Tool Design Data Book.pdf

TOOL DESIGN DATA BOOK

FOR

DIPLOMA IN MECHANICAL ENGINEERING (TOOL & DIE)

COURSE CODE 1220

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

CONTENTS

SL.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

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

Table 1 - MATERIAL PROPERTIES S.No MATERIAL SHEAR 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

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

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 = X 100 Strip of Area Blank of Area

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

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

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:

A B _{Minimum Distance – Die Hole To Outside Edge}C

Strip Thickness 0 to 1.5 1.5 to 3.1 3.1 to 4.7

Die Block Height 24 29 35

1

Smooth Die Hole Contour (1.125 B) 27 33 39 47 2 Inside Corners (1.5 B) 36 44 53 3

Sharp Inside Corners

(2 B) 48 58 70

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 101.6 101.6 15.8 69.8 69.8 23.8 M8 TAPPED THROUGH HOLE 101.6 127 15.8 69.8 95.2 23.8 M8 TAPPED THROUGH HOLE 101.6 152.4 15.8 69.8 120.6 23.8 M10 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

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 28.5 101.6 203.2 19 63.5 165.1 82.5 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 28.5 152.4 203.2 19 114.3 165.1 82.5 M10 TAPPED THROUGH HOLE 28.5 152.4 254 19 114.3 215.9 107.9 M10 TAPPED THROUGH HOLE 28.5

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 1/4oto 1oangular 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.

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/mm 2

Clearance per side can also be selected from the table given below:

Table 3.6 – Die clearance

Material Die clearance per side in percentage of sheet thickness

Mild steel 2.5%-5% Aluminum 1.5%-3% Brass 1.5%-3%

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) Stripper Plate thicknes s (A) in mm

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

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 6 8 10 14 10 12 14 16 12 15 18 20 16 18 20 22 18 22 24 26

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

PUNCH DESIGN DETAILS

Table 3.9 - Stepped Round Punch Table 3.10 – Round Punch

Table 3.13 – Punch Chamfered head Table 3.14 – Stepped Punch

Table 3.15 – Square Punch with shedder

Table 3.16 - COMMONLY USED PUNCH PL ATE

SIZES:-Table 3.17 - COMMONLY USED PUNCH PLATE SIZES A B 50 50 75 75 75 100 100 100 125 125 125 150 150 150 150 175 175 175 50 75 75 100 125 100 125 150 125 150 175 150 175 200 250 175 225 275 A B 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 12.7 15.8 19 22.2 25.4 28.5 31.7 34.9 38.1

Table 3.18 - PILOTS

ACORN TYPE PILOT

A B C D E MAT 3.1 4.7 6.3 7.9 9.5 11.1 12.7 14.2 15.8 17.4 19 3.1 4.7 6.3 7.9 9.5 11.1 12.7 14.2 15.8 17.4 19 0.7 1.19 1.5 1.98 2.3 2.77 3.1 3.57 3.9 4.3 4.7 3.9 4.7 7.1 9.5 11.1 12.7 14.2 15.8 17.4 19 22.2 2.3 3.1 4.7 6.3 7.1 7.9 9.5 11.1 11.9 12.7 14.2 D.R. D.R. D.R. D.R. D.R. D.R. D.R. D.R. D.R. D.R. D.R. FLATTENED POINT TYPE

A B C D E MAT 20.6 22.2 23.8 25.4 26.9 28.5 30.1 31.7 33.3 34.9 38.1 20.6 22.2 23.8 25.4 26.9 28.5 30.1 31.7 33.3 34.9 38.1 12.7 13.4 14.2 15.8 16.6 17.4 18.2 19 20.6 21.4 23.8 23.8 25.4 28.5 31.7 33.3 36.5 38.1 41.2 42.8 44.4 47.6 15.8 17.4 19 20.6 22.2 23.8 25.4 26.9 28.5 30.1 31.7 Tool Steel T.S T.S T.S T.S T.S T.S T.S T.S T.S T.S

