Tool Design Data Book.pdf

TOOL DESIGN DATA BOOK

FOR

DIPLOMA IN MECHANICAL ENGINEERING (TOOL & DIE)

COURSE CODE 1220

DIRECTORATE OF TECHNICAL EDUCATIONGOVERNMENT OF TAMILNADU

Tool Design Data Book Page 2

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


CONTENTSSL.NO TOPIC PAGE

NO.1. Material Properties 1

2. Sheet material SWG to mm & inch conversion 2

3. Data for stamping dies

Formulae 3

Strip layout 4

Die plate design data 5

Stripper design data 10

Punch design details 12

Punch holder data 15

Pilots 16

Finger stops 17

Automatic stops 18

Fasteners - Screws & dowels 21

Die set 23

Press data 27

Shut height 28

Punch and die materials & Heat treatment 29

Centre of Pressure 34

Spring design data 36


4. Data for bending dies 61

5. Data for drawing dies 66

6. Data for gauge Design

ISO System of limits and fits – tolerances & deviations 70

Reference Indian standard specifications for gauge design 102

7. Jigs & fixtures

Guidelines for selection of locators and clamps 103

Locating pins 104

Clamps 106

Jig feet & buttons 108

Jig bushes 110

Screws & nuts 113

Pressure pads 117

Spherical & ‘C’ Washers 118

Wing nuts 119

8. Unit Conversion tables 120


Table 1 - MATERIAL PROPERTIES

S.No MATERIALSHEAR STRENGTH

N/mm2

ULTIMATE TENSILE

STRENGTH

N/mm2

1. Stainless steel 539.70 719.6

2. Steel 0.1% carbon ( soft) 346.95 462.6

3. Steel 0.25%carbon ( mild) 385.5 514

4. Steel 0.5% carbon 539.70 719.6

5. Steel 0.75% carbon 616.8 822.4

6. Steel 1% carbon 655.35 873.8

7. Steel 1.2% carbon ( not tempered) 724.7 966.2

8. Steel 1.25% carbon( tempered hot) 1464.89 1953.18

9. Aluminium soft sheet 115.65 154.2

10. Aluminium half hard sheet 146.49 195.32

11. Aluminium hard sheet 192.75 257

12. Brass soft sheet 231.29 308.38

13. Brass half hard sheet 269.85 359.8

14. Brass hard sheet 308.40 411.20

15. Copper rolled 215.88 287.84

16. Cupro nickel 308.4 411.20

17. Duralumin soft sheet 231.29 308.39

18. Duralumin treated and cold rolled 308.10 410.80

19. Fibre hard 185.04 246.72

20. Lead 30.84 41.12

21. Leather 54 72

22. Oak ( wood) 54 72

23. Tin rolled sheet 38.55 51.4

24. Tin coated steel sheet 385.5 514

25. Zinc rolled sheet 138 184

26. Zinc hard rolled 154.20 205.6

27. Silver 231.29 308.38

28. Paper using hollow dies 23.13 30.84TOOL DESIG

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Table 2 - Sheet material SWG to mm & inch conversion

SWG inches Mm SWG inches Mm SWG inches mm

7/0 0.500 12.700 13 0.092 2.34 32 0.0108 0.27

6/0 0.464 11.79 14 0.080 2.03 33 0.0100 0.25

5/0 0.432 10.97 15 0.072 1.83 34 0.0092 0.23

4/0 0.400 10.16 16 0.064 1.63 35 0.0084 0.21

3/0 0.372 9.45 17 0.056 1.42 36 0.0076 0.19

2/0 0.348 8.84 18 0.048 1.22 37 0.0068 0.17

1/0 0.324 8.23 19 0.040 1.02 38 0.006 0.15

1 0.300 7.62 20 0.036 0.91 39 0.0052 0.13

2 0.276 7.01 21 0.032 0.81 40 0.0048 0.12

3 0.252 6.40 22 0.028 0.71 41 0.0044 0.11

4 0.232 5.89 23 0.024 0.61 42 0.004 0.10

5 0.212 5.39 24 0.022 0.56 43 0.0036 0.09

6 0.192 4.88 25 0.020 0.51 44 0.0032 0.08

7 0.176 4.47 26 0.018 0.46 45 0.0028 0.07

8 0.160 4.06 27 0.0164 0.42 46 0.0024 0.06

9 0.144 3.66 28 0.0148 0.38 47 0.002 0.05

10 0.128 3.25 29 0.0136 0.35 48 0.0016 0.04

11 0.116 2.95 30 0.0124 0.31 49 0.0012 0.03

12 0.104 2.64 31 0.0116 0.30 50 0.001 0.02

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DATA FOR STAMPING DIES

FORMULAE:

1. Cutting force = S*P*T

Where S = Shear strength of the component material in N/mm2

P = Perimeter of the component in mm

T = Thickness of the component in mm

2. Percentage of utilization = 100XStripofArea

BlankofArea

3. Percentage of scrap = 100 – Percentage of utilization

4. Stripping Force = 10 to 20% of cutting force

5. Press Capacities = Cutting Force x 1.3

6.Compressive force on punches = comp.stress of the punch matl. X area of cross section of punch

7. Buckling Forces =π2EI/LP2

WHERE E= modulus of elasticity in GN/mm2

I=moment of inertia in mm4

Lp=length of punch in mm

8. Strip layout

Margin (or) Bridge = 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

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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 3.5 4

Margin, (S), mm

10 1.5 1.2 1 1.4 1.5 1.8 2 2 2 2 2.5 2.5

50 2 1.7 1.75 1.9 2 2.2 2.5 2.8 3 3.5 3.7 4

100 3 2.4 2 2.4 2.5 2.7 3 3.2 3.5 4 4.2 4.5

150 3.5 2.9 2.5 2.9 3 3.2 3.5 3.7 4 4.5 4.7 5

250 4 3.4 3 3.4 3.5 3.7 4 4.2 4.5 5 5.2 5.5

350 4.5 3.9 3.5 3.9 4 4.2 4.5 4.7 5 5.5 5.7 6

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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:

Table 3.2 - Recommended minimum C distance for various die hole contour and die block heights B

