Assignment onDESIGN OF FORMING TOOLS

Abstract A form tool is precision-ground into a pattern

that resembles the part to

be formed. The form tool can be used as a single operation and therefore eliminate
many other operations from the slides (front, rear and/or vertical) and the turret, such as
box tools. A form tool turns one or more diameters while feeding into the work. Before
the use of form tools, diameters were turned by multiple slide and turret operations,
and thus took more work to make the part.

INTRODUCTION
Designing a forming tool is one of vital factor of tool engineering, which must be
known by every design engineer. Forming a tool means giving a particular and useful
shape with required dimensions to the part. The part formed by forming operation is
generally takes the shape of the dir or punch. In the forming operation, the metal flow
is not uniform and localized to some extent, depending upon the shape of the work piece.
Bending along a large radius in a straight line may also be referred to as a forming
operation. It is difficult to distinguish between a bending and forming tools. Forming
operation may be simple and extremely complicated.
A form tool is precision-ground into a pattern that resembles the part to be formed.
The form tool can be used as a single operation and therefore eliminate many other
operations from the slides (front, rear and/or vertical) and the turret, such as box tools.

A form tool turns one or more diameters while feeding into the work. Before the use
of form tools, diameters were turned by multiple slide and turret operations, and
thus took more work to make the part. For example, a form tool can turn many
diameters and in addition can also cut off the part in a single operation and eliminate
the need to index the turret. For single-spindle machines, bypassing the need to index
the turret can dramatically increase hourly part production rates. On long-running jobs
it is common to use a roughing tool on a different slide or turret station to remove the
bulk of the material to reduce wear on the form tool.
There are different types of form tools. Insert form tools are the most common for
short- to medium-range jobs (50 to 20,000 pcs). Circular form tools are usually for
longer jobs, since the tool wear can be ground off the tool tip many times as the
tool is rotated in its holder. There is also a skiving tool that can be used for light
finishing cuts.
A drawback when using form tools is that the feed into the work is usually slow,
0.0005" to 0.0012" per revolution depending on the width of the tool. Wide form tools
create more heat and usually are problematic for chatter. Heat and chatter reduces
tool life. Also, form tools wider than
2.5times the smaller diameter of the part being turned have a greater risk of the part
breaking off. When turning longer lengths, a support from the turret can be used to
increase turning length from 2.5 times to 5 times the smallest diameter of the part
being turned, and this also can help reduce chatter. Despite the drawbacks, the
elimination of extra operations often makes using form tools the most efficient option.
THEORY OF FORM TOOL:
PURPOSE OF FORMING TOOLS:
A form tool is defined as a cutting tool having one or more cutting edges with well
defined profile or contour that is reproduced as the desired form on the work piece
surface. Form tools utilized for turning applications are classified according to type of
cross section. The classification is shown in the tree diagram of Figure

Flat or blocked tools are further classified according to the setting of tool with respect to
the workpiece, viz. radial -fed tools and tangential -fed tools. Further, form tools are also
classified with respect to orientation of tools with respect to the workpiece axis.

VARIOUS TYPES OF FORMING TOOLS:

Flat Form Tool:Straight and flat form tools have a square or rectangular cross-section
with the form being along the side or end. These tools are similar in appearance to
the turning tools. These are usually set centrally so that they will cut their contour
which is identical to the desired contoured of the work piece. A typical example of Vnotch tool is shown in Figure. This type of tool is suitable for making deep straightsided form grooves. The cutting is restricted type due to the mixed chip flow.
Because of the existence of the good surface finish, this type of tool must be operated
at very low cutting speed.

Figure shows a typical flat form tool without rake angle. It is necessary to compute x to be machined in the tool in
order that the depth BC is correct profile. This distance x is to be planned by a fly cutter or planning tool and is
measured normal to the clearance face. The amount of x is less than actual depth of form AB produced on the
workpiece because of the clearance angle . From the geometry of the figure
x = AB cos ()

. . . (7.1)

Figure 7.3 shows a flat form tool with rake angle. The wedge angle is given by
(90 ) . Using geometry of the figure, the depth x to be ground or machined can be determined in the
following manner :
2

= r cos ( ) and l = R h

H = r sin ( s ), l s

Therefore,

R h

L =L L=
2

r cos ( )

= ( R r sin ( s )) r cos ( )
Now,

x = L2 cos ( + )

Hence,

x = ( ( R r sin (( s )) r cos ( )) cos ( + )

Introduction of rake angle to facilitate cutting action modifies the profile on the tool.