FINGER STOPS

Table 3.19 - FINGER STOPS

A STRIP THICKNESS

1

SMOOTH DIE HOLE CONTOUR 2 INSIDE CORNERS 3 SHARP CORNERS FRONT SPACER WIDTH FINGER STOP No. FRONT SPACER WIDTH FINGER STOP No. FRONT SPACER WIDTH FINGER STOP No. 0 to 1.5 1.5 to 3.1 3.1 to 4.7 4.7 to 6.3 Over 6.3 25 32 38 45 50 1 2 3 4 5 38 45 50 58 64 6 7 8 9 10 50 56 63 70 75 11 12 13 14 15 No. A B C D E F 1 2 3 4 5 3.2 4.8 6.4 8.0 9.5 6.3 7.9 9.5 11.1 12.7 16.6 20.6 24.6 28.5 32.5 37.3 44.4 51.5 58.7 65.8 1.6 2.4 3.2 4.0 4.8 46.22 57.37 66.92 76.50 86.05 6 7 8 9 10 3.2 4.8 6.4 8.0 9.5 9.5 11.1 12.7 14.2 15.8 23.8 27.7 31.7 35.7 39.6 50.8 57.9 65 72.2 79.3 1.6 2.4 3.2 4.0 4.8 61.31 70.86 80.41 89.99 99.56

Table 3.20- AUTOMATIC STOPS NO A B C D E F G H I J K L 1 2 3 4 5 6 101.6 477.5 965.2 1442.7 2092.9 127 6.3 6.3 6.3 7.9 7.9 7.9 19.8 23.8 58.4 160 302.2 441.9 8.7 9.5 10.3 11.1 11.9 12.7 6.3 6.3 6.3 7.9 7.9 7.9 119.3 160 241.3 302.2 340.3 401.3 241.3 281.9 360.6 441.9 523.2 604.5 4.7 6.3 7.9 9.5 11.1 12.7 2.3 3.1 3.1 4.7 4.7 4.7 3.1 3.9 3.9 5.5 5.5 5.5 7.1R. 7.1R. 7.1R. 8.7R. 10.3R. 11.1R. 4.7 6.3 6.3 7.1 7.9 9.5 NO M N O P Q R S T U 1 2 3 4 5 6

4.8Drill 9.5 depth 45° csk 1.6 deep 4.8Drill 9.5 depth 45° csk 1.6 deep 4.8Drill 9.5 depth 45° csk 1.6 deep 4.8Drill 9.5 depth 45° csk 1.6 deep 4.8Drill 9.5 depth 45° csk 1.6 deep 4.8Drill 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. 1.5 1.9 2.3 2.7 3.1 3.9 16.6 20.6 24.6 78.7 183 281.9

Table 3.21- AUTOMATIC STOPS NO A B C D E F G H I J K L M N 1 2 3 4 5 6 6.3 9.5 12.7 15.8 19 22.2 16.6 20.6 24.6 78.7 180.3 281.9 25.4 78.7 160 241.3 322.5 401.3 50.8 157.4 320 645.1 1127.7 76.2 25.4 78.7 160 241.3 322.5 401.3 12.7 14.2 15.8 17.4 19 20.6 19 20.6 23 24.6 58.4 99 322.5 78.7 523.2 119.3 238.7 401.3 3.1 3.1 3.1 3.9 3.9 3.9 3.1 3.1 3.1 3.9 3.9 3.9 6.3 6.3 6.3 7.9 7.9 7.9 7.9 8.7 8.7 10.3 11.9 12.7 9.1 10.3 11.1 12.7 14.2 15.8 7.9 8.7 9.5 11.1 11.9 13.4 NO O P Q R S T U 1 2 3 4 5 6 33° 33° 33° 33° 33° 33° 5.5 6.7 6.7 7.9 8.7 9.5 3.1 4.7 6.3 7.9 9.5 11.1 0.8 X 45° 0.8 X 45° 0.8 X 45° 0.8 X 45° 0.8 X 45° 0.8 X 45°. 2.3 3.1 3.1 4.7 4.7 4.7 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

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

NO A B C D E F G 1 2 37.30 39.68 34.93 37.30 25.4 78.7 7.9 7.9 19 20.6 322.5 401.3 M6 TAP M6 TAP

Table 3.22- AUTOMATIC STOPS

Table 3.23 - FULCRUM PIN DIMENSIONS

STOP NO. A 1 2 3 4 5 6 28.5 30.1 31.7 33.3 34.9 36.5 STOP NO. A 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 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 STOP NO A B 1 22.22 2.40 2 25.40 3.175 3 28.575 3.175 4 31.75 4.80 5 34.925 4.80 6 38.10 4.80

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/Dowels

S

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.