A BC

Minimum Distance – Die Hole To Outside Edge

Strip Thickness

0 to 1.5

1.5 to 3.1

3.1 to 4.7

4.7 to 6.3

Over 6.3

Die Block Height

24

29

35

42

48

1Smooth Die Hole Contour

(1.125 B)

27

33

39

47

54

2Inside Corners

(1.5 B)

36

44

53

63

72

3Sharp Inside Corners

(2 B)

48

58

70

84

96

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Table 3.3 - Tabulation of suggested standard die block sizes

A B C D E F G

76.2 88.9 15.8 44.4 57.1 23.8 M8 TAPPED THROUGH HOLE

76.2 127 15.8 44.4 95.2 23.8 M8 TAPPED THROUGH HOLE


101.6 127 15.8 69.8 95.2 23.8 M8 TAPPED THROUGH HOLE


127 127 19 88.9 88.9 23.8 M10 TAPPED THROUGH HOLE

127 152.4 19 88.9 114.3 23.8 M10 TAPPED THROUGH HOLE

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Table 3.4 - Tabulation of suggested standard medium size die block sizes:

A B C D E F G H

101.6 177.8 19 63.5 139.7 69.8 M10 TAPPED THROUGH HOLE 28.5


127 203.2 19 88.9 165.1 82.5 M10 TAPPED THROUGH HOLE 28.5

127 254 19 88.9 215.9 107.9 M10 TAPPED THROUGH HOLE 28.5


152.4 254 19 114.3 215.9 107.9 M10 TAPPED THROUGH HOLE 28.5


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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 Angular clearance per side

0 to 1.5875 1/4o

1.5875 to 4.76 1/20

4.76 to 7.9 3/40

Over 7.9 10

Soft materials require greater angular clearance than hard materials.

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Die clearance:-

Clearance per side = C *T * √ (τmax/10)

Where C= constant = 0.005 for very accurate components

=0.01 for normal component.

T= Sheet thickness in mm.

τmax = 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 Die clearance per side in percentageof sheet thickness

Mild steel 2.5%-5%

Aluminum 1.5%-3%

Brass 1.5%-3%

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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(thickness *width)

StripperPlatethickness (A)in mm

Note:-For design and manufacturing simplicity, the width and length of stripper isassumed same as that of the die plate

1.6x751.6x1501.6x2251.6x300

3.2x753.2x1503.2x2253.2x300

4.8x754.8x1504.8x2254.8x300

6.35x756.35x1506.35x2256.35x300

7.8x757.8x1507.8x2257.8x300

68

1014

10121416

12151820

16182022

18222426

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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 1.6 0.8

1.587-3.175 2.4 0.8

3.175-4.762 3.2 0.8

4.762-6.35 4.0 0.8

6.35-7.937 4.8 0.8

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PUNCH DESIGN DETAILS

Table 3.9 - Stepped Round Punch Table 3.10 – Round Punch

TOOL DESIG

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Table 3.11 – Square Punch Table 3.12 – Quick change punch

TOOL DESIG

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Table 3.13 – Punch Chamfered head Table 3.14 – Stepped Punch

Table 3.15 – Square Punch with shedder

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Table 3.16 - COMMONLY USED PUNCH PL ATE SIZES:-

Table 3.17 - COMMONLY USED PUNCH

PLATE SIZES

A B5050757575100100100125125125150150150150175175175

507575100125100125150125150175150175200250175225275

A B0 to 7.97.9 to 1111 to 12.712.7 to 15.815.8 to 17.417.4 to 1919 to 22.222.2 to 23.823.8 to 25.4

12.715.81922.225.428.531.734.938.1

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Table 3.18 - PILOTS

ACORN TYPE PILOTA B C D E MAT3.14.76.37.99.511.112.714.215.817.419

3.14.76.37.99.511.112.714.215.817.419

0.71.191.51.982.32.773.13.573.94.34.7

3.94.77.19.511.112.714.215.817.41922.2

2.33.14.76.37.17.99.511.111.912.714.2

D.R.D.R.D.R.D.R.D.R.D.R.D.R.D.R.D.R.D.R.D.R.

FLATTENED POINT TYPEA B C D E MAT20.622.223.825.426.928.530.131.733.334.938.1

20.622.223.825.426.928.530.131.733.334.938.1

12.713.414.215.816.617.418.21920.621.423.8

23.825.428.531.733.336.538.141.242.844.447.6

15.817.41920.622.223.825.426.928.530.131.7

Tool SteelT.ST.ST.ST.ST.ST.ST.ST.ST.ST.S

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FINGER STOPS

Table 3.19 - FINGER STOPS

AUTOMATIC STOPS

ASTRIP

THICKNESS

1SMOOTH DIE HOLE

CONTOUR

2INSIDE CORNERS

3SHARP CORNERS

FRONTSPACERWIDTH

FINGERSTOPNo.

FRONTSPACERWIDTH

FINGERSTOPNo.

FRONTSPACERWIDTH

FINGERSTOP No.

0 to 1.51.5 to 3.13.1 to 4.74.7 to 6.3Over 6.3

2532384550

12345

3845505864

678910

5056637075

1112131415

No. A B C D E F12345

3.24.86.48.09.5

6.37.99.511.112.7

16.620.624.628.532.5

37.344.451.558.765.8

1.62.43.24.04.8

46.2257.3766.9276.5086.05

678910

3.24.86.48.09.5

9.511.112.714.215.8

23.827.731.735.739.6

50.857.96572.279.3

1.62.43.24.04.8

61.3170.8680.4189.9999.56

1112131415

.3.24.86.48.09.5

9.511.112.714.215.8

36.40.444.448.452.3

63.570.673.581.388.4

1.62.43.24.04.8

74.0183.5693.11102.69112.26

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Table 3.20- AUTOMATIC STOPS

NO A B C D E F G H I J K L123456

101.6477.5965.21442.72092.9127

6.36.36.37.97.97.9

19.823.858.4160302.2441.9

8.79.510.311.111.912.7

6.36.36.37.97.97.9

119.3160241.3302.2340.3401.3

241.3281.9360.6441.9523.2604.5

4.76.37.99.511.112.7

2.33.13.14.74.74.7

3.13.93.95.55.55.5

7.1R.7.1R.7.1R.8.7R.10.3R.11.1R.

