page 114
d
M10 M12 M16 M20
a
6 7.5 10.0 12.5
d2
3 4 5 6
E
75 90 117 150
g
3.5 4.0 4.5 6.5
h
12 15 19 24
l2
40 50 63 80 l l1 l l1 l l1 l l1 40 25 50 31 65 40 80 49
Table 7.22 Handle grip screws
O T
L O
G I S E
45 30 55 36 70 45 85 54
A T A
50 35 60 41 75 50 90 59 55 40 65 46 85 60 100 69
O O B
65 50 75 56 105 80 120 89 80 61 130 99
60 45 70 51 95 70 110 79
Page 115
Table 7.23 - WING/ FLY SCREWS
d M5 M6 M8 M10
a 3 4 5 6
d2
g approx. 1.5 2.0 2.5 3.5
h 7
h1
1.5 25 1.5 32 2.0 40 3.0 50
O T
L O
G I S E
l l1 l 8 16 l1 l 9.5 20 l1 l 12.0 25 l1 12
A T A
25 16 28 20 35 25 50 38 30 22 40 30 55 43
O O B
35 27 45 35 60 65 48 53
Page 116
Table 7.24 - PRESSURE PADS
Max.dia. d1 10 12 16 20 25 32 40
d4 3.8 4.8 6.4 7.4 9.5 12.5 15.5
d5 8 10 12 15 18 22 28
d6 4 5 7 8 10 14 18
d7 1.5 1.5 2 2 3 3 4
r1 1.2 1.5 2 2 3 3 4
r2
2.5 2.5 7 2.5 2.5 8 3 3.5 9.5 3.5 5 12 4.5 6 15 6 7 19 7.5 9 24
Table 7.25 - Cam clamp (Material Mild steel) A B C 10 13 1.5 12 16 2 16 20 2.5
O T
L O
G I S E
20
N
25
D
3
0.3 0.5 4.5 0.3 0.5 5 0.4 0.5 6 0.4 1 7 0.6 1 9 0.6 1 12 0.8 1 15
A T A
t2 t1
For screw with thread M5 M6 M8 M10 M12 M16 M20
O O B
Fastening pin 1.5m6 x 6 1.5m6 x 8 2m6 x 8 2m6 x 14 3m6 x 14 3m6 x 16 4m6 x 20
D 3 4 5 6
E 12 15 18 24
F 60 70 90 110
G 10 12 16 20
Page 117
Table 7.26 - Quarter turn screw A M10 M12 M16 B 50 62 82 C 35 38 47 D 12 15 20 E 28 32 35 F 5 6 6
M20
100
60
22
40
10
Table 7.27 - Spherical washer A 9 11 14 18 Table 7.28 - C WASHER

d H12 6.4 8.4 10.5 13 17 21 25
B 20 22 28 40
O T
L O
S E
IG
N
31
6 8 10 10 12 12 12
D
l 25
A T A
D 32 32 40 40 50 50 63 63 63
C 20 22 28 40
D 2.5 2.5 2.5 3
E 4 6 6.5 12
O O B
F 2.5 2.5 2.5 3 G 5 6 6.5 7
For bolt or screw size M6 M8 M10 M12 M16 M20 M24
80 80 80
100
15
80
100
M30
Page 118
Table 7.29 - WING NUT(hot stamped or cast) IS 2636-1972

Size d
Nom max min
M2
M2.5 8 8.45 7.55 6
M3
M4
M5 10 10.45 9.55 8
M6 12 12.55 11.45 10
M8 16 16.55 15.45 12
M10 20 20.65 19.35 16
M12 23 23.65 22.35 19
M16 28 28.65 27.35 22
M20 36 36.80 35.20 28
A(js16)
Nom
e(js16) min
Nom max
20 20.6 19.4 1.6 1.9 1.3 2 10 10.4 9.6 5 3
25 25.6 24.4 2 2.3 1.7 2.5
32 32.8 31.2 2.5 2.8 2.2 3
40 40.8 39.2
g1(js16)
Nom max min Nom Nom max min
g2
h1(js16)
m nom
r1 Nom
r2 Nom
r3 Nom
O T
L O
r4 Nom
Radiused.
D
* 0.5 2
G I S E
12 12.6 11.4 6 4 * 16 16.6 15.4 8 5 * 1 3 0.5 2.5
N
4 20 20.6 19.4 10 6 * 1 4
3 3.3 2.7
D
4 4.4 3.6 5 25 25.6 24.4 12 8 1 1.2 5
50 50.8 49.2
A T A
64 65.0 63 5 5.4 4.6 6 32 32.8 31.2 14 10 1 1.2 6 72 73.0 71 6 6.4 5.6 7 36 36.8 35.2 16 11 1.2 1.6 7 9
O O B
M24 45 45.80 44.20 36 112 113.0 111.0 9 9.4 8.6 11 56 57.0 55 24 18 2.5 3 11
90 91.1 88.9 7 7.4 6.6
45 45.8 44.2 20 14 1.6 2 9
Page 119
Table 8 - Unit conversions Conversions factors