Table 3.24 - NO OF SCREWS BASED ON STRIPPING FORCE STRIPPING FORCE IN M6 M8 M10 M12 M16 M20 TON N 0.2 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.

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

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

Table 3.28 - SLEEVE BUSH FOR DIE SETS

Sleeve Bush Standard Bush Sleeve Bush Non Standard Bush

No D-2 I.D D-3 O.D. D-4 Stap O.D. Length L-1 Length L No 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

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, 350

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 KN (Tonnes) Capacity in KN (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)

Using the same principle, die shut height for stamping dies, bendingdies, and formingdies 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.

Table 3.32 - PUNCH AND DIE MATERIAL SELECTION AND HEAT TREATMENT

Table 3.33 - SELECTION OF STEEL FOR DIFFERENT

APPLICATIONS

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,l3respectively.

y1,y2,y3..= y distance of the centroids of line elements l1,l2,l3respectively.

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:-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

- 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 3.35 Contd…

Table 3.36 Contd…

Table 3.37 Contd….

Table 3.38 Contd…

Table 3.40 - Circular spring – Light load

Table 3.42- Circular spring – Heavy load

Table 3.43 Contd….

Table 3.44 – Spring retainer

Table 3.46 - RUBBER SPRINGS

Table 3.48 - RUBBER SPRINGS

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

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

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.

‘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

‘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

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°

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

t / D Consideration:

t / D decides the severity of wrinkling

t / D Percentage

Upto 0.5

Wrinkling is a severe and compressive load must be reduced.

Blank holder must be used, so a double action press is preferable

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

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

Over 2.5

No wrinkling so blank holder is

unnecessary even with high compressive load

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

(t / D) x 100 % reduction for 1stDraw

[(D1– D2) / D1] x 100

Single action Double action

1.5 0.15 0.2 0.3 30 35 40 2.0 0.4 45 2.5 0.5 47.5 Where,

D1= Blank diameter. After adding trim allowance

D2= Diameter. Of 1stDraw

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

h / d ratio No. of

Draws

First draw Second draw

Third draw Fourth draw 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 = 1/3rdof drawing pressure

Press capacity:

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

Table 5.4 - Drawing speed

Material Single action drawing Double action drawing

Ft / Min M / Sec Ft / Min M / Sec

Steel 60 0.3048 35 – 55 0.1778-0.27 Stainless steel - - 20 – 30 0.1016-0.1524 Aluminum 180 0.9144 100 0.508 Aluminum alloys - - 30 – 40 0.1524 – 0.2032 Copper 150 0.762 85 0.4318 Brass 200 1.016 100 0.508

Table 5.5 - Draw die clearance

Blank thickness(t) 1stDraw 2

nd

draw/

Intermittent draw Sizing draw

Upto 0.38 1.07t – 1.09t 1.08t – 1.1t 1.04t – 1.05t

0.4 – 1.27 1.08t – 1.1t 1.09t – 1.12t 1.05t – 1.06t

1.28 – 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 – 1.1t

t 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 material Less than 1000 Plastic (or) zinc

6. DATA FOR GAUGE

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 – 1983

Gauging members for Plain plug gauges, GO and NO GO members

(Size range from 1 upto and including 40mm)

IS: 6244- 1980

Gauging members for Plain plug gauges, GO and NO GO members

(Size range above 40 to 120 mm)

IS: 6246 – 1980

Gauging members for Plain plug gauges, GO and NO GO members

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

IS: 7018 (Part 1)

– 1983

Technical 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.

JIGS & FIXTURES

Table 7.1 - GUIDELINES FOR SELECTION OF LOCATORS

SI.NO

LOCATING DEVICE

APPLICATION

1

Six point locator(3-2-1) pin and button

locators

Locating flat surfaces

2

V-block

Locating round circular

flat

3

Nesting locator

Locating cylindrical

profile in vertical

position.

4

V-block, horizontal (one side is fixed and

other end is adjustable or cam operated)

V-locator.

Locating elliptical and

irregular surfaces.

5

Jack pin locator

Locating a rough work

piece.

6

Eccentric locators

Variation in work piece

size.

Table 7.2 - GUIDELINES FOR SELECTION OF CLAMPS

CLAMPS SITUATIONS

Strap clamp Commonly used for rectangular work

pieces.

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.