4.76.36.37.17.99.5

NO M N O P Q R S T U123456

4.8Drill 9.5 depth 45° csk 1.6 deep4.8Drill 9.5 depth 45° csk 1.6 deep4.8Drill 9.5 depth 45° csk 1.6 deep4.8Drill 9.5 depth 45° csk 1.6 deep4.8Drill 9.5 depth 45° csk 1.6 deep4.8Drill 9.5 depth 45° csk 1.6 deep

6°6°6½°6½°7°7½°

1.5 R.1.9 R.1.9 R.2.3 R.2.3 R.2.3 R.

12.7R.12.7R.12.7R.12.7R.12.7R.12.7R.

30°30°30°30°30°30°

1.1R.1.1R.1.1R.1.1R.1.1R.1.1R.

3.1R.3.1R.3.1R.3.1R.3.1R.3.1R.

1.51.92.32.73.13.9

16.620.624.678.7183281.9

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NO A B C D E F G H I J K L M N123456

6.39.512.715.81922.2

16.620.624.678.7180.3281.9

25.478.7160241.3322.5401.3

50.8157.4320645.11127.776.2

25.478.7160241.3322.5401.3

12.714.215.817.41920.6

1920.62324.658.499

322.578.7523.2119.3238.7401.3

3.13.13.13.93.93.9

3.13.13.13.93.93.9

6.36.36.37.97.97.9

7.98.78.710.311.912.7

9.110.311.112.714.215.8

7.98.79.511.111.913.4

NO O P Q R S T U123456

33°33°33°33°33°33°

5.56.76.77.98.79.5

3.14.76.37.99.511.1

0.8 X 45°0.8 X 45°0.8 X 45°0.8 X 45°0.8 X 45°0.8 X 45°.

2.33.13.14.74.74.7

6.75dr 10.31 c bore 6.35 deep6.75dr 10.31 c bore 6.35 deep8.33dr 11.90 c bore 7.93 deep8.33dr 11.31 c bore 7.93deep9.92dr 15.08 c bore14.28deep9.92dr 15.08c bore 14.28deep

4.8 drill 2.4 deep 45° csk 1.19 deep4.8 drill 2.4 deep 45° csk 1.19 deep4.8 drill 2.4 deep 45° csk 1.19 deep4.8 drill 2.4 deep 45° csk 1.19 deep4.8 drill 2.4 deep 45° csk 1.19 deep4.8 drill 2.4 deep 45° csk 1.19 deep

NO A B C D E F G123456

37.3039.6843.6547.6250.8054.76

34.9337.3041.6744.8448.0252.38

25.478.7160241.3322.5401.3

7.97.98.710.310.311.1

1920.62324.658.499

322.5401.3523.2604.5238.7401.3

M6 TAPM6 TAPM8TAPM8TAPM10 TAPM10 TAP

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Table 3.23 - FULCRUM PIN DIMENSIONS

STOPNO.

A

123456

28.530.131.733.334.936.5

STOPNO.

A

1

22-A

33-A3-B

44-A4-B4-C

55-A5-B5-C

66-A6-B

19.8

23.825.4

27.729.330.9

31.7533.3334.9236.51

37.338.8940.4842.06

42.8644.4546.03

STOP NO A B1 22.22 2.402 25.40 3.1753 28.575 3.1754 31.75 4.805 34.925 4.806 38.10 4.80TOOL D

ESIGN D

ATA BOOK


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 = Die clearance x Stripping Load

Stripping Load = 10% of vertical Force

Load/Dowel = Horizontal Force / No. of Dowels

Area = Load/DowelsS

Dowel diameter = √(Area/0.7854)

If Dowel size becomes too big more number of smaller dowels having same total sectional

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.

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Table 3.24 - NO OF SCREWS BASED ON STRIPPING FORCE

STRIPPING FORCE IN M6 M8 M10 M12 M16 M20TON N0.2 1992.8to2491.0 2 * * * * *0.4 3985.6 3 2 * * * *0.63 6277.3 4 2 * * * *0.8to1.0 7971.2to9964.02 6 3 2 2 * *1.25 12455.0 8 4 3 2 * *1.60 15942.4 * 5 3 2 2 *2.5 24910.0 * 8 5 4 3 *4.0 39856.0 * * 8 6 3 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.

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Table 3.25 - DIE SET DETAILS

