Tool design is a branch of engineering that focuses on the creation of tools and their optimization for use in specific applications. The goal of tool design is to create tools that are efficient, reliable, and cost-effective. Tool design encompasses a wide array of topics, including the selection of materials, the optimization of tool geometry, and the optimization of the manufacturing process. Tool design also includes the development of software tools to facilitate the optimization process.
The selection of materials for tools is an important aspect of tool design. The material selected must have the necessary strength and durability to withstand the application’s operating conditions. In addition, the material must be cost-effective and easily machinable. Common materials used in tool design include high-speed steel, carbide, and titanium alloys (Meyers, 2010).
The geometry of a tool is essential for its performance. Geometric optimization of the tool involves selecting the correct cutting angle, cutting radius, and rake angle. The cutting angle, or the angle of the cutting edge, determines the strength and durability of the tool (Gopinath, 2017). The cutting radius determines the size of the cutting edge and the amount of material that can be removed from the workpiece. The rake angle is the angle between the cutting edge and the workpiece and affects the cutting forces and chip formation (Gopinath, 2017).
The manufacturing process of the tool is also an important factor in tool design. The manufacturing process must be optimized to ensure the tool is cost-effective and produces good quality parts. Common manufacturing processes used in tool design include grinding, milling, and electrochemical machining (ECM) (Meyers, 2010).
Software tools are also used in tool design to optimize the design process. Computer-aided-design (CAD) software is used to create a 3D model of the tool and simulate the cutting process. Computer-aided-manufacturing (CAM) software is used to generate the code for the manufacturing process. Finite Element Analysis (FEA) software is used to analyze the strength and rigidity of the tool and optimize its geometry (Gopinath, 2017).
In conclusion, tool design is a complex engineering process that involves the optimization of the tool’s geometry, material selection, and its manufacturing process. Software tools are used to facilitate the design process and optimize the tool to meet the requirements of the application.
References
Gopinath, R. (2017). Finite element analysis of cutting tool using ANSYS workbench. International Journal of Applied Engineering Research, 12(18), 6420-6425.
Meyers, M. A. (2010). Machining and machine tools. In M. A. Meyers (Ed.), Encyclopedia of physical science and technology (3rd ed., Vol. 9). Academic Press.