Table 7.3 -

LOCATING PINS (ROUND) - IS 5093

D g

6

d

d

1

p

6

d

2

h

1

h

2

10

9.5

8

7.5

8

16

12

11.5

10

9.5

10

18

16

15

12

11.5

14

22

20

19

16

15.5

18

25

25

24

20

19.5

22

32

32

31

25

24.5

25

36

Table 7.4 - END LOCTING PLUGS - IS 5095

D

h

6

d

d

1

p

6

d

2

h

1

h

2

16

15

12

11.5

12

16

25

40

20

19

16

15.5

15

20

32

45

25

24

20

19.5

18

25

40

60

32

31

25

24.5

22

40

63

40

39

32

31.5

25

50

80

Table 7.5 - DIAMOND LOCATING PINS - IS 5094

D

e

8

d

d

1

p

6

d

2

b

h

1

h

2

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

D g6 d d1 p6 d2 d3 d4 s7 h h1 h2 1 2 11. 5 1 0 9.5 M6 5 4 0 1 0 1 2 1 8 17 1 4 13. 5 M8 6 5 5 1 6 1 8 2 0 19 1 6 15. 5 M1 0 8 6 2 1 8 2 0 2 24 2 19. M1 1 7 2 2

25

20

35

15

32

15

7

36

25

50

20

45

25

9

50

32

60

22

55

30

11

Table 7.8 - V-Block

a

b

c

d

max

d

min

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 W

1

t

L

L

1

L

2

L

3

a

r

Size of 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

l

1

a

b

c

h

s

For

screw

size

7 50 10 20 8 10 20 M6 10 60 13 22 10 12 25 M8

28 200(250) 35 80(105) 26 30(40) 70 M24

35 250(315) 45 100(130) 34 40(50) 80 M30

42 315(350) 48 125(150) 40 45(55) 90 M36

45 350(400) 53 150(180) 45 55(60) 100 M39

Table 7.10 - SWING ‘C’ WASHER- IS 4298

d

H

13

d

1

R

R

1

R

2

R

3

R

4

r

t

Nom

For

bolt

or

screw

size

6.6 8.5 18 8 21.3 14.7 10.0 2.0 6 M6 9.0 8.5 21 8 25.5 16.5 13.0 2.5 6 M8 11 8.5 24 8 29.5 18.5 16.0 2.5 6 M10 14 10.5 27 10 34.0 20.0 20.0 3.0 8 M12 18 10.5 33 10 42.0 24.0 25.0 3.0 8 M16 22 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

Table 7.11 - JIG BUTTON (IS 4294)

MATERIAL: C45

HARDNESS: 45 – 50

RC

d

1

d

2

h

a

l

Under cut

6 4 5 1.2 6 A2 X 0.2 10 6 8 1.6 8 B2 X 0.2 16 8 5/13 2.0 10 B2 X 0.2 25 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 FEET

MATERIAL: FREE CUTTING STEEL – HARDNESS:56 ± 2R

C

H d b d1 d2 e1 K l r1 r2 S X ∞ 10 20 M6 11 6 8 12.7 5 21 31 0.5 1 11 2.0 34º 13º 15 30 M8 13 9 10 16.2 6 28 43 0.5 1 14 2.5 22º 9º 20 40 M1 0 16 12 12 19.6 8 36 56 0.5 1.5 17 2.5 18º 7º 25 50 M1 2 20 15 15 25.4 10 45 70 0.5 1.5 22 3.0 20º 8º 30 60 M1 6 24 20 19 31.2 12 54 84 1.0 2 27 3.0 18º 7º 40 80 M2 0 29 26 24 36.9 16 69 109 1.0 2 32 4.0 13º 5º