S. No. X D Y INCH SIZE L W T B Pillar (OD) TYPE

1 60 52 - 04 X 04 100 100 20 22 16 Back Pillar

2 100 52 - 04 X 06 150 100 20 22 20 Back Pillar

3 150 52 - 04 X 08 200 100 25 30 20 Back Pillar

4 100 75 - 05 X 05 130 130 20 25 20 Back Pillar

5 95 100 - 05 X 06 125 150 22 25 20 Back Pillar

6 120 100 - 06 X 06 150 150 22 25 20 Back Pillar

7 120 120 - 06 X 07 150 180 25 30 25 Back Pillar

8 - 140 130 06 X 09 230 150 20 20 20 Blister Cen

9 - 170 100 06 X 12 305 150 30 35 28 Cent Pillar

10 150 120 - 07 X 07 180 180 25 30 25 Back Pillar

11 150 145 - 07 X 08 180 200 25 30 25 Back Pillar

12 160 135 - 08 X 08 200 205 30 35 28 Back Pillar

13 160 160 - 08 X 09 200 230 30 35 28 Back Pillar

14 160 180 - 08 X 10 205 254 30 35 28 Back Pillar

15 - 160 170 08 X 12 200 305 30 35 32 Cent Pillar

16 - 180 170 08 X 13 200 330 30 35 32 Cent Pillar

17 200 160 - 09 X 09 230 230 30 35 28 Back Pillar

18 200 180 - 09 X 10 230 250 30 35 28 Back Pillar

19 200 185 - 10 X 10 254 254 30 35 28 Back Pillar

20 - 120 200 10 X 10 254 254 30 35 28 Diago. Pillar

21 - 120 200 10 X 10 254 254 30 35 28 Four Pillar

22 200 210 - 10 X 11 254 280 30 35 32 Back Pillar

23 200 235 - 10 X 12 254 305 30 35 32 Back Pillar

24 - 230 200 10 X 15 254 380 35 40 32 Cent Pillar

25 230 210 - 11 X 11 280 280 30 35 32 Back Pillar

26 255 235 - 12 X 12 305 305 30 35 32 Back Pillar

27 - 165 255 12 X 12 305 305 30 35 32 Diago. Pillar

28 - 165 255 12 X 12 305 305 30 35 28 Four Pillar

29 255 260 - 12 X 13 305 330 30 35 32 Back Pillar

30 280 255 - 13 X 13 330 330 35 40 36 Back PillarTOOL DESIG

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BALL BEARING CAGES

Table 3.26 - Ball Bearing Cages

Standard bearing Al./Brass

Table – 3.27 Ball Bearing Cages

Non Standard bearing Al./Brass

No. I.D.X. O.D.X Length X Ball

1 20 26 65 3

2 25 31 70 3

3 28 36 80 4

4 32 40 80 4

5 32 40 95 4

6 36 44 90 4

7 40 48 90 4

No. I.D.X. O.D.X. Length X Ball

1 15 21 70 3

2 16 22 70 3

3 19 25 70 3

4 24 30 70 3

5 18 24 70 3

6 30 38 80 4

7 32 40 100 4

8 36 44 105 4

9 38 46 105, 125 4

10 40 48 105, 125 4

11 48 58 105, 125 5

12 50 60 105, 125 5

13 60 70 125 5

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Table 3.28 - SLEEVE BUSH FOR DIE SETS

Sleeve Bush Standard Bush Sleeve Bush Non Standard Bush

NoD-2

I.D

D-3

O.D.

D-4

Stap

O.D.

Length

L-1

Length

LNo

D-2

I.D.

D-3

O.D.

D-4 Stap

O.D.Length L

1 20 36 40 20 60 1 21 32 36 60

2 25 42 46 23 70 2 22 32 36 60

3 28 50 54 28 80 3 25 36 40 70

4 32 52 56 28 80 4 30 42 46 70

5 36 58 62 30 90 5 38 50 54 80

6 40 60 65 30 90 6 46 60 65 90

7 26 36 40 20 60 7 30 44 50 110

8 31 42 46 23 70 8 25 38 42 90

9 36 50 54 28 80 9 15 32 36 60

10 40 52 56 28 80 10 16 32 36 60

11 40 56 60 30 90 11 31 42 46 110

12 44 58 62 30 90 12 36 50 54 110

13 48 60 65 30 90 13 20 36 - 75

14 26 36 - 80

15 33 42 46 90

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PILLAR PINS FOR DIE SETS

Table 3.29 - Standard Pillar

S. No D L

1 20 125, 150

2 25 140, 160, 180

3 28 180, 200

4 30 180, 190

5 32 150, 180, 200, 230

6 36 170, 200, 250

7 40 200, 250

Table 3.30 - Non Standard Pillar

S. No D L

1 15 90, 100

2 16 90, 100

3 19 125, 150

4 20 100, 180

5 24 140, 160, 180, 200, 225

6 25 200, 250, 300

7 28 150, 225, 250, 300

8 30 150, 200, 225, 250

9 32 300, 250, 350

10 36 225, 275, 300, 350

11 40 225, 275, 300, 350, 400

12 50 200, 225, 255, 270, 300, 350TOOL DESIG

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SELECTION OF PRESS (TON)

Press capacity required =Cutting Force x 1.3 ( Select nearest higher capacitypress from the data given below)

Table 3.31 - Preferred capacities of Mechanical and Hydraulic presses( as per IS7469-1974):-

Capacity inKN (Tonnes)

Capacity inKN (Tonnes)

10 (1) *2000 (200)

16 (1.6) 2500 (250)

25 (2.5) *3150 ( 315)

40 (4.0) 4000 ( 400)

63 (6.3) *5500 ( 550)

100 (10) 6300 (630)

160 (16) *8000 (800)

250 (25) 10000 (1000)

400 (40) 12500 (1250)

630 (63) 16000 (1600)

*800 (80) 20000 (2000)

1000 (100) 25000 (2500)

*1250 (125) 31500 (3150)

1600 (160) 40000 (4000)

Note –capacities marked with asterisk(*) are optional in the range.

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Using the same principle, die shut height for stamping dies, bendingdies, andformingdies can also be calculated

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,

The shut height of the tool must be kept according to the available press shut heights.

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Table 3.32 - PUNCH AND DIE MATERIAL SELECTION AND HEATTREATMENT

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Table 3.33 - SELECTION OF STEEL FOR DIFFERENTAPPLICATIONS

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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+…. = Σlx/Σl

= (l1y1+l2y2+l3y3+……)/l1+l2+l3+…. = Σly/Σl

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.

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SPRING DESIGN DATA1. 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:-

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.

Step 4:-Estimate total initial spring load ‘L” required for all springs when

springs are compressed “X” in mm

Step 5:-TOOL DESIG

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- 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.

Table 3.34 – Spring Compressed length to free length conversion chart

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Table 3.35 – Rectangular spring – light load

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Table 3.35 Contd…

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Table 3.36 – Rectangular spring – Medium load

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Table 3.36 Contd…

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Table 3.37– Rectangular spring – Heavy load

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Table 3.37 Contd….

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Table 3.38 - Rectangular spring – Extra Heavy load

TOOL DESIG

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Table 3.38 Contd…

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Table 3.39 - Rectangular spring – Ultra Heavy load

TOOL DESIG

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Table 3.40 - Circular spring – Light load

TOOL DESIG

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Table 3.41 - Circular spring – Medium load

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Table 3.42- Circular spring – Heavy load

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Table 3.43- Circular spring

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Table 3.43 Contd….