SI 1N 1 N/m2 1kW 1 Nm/s PHYSICAL QUANTITY Force Pressure Power Power MKS 0.1016 kgf 10.19 x 10-6 kgf/cm2 1kW, 1.36hp 0.1019 kgfm/s 0.2248 Ibf FPS 145.038x10-6 kgf/cm2 1.34hp 0.7375 ft lpf/s
Metric conversion table Multiply

Inch Foot Yard Mile Inch2 Foot2 Yard2 Inch3 Yard3
By
Length 25.4 0.3048 0.9144 1.609 Area 645.2 6.45 0.0929 0.8361 Volume 16.387 16.387 Mass 0.4536 907.18 Force 9.807 0.278 Acceleration 0.3048 0.0254 Power 0.746
Pound Ton
Kilogram Ounce
Foot/Second2 Inch/Second2
O T
L O
Horse power
G I S E
A T A
mm3 cm3
To get equivalent number to

Millimeters (mm) Meters (m) Meters (m) Kilometers(km)
O O B
Millimeters2(mm2) Centimeters2(cm2) Meters2 (m2) Meters2
Kilograms (kg) Kilograms (kg) Newton (N) Newton(N) Meter per second2(m/s2) Meter per second2 Kilowatts(kW)
Page 120

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TOOL DESIGN DATA BOOK

DIPLOMA IN MECHANICAL ENGINEERING (TOOL & DIE) COURSE CODE 1220

DIRECTORATE OF TECHNICAL EDUCATION GOVERNMENT OF TAMILNADU

DIRECTORATE OF TECHNICAL EDUCATION GUINDY, CHENNAI 25 TOOL DESIGN DATA BOOK

Tool Design Data Book

Tool Design Data Book

Unit Conversion tables

Tool Design Data Book

Table 1 - MATERIAL PROPERTIES

SHEAR STRENGTH S.No MATERIAL N/mm

ULTIMATE TENSILE STRENGTH N/mm2

539.70 346.95 385.5 539.70

719.6 462.6 514 719.6

Tool Design Data Book

Table 2 - Sheet material SWG to mm & inch conversion

SWG 7/0 6/0 5/0 4/0 3/0 2/0 1/0 1 2 3 4 5 6 7

inches 0.0108 0.0100 0.0092 0.0084 0.0076 0.0068 0.006

Tool Design Data Book

DATA FOR STAMPING DIES FORMULAE: 1. Cutting force = Where S P T 2. 3. 4. 5. = = = S*P*T

Shear strength of the component material in N/mm2 Perimeter of the component in mm

Thickness of the component in mm = = = =

Percentage of utilization Percentage of scrap Stripping Force

E= modulus of elasticity in GN/mm2 I=moment of inertia in mm4

Lp=length of punch in mm Strip layout Margin (or) Bridge

100 Percentage of utilization 10 to 20% of cutting force Cutting Force x 1.3

= 1.5t where t is the sheet metal thickness in mm

Tool Design Data Book

Table - 3.1 - DATA FOR STRIP LAYOUT

10 50 100 150 250 350

Tool Design Data Book

DIE PLATE DESIGN DATA: Die block thickness =

F Where F is cutting force in Kg.

1.5 to 3.1 3.1 to 4.7 4.7 to 6.3 Over 6.3

C Minimum Distance Die Hole To Outside Edge 2 Inside Corners (1.5 B)

1 Smooth Die Hole Contour (1.125 B)

3 Sharp Inside Corners

Tool Design Data Book

Table 3.3 - Tabulation of suggested standard die block sizes

Tool Design Data Book

A 101.6 101.6 127

127 152.4 152.4 177.8

139.7 165.1 165.1 215.9 165.1 215.9 241.3

Tool Design Data Book

Table 3.5 Anglular clearance data

Soft materials require greater angular clearance than hard materials.

Angular clearance per side 1/4o 1/20 3/40 10

Tool Design Data Book

Table 3.6 Die clearance

Die clearance per side in percentage of sheet thickness 2.5%-5% 1.5%-3%

Tool Design Data Book

Table 3.7 Stripper plate thickness

Tool Design Data Book

Table 3.8 Clearance between Strip and Strip gudie

1.587-3.175 3.175-4.762 4.762-6.35

1.6 2.4 3.2 4.0 4.8

Tool Design Data Book

Tool Design Data Book

Table 3.11 Square Punch

Table 3.12 Quick change punch

Tool Design Data Book

Table 3.13 Punch Chamfered head

Table 3.14 Stepped Punch

Table 3.15 Square Punch with shedder

DATA FOR STAMPING DIES FORMULAE: 1. Cutting force = Where S P T 2. 3. 4. 5. = = = SPT

KN 2000 2500 3150