Table 7.13 - FEET BOLT

Basic

size

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

Basic

size M10 M10 M10 M10 M12 M12 M12 M12 M12 M12 M12

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

Table 7.15 - JIG BUSH

FIXED BUSH

d

1

Short

l

1

l

2

Long

l

1

l

2

d

2

d

3

d

4

r

1

r

2

Z

Upto 1

6

4

9

7

3

6

-

1.2

0.2

0.005

1.0-1.8

6

4

9

7

4

7

-

1.2

0.2

0.005

1.8-2.6

6

4

9

7

5

8

-

1.2

0.3

0.005

2.6-3.3

8

6

12

9

6

10

-

1.6

0.3

0.005

3.3-4.0

8

6

12

9

7

11

-

1.6

0.4

0.005

4.0-5.0

8

6

12

9

8

12

-

2.0

0.4

0.005

5.0-6.0

10

7

16

13

10

14

-

2.0

0.4

0.01

6.0-8.0

10

7

16

13

12

16

10

2.0

0.6

0.01

8.0-10

12

8

20

16

16

20

13

2.5

0.8

0.01

10-12

12

8

20

16

18

22

16

2.5

0.8

0.01

12-15

16

12

28

24

25

26

20

4.0

0.8

0.01

15-18

16

12

28

24

25

30

24

4.0

0.8

0.01

18-22

20

15

36

31

30

35

28

6.0

1.0

0.01

22-26

20

15

36

31

36

41

33

6.0

1.0

0.02

26-30

20

15

36

31

42

47

40

6.0

1.0

0.02

30-35

25

20

45

40

48

55

46

8.0

1.0

0.02

35-42

25

20

45

40

56

63

52

8.0

1.0

0.02

42-48

32

25

56

50

63

70

59

8.0

1.6

0.02

48-55

32

25

56

50

70

77

67

8.0

1.6

0.02

55-63

36

30

72

66

80

87

75

8.0

1.6

0.02

Table 7.16 - LINER BUSH

d

1

Short

Long

d

2

r

1

r

2

z

Upto 1

6

9

3

1.2

0.2

0.005

1.0-1.8

6

9

4

1.2

0.2

0.005

1.8-2.6

6

9

5

1.2

0.3

0.005

2.6-3.3

8

12

6

1.6

0.3

0.005

3.3-4.0

8

12

7

1.6

0.4

0.005

4.0-5.0

8

12

8

2.0

0.4

0.005

5.0-6.0

10

16

10

2.0

0.4

0.01

6.0-8.0

10

16

12

2.0

0.6

0.01

8.0-10

12

20

16

2.5

0.8

0.01

10-12

12

20

18

2.5

0.8

0.01

12-15

16

28

22

4.0

0.8

0.01

15-18

16

28

25

4.0

0.8

0.01

18-22

20

36

30

6.0

0.8

0.01

22-26

20

36

36

6.0

1.0

0.02

26-30

20

36

42

6.0

1.0

0.02

30-35

25

45

48

8.0

1.0

0.02

35-42

25

45

56

8.0

1.0

0.02

42-48

30

56

63

8.0

1.6

0.02

48-55

30

56

70

8.0

1.6

0.02

55-63

36

70

80

8.0

1.6

0.02

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 12 15-18 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

Table 7.18 - LOCKING SCREWS

d

6

d

7

d

8

l

4

l

5

l

6

h

d

6

m

6

Ø * l

m

n

t

r

2

c

M5

M5

M5

M5

M5

10

5

6

6

15

2

2.5 X 14

2.5 X 14

2.5 X 14

3.0 X 14

3.0 X 14

10

12

12

16

16

1.6 2.0 0.6

15

16

18

20

22

M6

M6

M6

13

6

8

8

20

2

5 X 20

5 X 20

5 X 20

20

20

20

2.0 2.5 1.0

26

29

33

M8

M8

M8

M8

M8

16

8

10

10

25

2.5

6 X 24

6 X 24

6 X 24

6 X 24

6 X 28

25

25

30

30

35

2.5 3.0 1.6

38

41

45

48

55

TOMMY NUT (Material –C 45)

Basic size

AØ

BØ

M10

25

28

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

25

22

12

3

M12

28

25

14

3

M16

35

28

16

3

Table 7.20 - THUMB NUT (Material –C 45)

d

1

d

2

b

h

e

M6

7

28

12

12

M8

9

32

14

14

M10

11

36

16

16

M12

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 K 41 32 23 M12 14 8 3 6 3 25 54 38 27 M16 17 13 5 8 5 35 58 41 30 M20 17 13 5 8 5 35 64 45 32 M22 19 17 5 10 6 41 70 50 38 M24 21 17 6 10 6 44 80 56 45 M30 25 19 8 11 8 52

d

a

d

2

E

g

h

l

2 M10 6 3 75 3.5 12 40 l l1 40 25 45 30 50 35 55 40 60 45 65 50 M12 7.5 4 90 4.0 15 50 l l1 50 31 55 36 60 41 65 46 70 51 75 56 80 61 M16 10.0 5 117 4.5 19 63 l l1 65 40 70 45 75 50 85 60 95 70 105 80 M20 12.5 6 150 6.5 24 80 l l1 80 49 85 54 90 59 100 69 110 79 120 89 130 99