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Table 3.43 Contd…

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Table 3.44 – Spring retainer

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Table 3.45 - RUBBER SPRINGS

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Table 3.50 RUBBER SPRINGS

D d d1 t d2

10 18 23 6 1.6

13 23 26 6

16 28 31 6

20 33 36 7

25 40 43 7 3.0

32 50 55 7

38 60 65 8

40 60 65 8

D L

Stripping Pressure (N) at Deflection of

3mm 6mm 9mm

10

44 978 1401 -

54 734 1290 1512

64 703 1060 1268

74 670 1020 1220

13

44 1566 2647 -

54 1357 2180 2469

64 1081 1780 2158

74 811 1707 2139

16

44 2433 3513 -

54 1779 2958 3692

64 1526 2736 3202

74 1490 2650 3182

20

44 3002 4359 -

54 2580 3936 4581

64 2046 3424 4226

74 1939 3180 3980

25

44 4737 6605 -

54 3425 5515 6672

64 3291 5070 6205

74 3158 4781 5887

32

44 6383 9185 -

54 5693 8674 10008

64 4480 6961 8118

74 3469 6491 7570

40

44 8562 12521 -

54 6583 10497 12744

64 5804 9563 11453

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BENDING TOOL DESIGN DATA

Bending Allowance(L):

L = (π / 180) x A x (R + 0.5T) When R ≥ 2T

L = (π / 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

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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.

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‘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

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‘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

Die radius, RD = RP+ (1.2 to 1.25) t s

C = Die clearance

T =Thickness of blank in ‘mm’

L =Length of bent part.

S = ultimate tensile strength in N/mm2

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WIPING DIES:

Bending Force, F = [(0.333LST2)/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

400N/mm2 600N/mm2

R = T 4° 7°

R = 5T 6° 12°

Table 4.1 – Spring back data

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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) when d / r 20 or more

D = √ (d2+4dh – 0.5r) when d / r is between15&20

D = √ (d2+4dh – r) when d / r is between10&15

D = √[(d – 2r)2+4d(h- r) + 2πr(d – 0.7r)] when d / r is below 10

Where,

D – Blank diameter in mm

d – Shell outer diameter in mm

h – Shell Height in mm

r – Corner radius of punch

Considering Trim allowance:

Trim allowance = 0.05mm for every 10 mm diameter. Of drawn cup

Where,

Initial diameter of blank (D1) = D (Theoretical diameter.) + Trim allowance

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t / D Consideration:

t / D decides the severity of wrinkling

t / D Percentage

Upto 0.5

Wrinkling is a severe and compressive loadmust be reduced.

Blank holder must be used, so a doubleaction press is preferable

Above 0.5 upto 1.5Wrinkling is moderate and low blankholding forces are permitted

Above 1.5 upto 2.5Wrinkling is very light so, single actionpress is enough

Over 2.5No wrinkling so blank holder isunnecessary even with high compressiveload

Table 5.1 - Selection of percentage reduction for 1st Draw using t / D ratio:

(t / D) x 100 % reduction for 1 st Draw[(D1 – D2) / D1] x 100Single action Double action

1.50.150.20.3

303540

2.0 0.4 452.5 0.5 47.5

Where,

D1 = Blank diameter. After adding trim allowance

D2 = Diameter. Of 1st Draw

Table 5.2 - Allowable percentage reduction for successive draws

First draw (t / D) %Second draw 25%Third draw 15%Fourth draw 10 %

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Table 5.3 - No. Of Draws according to h / d ratio

h / d ratio No. ofDraws

First draw Seconddraw

Third draw Fourthdraw

Up to 0.75 1 40 -- -- --0.75 – 1.5 2 40 25 -- --

1.5 - 3 3 40 25 15 --3 – 4.5 4 40 25 15 10

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 = π 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’

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:

Press capacity = (Drawing pressure + Blank holding pressure) x 1.3

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Table 5.4 - Drawing speed

MaterialSingle action drawing Double action drawing

Ft / Min M / Sec Ft / Min M / SecSteel 60 0.3048 35 – 55 0.1778-0.27

Stainless steel - - 20 – 30 0.1016-0.1524Aluminum 180 0.9144 100 0.508

Aluminum alloys - - 30 – 40 0.1524 – 0.2032Copper 150 0.762 85 0.4318Brass 200 1.016 100 0.508

Table 5.5 - Draw die clearance

Blank thickness(t) 1st Draw2nd draw/

Intermittent drawSizing draw

Upto 0.38 1.07t – 1.09t 1.08t – 1.1t 1.04t – 1.05t0.4 – 1.27 1.08t – 1.1t 1.09t – 1.12t 1.05t – 1.06t1.28 – 3.18 1.1t – 1.12t 1.12t – 1.14t 1.07t – 1.09t

3.5 and above 1.12t – 1.14t 1.15t – 1.2t 1.08t – 1.1tt is the thickness of the original blank

Punch radius:

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:

Rate of production Die materialLess than 1000 Plastic (or) zincAround 1000 Nos. C.IAbove 10000 Nos. Tool SteelAbove 10,00,000 Carbide Punches & die

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6. DATA FOR GAUGE DESIGN:-

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TOOL DESIG

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Table 6.34 - REFERENCE INDIAN STANDARDS FOR GAUGE DESIGN:-

IS NO. INDIAN STANDARD SPECIFICATION FOR

IS: 3455 – 1971 Gauging practice for Plain work pieces

IS: 6137 – 1983Gauging members for Plain plug gauges, GO and NO GO members

(Size range from 1 upto and including 40mm)

IS: 6244- 1980Gauging members for Plain plug gauges, GO and NO GO members

(Size range above 40 to 120 mm)

IS: 6246 – 1980Gauging members for Plain plug gauges, GO and NO GO members

(Size range above 120 up to and including 250 mm)

IS: 7018 (Part 1)

– 1983Technical supply conditions for gauges – Part 1 General

IS: 7018 (Part 2)

– 1983

Technical supply conditions for gauges – Part 2 - Assembly and

inspection Plain Plug gauges ( Size range from 1 mm upto and

including 250 mm)

IS: 7018 (Part 3)

– 1983

Technical supply conditions for gauges – Part 3- Assembly and

identification of screw plug gauges for ISO metric screw threads (

Size range from M1 upto and including M200)

IS: 5388 – 1983 Hexagon handles for Plain and Threaded Plug gauges

IS: 3477 – 1973 GO and NO GO Snap Gauges for size range 3 to 250 mm

IS: 3485 - 1966 Plain ring gauges

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.