Table 7.22 – Handle grip screws

Table 7.23 - WING/ FLY SCREWS

d

a

d

2

e

g

approx.

h

h

1

M5

3

1.5

25

1.5

7

12

l

l

1

25

16

M6

4

1.5

32

2.0

8

16

l

l

1

28

20

30

22

35

27

M8

5

2.0

40

2.5

9.5

20

l

l

1

35

25

40

30

45

35

M10

6

3.0

50

3.5

12.0 25

l

l

1

50

38

55

43

60

48

65

53

Table 7.24 - PRESSURE PADS

Max.dia. d1 d4 d5 d6 d7 e f h r1 r2 t2 t1 For screw with thread Fastening 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 6 12 4.8 10 5 1.5 2.5 2.5 8 1.5 0.3 0.5 5 M6 1.5m6 x 8 16 6.4 12 7 2 3 3.5 9.5 2 0.4 0.5 6 M8 2m6 x 8 20 7.4 15 8 2 3.5 5 12 2 0.4 1 7 M10 2m6 x 14 25 9.5 18 10 3 4.5 6 15 3 0.6 1 9 M12 3m6 x 14 32 12.5 22 14 3 6 7 19 3 0.6 1 12 M16 3m6 x 16 40 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

G

10

13

1.5

3

12

60

10

12

16

2

4

15

70

12

16

20

2.5

5

18

90

16

20

25

3

6

24

110

20

Table 7.26 - Quarter turn screw

A

B

C

D

E

F

M10

50

35

12

28

5

M12

62

38

15

32

6

M16

82

47

20

35

6

M20

100

60

22

40

10

Table 7.27 - Spherical washer

A

B

C

D

E

F

G

9

20

20

2.5

4

2.5

5

11

22

22

2.5

6

2.5

6

14

28

28

2.5

6.5

2.5

6.5

18

40

40

3

12

3

7

Table 7.28 - C WASHER

d H12 l D For bolt or screw size 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

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 Nom A(js16) max min 8 8.45 7.55 10 10.45 9.55 12 12.55 11.45 16 16.55 15.45 20 20.65 19.35 23 23.65 22.35 28 28.65 27.35 36 36.80 35.20 45 45.80 44.20 b Nom 6 8 10 12 16 19 22 28 36 Nom e(js16) max min 20 20.6 19.4 25 25.6 24.4 32 32.8 31.2 40 40.8 39.2 50 50.8 49.2 64 65.0 63 72 73.0 71 90 91.1 88.9 112 113.0 111.0 Nom g1(js16) max min 1.6 1.9 1.3 2 2.3 1.7 2.5 2.8 2.2 3 3.3 2.7 4 4.4 3.6 5 5.4 4.6 6 6.4 5.6 7 7.4 6.6 9 9.4 8.6 g2 Nom 2 2.5 3 4 5 6 7 9 11 Nom h1(js16) max min 10 10.4 9.6 12 12.6 11.4 16 16.6 15.4 20 20.6 19.4 25 25.6 24.4 32 32.8 31.2 36 36.8 35.2 45 45.8 44.2 56 57.0 55 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 r4Nom 2 2.5 3 4 5 6 7 9 11

Table 8 - Unit conversions

Conversions factors

SI PHYSICAL QUANTITY MKS FPS 1 N Force 0.1016 kgf 0.2248 Ibf 1 N/m2 Pressure 10.19 x 10-6kgf/cm2 145.038x10-6kgf/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

By

To get equivalent number

to

Inch Foot Yard Mile Length 25.4 0.3048 0.9144 1.609 Millimeters (mm) Meters (m) Meters (m) Kilometers(km) Inch2 Foot2 Yard2 Area 645.2 6.45 0.0929 0.8361 Millimeters2(mm2) Centimeters2(cm2) Meters2(m2) Meters2 Inch3 Yard3 Volume 16.387 16.387 mm3 cm3 Pound Ton Mass 0.4536 907.18 Kilograms (kg) Kilograms (kg) Kilogram Ounce Force 9.807 0.278 Newton (N) Newton(N) Foot/Second2 Inch/Second2 Acceleration 0.3048 0.0254

Meter per second2(m/s2) Meter per second2

Horse power

Power

0.746 Kilowatts(kW)