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JIGS & FIXTURES

Table 7.1 - GUIDELINES FOR SELECTION OF LOCATORS

SI.NO LOCATING DEVICE APPLICATION1 Six point locator(3-2-1) pin and button

locatorsLocating flat surfaces

2 V-block Locating round circularflat

3 Nesting locator Locating cylindricalprofile in verticalposition.

4 V-block, horizontal (one side is fixed andother end is adjustable or cam operated)V-locator.

Locating elliptical andirregular surfaces.

5 Jack pin locator Locating a rough workpiece.

6 Eccentric locators Variation in work piecesize.

Table 7.2 - GUIDELINES FOR SELECTION OF CLAMPSCLAMPS SITUATIONS

Strap clamp Commonly used for rectangular workpieces.

Swinging strap clamp For easy loading and un loading.

Cam operated clamp Effective and fast, but should be used.

Toggle clamp Adapted for many types of fixtures.

Screw clamp Components are to grip on.

Equalizing clamp Exerting equal pressure to hold.

Hydraulic and pneumatic clamp Faster, uniform and effective.

Hydraulic clamp with rack and pinion Circular rod in V-block

Spider clamp Circular and symmetrical workpiececlamping.

Edge clamp Used during facing operation.

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Table 7.3 - LOCATING PINS (ROUND) - IS 5093

D g6 dd1

p6 d2 h1 h2

10 9.5 8 7.5 8 1612 11.5 10 9.5 10 1816 15 12 11.5 14 2220 19 16 15.5 18 2525 24 20 19.5 22 32

32 31 25 24.5 25 36

Table 7.4 - END LOCTING PLUGS - IS 5095Dh6

dd1

p6d2 h1 h2

16 15 12 11.5 12162540

20 19 16 15.5 15203245

25 24 20 19.5 18254060

32 31 25 24.5 2240

63

40 39 32 31.5 2550

80

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Table 7.5 - DIAMOND LOCATING PINS - IS 5094De8

dd1

p6d2 b h1 h2

12 11 8 7.5 4 8 12

14 13 10 9.5 5 10 14

18 17 12 11.5 6 14 18

22 21 16 15.5 8 18 21

28 27 20 19.5 10 22 28

36 35 25 24.5 12 25 32

Table 7.6 - ROUND LOCATING STUDS - IS 5096

Dg6

dd1

p6d2 d3

d4

s7h h1 h2

12

11.5

10

9.5 M6 540

10

12

18

1714

13.5

M8 655

16

18

20

1916

15.5

M10

862

18

20

25

2420

19.5

M12

10

70

22

25

32

3125

24.5

M16

12

85

25

28

Table 7.7 - V-LocatorL1 l2 l3 b1 b2 b3 dTOOL D

ESIGN D

ATA BOOK


25 20 35 15 32 15 7

36 25 50 20 45 25 9

50 32 60 22 55 30 11Table 7.8 - V-Block

a b c dmax dmin

50 40 40 40 5

63 50 50 50 5

80 63 63 63 7

100 80 80 83 7

200 200 200 200 10

300 300 300 300 12

Table 7.8 - SWING CLAMP - IS 5250

d w W1 t L L1 L2 L3 a rSizeof

screw

6.6 20 7 12 52 20 25 14 4 12 M6

9 25 9 14 60 22 30 18 5 14 M8

11 30 11 16 70 24 35 20 6 16 M10

14 35 15 20 80 26 40 22 7 20 M12

18 45 18 25 90 32 45 28 9 25 M16

22 50 23 30 100 38 50 32 11 30 M20

Table 7.9 - STRAP CLAMP – IS 4292

d l1 a b c h sFor

screwsize

7 50 10 20 8 10 20 M610 60 13 22 10 12 25 M812 80 15 30 12 15 30 M1015 100(125) 21 40(50) 14 20 40 M1219 125(160) 26 45(65) 18 25 50 M1624 160(200) 30 60(80) 22 30 60 M20TOOL D

ESIGN D

ATA BOOK


28 200(250) 35 80(105) 26 30(40) 70 M2435 250(315) 45 100(130) 34 40(50) 80 M3042 315(350) 48 125(150) 40 45(55) 90 M3645 350(400) 53 150(180) 45 55(60) 100 M39

Table 7.10 - SWING ‘C’ WASHER- IS 4298

dH13

d1 R R1 R2 R3 R4 rt

Nom

Forboltor

screwsize

6.6 8.5 18 8 21.3 14.7 10.0 2.0 6 M69.0 8.5 21 8 25.5 16.5 13.0 2.5 6 M811 8.5 24 8 29.5 18.5 16.0 2.5 6 M1014 10.5 27 10 34.0 20.0 20.0 3.0 8 M1218 10.5 33 10 42.0 24.0 25.0 3.0 8 M1622 10.5 38 10 49.0 27.0 30.0 3.0 8 M20

26 12.5 42 12 55.0 29.0 32.5 4.0 10 M24

30 12.5 45 12 60.0 30.0 35.0 4.0 10 M27

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Table 7.11 - JIG BUTTON (IS 4294)MATERIAL: C45 HARDNESS: 45 – 50RC

d1 d2 h a l Under cut6 4 5 1.2 6 A2 X 0.210 6 8 1.6 8 B2 X 0.216 8 5/13 2.0 10 B2 X 0.225 12 8/20 2.5 14 B2 X 0.2

40 20 13/32 3.2 20 B2 X 0.2

Table 7.12 - JIG FEETMATERIAL: FREE CUTTING STEEL – HARDNESS:56 ± 2RC

H d b d1 d2 e1 K l r1 r2 S X ∞

1020

M6 11 6 8 12.7 52131

0.5 1 11 2.034º13º

1530

M8 13 9 10 16.2 62843

0.5 1 14 2.522º9º

2040

M10

16 12 12 19.6 83656

0.5 1.5 17 2.518º7º

2550

M12

20 15 15 25.4 104570

0.5 1.5 22 3.020º8º

3060

M16

24 20 19 31.2 125484

1.0 2 27 3.018º7º

4080

M20

29 26 24 36.9 1669

1091.0 2 32 4.0

13º5º

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Table 7.13 - FEET BOLTBasicsize

A B C D E ø F ø

M10 50 28 12 12-20 10 20

M10 65 28 12 12-20 10 20

M10 75 28 12 12-20 10 20

M10 90 28 12 12-20 10 20

M12 75 35 18 20-25 12 25

M12 90 35 18 20-25 12 25

M12 100 35 18 20-25 12 25

M12 112 35 18 20-25 12 25

M12 125 35 18 20-25 12 25

M12 140 35 18 20-25 12 25

M12 150 35 18 20-25 12 25

Table 7.14 - FEET NUTS

Basicsize

M10 M10 M10 M10 M12 M12 M12 M12 M12 M12 M12

A 20 25 36 50 20 25 36 50 62 75 87

B ø 20 20 20 20 25 25 25 25 25 25 25

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Table 7.15 - JIG BUSHFIXED BUSH

d1Short

l1 l2

Longl1 l2

d2 d3 d4 r1 r2 Z

Upto 1 6 4 9 7 3 6 - 1.2 0.2 0.0051.0-1.8 6 4 9 7 4 7 - 1.2 0.2 0.0051.8-2.6 6 4 9 7 5 8 - 1.2 0.3 0.0052.6-3.3 8 6 12 9 6 10 - 1.6 0.3 0.0053.3-4.0 8 6 12 9 7 11 - 1.6 0.4 0.0054.0-5.0 8 6 12 9 8 12 - 2.0 0.4 0.0055.0-6.0 10 7 16 13 10 14 - 2.0 0.4 0.016.0-8.0 10 7 16 13 12 16 10 2.0 0.6 0.018.0-10 12 8 20 16 16 20 13 2.5 0.8 0.0110-12 12 8 20 16 18 22 16 2.5 0.8 0.0112-15 16 12 28 24 25 26 20 4.0 0.8 0.0115-18 16 12 28 24 25 30 24 4.0 0.8 0.0118-22 20 15 36 31 30 35 28 6.0 1.0 0.0122-26 20 15 36 31 36 41 33 6.0 1.0 0.0226-30 20 15 36 31 42 47 40 6.0 1.0 0.0230-35 25 20 45 40 48 55 46 8.0 1.0 0.0235-42 25 20 45 40 56 63 52 8.0 1.0 0.0242-48 32 25 56 50 63 70 59 8.0 1.6 0.0248-55 32 25 56 50 70 77 67 8.0 1.6 0.0255-63 36 30 72 66 80 87 75 8.0 1.6 0.02

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Table 7.16 - LINER BUSH

d1Short Long d2 r1 r2 z

Upto 1 6 9 3 1.2 0.2 0.0051.0-1.8 6 9 4 1.2 0.2 0.0051.8-2.6 6 9 5 1.2 0.3 0.0052.6-3.3 8 12 6 1.6 0.3 0.0053.3-4.0 8 12 7 1.6 0.4 0.0054.0-5.0 8 12 8 2.0 0.4 0.0055.0-6.0 10 16 10 2.0 0.4 0.016.0-8.0 10 16 12 2.0 0.6 0.018.0-10 12 20 16 2.5 0.8 0.0110-12 12 20 18 2.5 0.8 0.0112-15 16 28 22 4.0 0.8 0.0115-18 16 28 25 4.0 0.8 0.0118-22 20 36 30 6.0 0.8 0.0122-26 20 36 36 6.0 1.0 0.0226-30 20 36 42 6.0 1.0 0.0230-35 25 45 48 8.0 1.0 0.0235-42 25 45 56 8.0 1.0 0.0242-48 30 56 63 8.0 1.6 0.0248-55 30 56 70 8.0 1.6 0.0255-63 36 70 80 8.0 1.6 0.02

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Table 7.17 - SLIP BUSH

d1 d2 d3 d4 d5 l1 l2 l3 a b r1 z X

Upto 4 8 16 11 2.5 20 10 1 3 4 3 0.01 14

4-6 10 19 14 2.5 22 12 1 3 4 3 0.01 12

6-8 12 22 17 2.5 25 12 1 3 4 4 0.01 10

8-10 16 26 21 3.0 28 16 1 4 5 5 0.01 12

10-12 18 30 24 3.0 28 16 1 4 5 5 0.01 10

12-15 22 35 29 5.0 36 20 1 5 7 5 0.01 1215-18 25 40 35 5.0 36 20 1 5 7 5 0.01 8

18-22 30 47 41 5.0 36 20 1 5 7 6 0.01 0

22-26 36 56 47 6.0 45 25 2 6 8 6 0.02 0

26-30 42 62 54 6.0 45 25 2 6 8 6 0.02 0

30-35 48 69 61 6.0 50 32 2 6 11 8 0.02 0

35-42 56 78 69 6.0 50 32 2 6 11 8 0.02 0

42-48 63 85 78 6.0 56 36 2 6 14 8 0.02 0

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Table 7.18 - LOCKING SCREWS

d6 d7 d8 l4 l5 l6 h d6 m6Ø * l m n t r2 cM5M5M5M5M5

10 5 6 6 15 2

2.5 X 142.5 X 142.5 X 143.0 X 143.0 X 14

1012121616

1.6 2.0 0.6

1516182022

M6M6M6

13 6 8 8 20 25 X 205 X 205 X 20

202020

2.0 2.5 1.0262933

M8M8M8M8M8

16 8 10 10 25 2.5

6 X 246 X 246 X 246 X 246 X 28

2525303035

2.5 3.0 1.6

3841454855

TOMMY NUT (Material –C 45)Basic size AØ BØ

M10 25 28

M12 25 35

M16 32 38

TOOL DESIG

N DATA B

OOK


Table 7.19 - KNURLED THUMB NUT (Material –C 45)Basic size AØ BØ C D

M6 20 16 10 1.5

M8 22 20 12 1.5

M10 2522

12 3

M12 2825

14 3

M16 3528

16 3

Table 7.20 - THUMB NUT (Material –C 45)d1 d2 b h e

M6 7 28 12 12M8 9 32 14 14M10 11 36 16 16M12 13 45 18 18

M16 18 54 22 22

Table 7.21 – Hand nut

HAND NUT (Material –C 45)

AØ BØ CØ DØ E F G H J K41 32 23 M12 14 8 3 6 3 2554 38 27 M16 17 13 5 8 5 3558 41 30 M20 17 13 5 8 5 3564 45 32 M22 19 17 5 10 6 4170 50 38 M24 21 17 6 10 6 4480 56 45 M30 25 19 8 11 8 52

TOOL DESIG

N DATA B

OOK


d a d2 E g h l2

M10 6 3 75 3.5 12 40ll1

4025

4530

5035

5540

6045

6550

M12 7.5 4 90 4.0 15 50ll1

5031

5536

6041

6546

7051

7556

8061

M16 10.0 5 117 4.5 19 63ll1

6540

7045

7550

8560

9570

10580

M20 12.5 6 150 6.5 24 80ll1

8049

8554

9059

10069

11079

12089

13099

Table 7.22 – Handle grip screws

TOOL DESIG

N DATA B

OOK


Table 7.23 - WING/ FLY SCREWS

d a d2 eg

approx.h h1

M5 3 1.5 25 1.5 7 12ll1

2516

M6 4 1.5 32 2.0 8 16ll1

2820

3022

3527

M8 5 2.0 40 2.5 9.5 20ll1

3525

4030

4535

M10 6 3.0 50 3.5 12.0 25ll1

5038

5543

6048

6553

TOOL DESIG

N DATA B

OOK


Table 7.24 - PRESSURE PADS

Max.dia.d1

d4 d5 d6 d7 e f h r1 r2 t2 t1For screw

with threadFastening

pin

10 3.8 8 4 1.5 2.5 2.5 7 1.2 0.3 0.5 4.5 M5 1.5m6 x 612 4.8 10 5 1.5 2.5 2.5 8 1.5 0.3 0.5 5 M6 1.5m6 x 816 6.4 12 7 2 3 3.5 9.5 2 0.4 0.5 6 M8 2m6 x 820 7.4 15 8 2 3.5 5 12 2 0.4 1 7 M10 2m6 x 1425 9.5 18 10 3 4.5 6 15 3 0.6 1 9 M12 3m6 x 1432 12.5 22 14 3 6 7 19 3 0.6 1 12 M16 3m6 x 1640 15.5 28 18 4 7.5 9 24 4 0.8 1 15 M20 4m6 x 20

Table 7.25 - Cam clamp (Material – Mild steel)A B C D E F G10 13 1.5 3 12 60 1012 16 2 4 15 70 1216 20 2.5 5 18 90 16

20 25 3 6 24

110 20

TOOL DESIG

N DATA B

OOK


Table 7.26 - Quarter turn screwA B C D E F

M10 50 35 12 28 5M12 62 38 15 32 6M16 82 47 20 35 6

M20 100 60 22 40 10

Table 7.27 - Spherical washerA B C D E F G9 20 20 2.5 4 2.5 5

11 22 22 2.5 6 2.5 614 28 28 2.5 6.5 2.5 6.518 40 40 3 12 3 7

Table 7.28 - C WASHER

dH12

l D

Forboltor

screwsize

6.4 6 25 32 M6

8.4 8 32 40 M8

10.5 10 40 50 M10

13 10 50 63 M12

17 12 63 80 M16

21 12 63 80 M20

25 12 80 100 M24

31 15 80 100 M30

TOOL DESIG

N DATA B

OOK


Table 7.29 - WING NUT(hot stamped or cast) IS 2636-1972

Size d M2 M2.5 M3 M4 M5 M6 M8 M10 M12 M16 M20 M24

NomA(js16) max

min

88.457.55

1010.459.55

1212.5511.45

1616.5515.45

2020.6519.35

2323.6522.35

2828.6527.35

3636.8035.20

4545.8044.20

b Nom 6 8 10 12 16 19 22 28 36

Nome(js16) max

min

2020.619.4

2525.624.4

3232.831.2

4040.839.2

5050.849.2

6465.063

7273.071

9091.188.9

112113.0111.0

Nomg1(js16) max

min

1.61.91.3

22.31.7

2.52.82.2

33.32.7

44.43.6

55.44.6

66.45.6

77.46.6

99.48.6

g2 Nom 2 2.5 3 4 5 6 7 9 11

Nomh1(js16) max

min

1010.49.6

1212.611.4

1616.615.4

2020.619.4

2525.624.4

3232.831.2

3636.835.2

4545.844.2

5657.055

m nom 5 6 8 10 12 14 16 20 24

r1 Nom 3 4 5 6 8 10 11 14 18

r2 Nom * * * * 1 1 1.2 1.6 2.5

r3 Nom 0.5 0.5 1 1 1.2 1.2 1.6 2 3

r4 Nom 2 2.5 3 4 5 6 7 9 11

Radiused.

TOOL DESIG

N DATA B

OOK


Table 8 - Unit conversionsConversions factors

SIPHYSICALQUANTITY

MKS FPS

1 N Force 0.1016 kgf 0.2248 Ibf

1 N/m2 Pressure 10.19 x 10-6 kgf/cm2 145.038x10-6 kgf/cm2

1kW Power 1kW, 1.36hp 1.34hp

1 Nm/s Power 0.1019 kgfm/s 0.7375 ft lpf/s

Metric conversion table

Multiply ByTo get equivalent number

to

InchFootYardMile

Length25.4

0.30480.91441.609

Millimeters (mm)Meters (m)Meters (m)

Kilometers(km)

Inch2

Foot2

Yard2

Area645.26.45

0.09290.8361

Millimeters2(mm2)Centimeters2(cm2)

Meters2 (m2)Meters2

Inch3

Yard3

Volume16.38716.387

mm3

cm3

PoundTon

Mass0.4536907.18

Kilograms (kg)Kilograms (kg)

KilogramOunce

Force9.8070.278

Newton (N)Newton(N)

Foot/Second2

Inch/Second2

Acceleration0.30480.0254

Meter per second2(m/s2)Meter per second2

Horse powerPower0.746 Kilowatts(kW)

TOOL DESIG

N DATA B

OOK

Documents

Tool Design Data Book.pdf