Circular Form Tool

The circular form tool is circular in shape. It has depth x or projection of distance x
produced all around the diameter in the form of annular grooves. The outside diameter of
circular form tool is determined in accordance with the height of profile to be turned. The
graphical method is recommended for this purpose. Circular form tool is shown in Figure.

7.4GRAPHICAL
METHOD
PROFILE OF FORM TOOL
.4.1 Profile of Flat Form Tool

OF

DETERMINING

The graphical method profile of flat form tool is

shown in Figure 7.5. The graphical method is
described as follows :
(a) Draw profile of the workpiece in lower left corner.
(b) Project basic points on the axis I-I viz. 1, 2, 3 etc. and
form point O as a centre. Draw circles corresponding to
radius r1, r2, r3 passes through 1, 2, 3
respectively.
(c ) Assign proper value of , . Find outer diameter and centre of flat
through point form tool.
d)Through point 1, 2, 3, draw a line parallel to the flank.

e)To construct the cross-section of the tool perpendicular to the

flank (set N-N), draw line LL (perpendicular to flank).

f)From the line LL, we lay off the lengths l1 and l2, since the
dimensions of the tool profile measured along the workpiece are
equal to the corresponding axial dimensions of the workpiece.
g)At lengths l1, and l2 draw lines parallel to LL and obtain point of
intersection as 1, 2, and 3, which on joining gives profile of
form tool.

Profile of Circular Form Tool

The profile of circular form tool is shown in Figure
The graphical method is as follows :
(a) Draw profile of workpiece in lower left corner.
(b) Project basic points on the axis I-I viz. 1, 2, 3 etc. and
form point O as a centre. Draw circles corresponding to
radius r1, r2, r3 passes through 1, 2, 3 respectively.
(c) Assign proper value of , . Find outer diameter and centre of
circular form tool.
(d) Draw circles passing through point 1, 2, 3 with radius R1, R2,
and R3 of tool corresponding to radii r1, r2, and r3 of workpiece.
(e) To construct tool profile in radial section, draw a radial line NN to lay off distance l1, l2 to the right on line perpendicular to
N-N.
(f) Draw lines perpendicular to N-N to lay off distance P2 and P3
from points I, II, and III.
(g) On the intersection of the lines corresponding to the
dimensions P2 and P3 with lines determining dimensions l2
and l1, obtain points 1, 2, and 3.
(h) Connect the points 1, 2, and 3 by straight lines; we obtain
profile of form tool in radial cross section.

SUMMARYA form tool has one or more cutting edges with well defined profile or
contour that is to be reproduced as the desired shape on the workpiece
surface. Form tools are classified as flat form tools and circular form
tools. Straight and flat form tools have square or rectangular crosssection with the form along its side or end. The graphical method to
determine the profile of flat and circular form tool is depicted in this
unit.
STRESSES ACTING ON A FORM TOOL:
Types of stress to which tools are exposed:
The types of tool load sustained in a range of non-chip forming
manufacturing techniques, are shown in figure
The upper die of cutting tools is exposed to shock-like
compressive and bending loads. The cutting and the lateral area is

affected by wear strain as a result of friction between the work

piece and the tool. The bottom die is exposed to pressure and is
subjected to mainly sliding friction (wear). The face of the upper die
and the surface of the lower die should have as high a friction coefficient as possible, whilst the lateral area of the upper die
should have a low friction co-efficient so that the sheet does not
move during the cutting operation.
The situation in deep drawing operations is similar. Here, the
upper die is exposed mainly to pressure and only to a low level of
bending load, the lower die is exposed mainly to friction and to a
lesser degree to pressure. As in the cutting operation, care must
be taken to ensure that the sheet does not flow at the upper die
area. The friction co- efficient should therefore be as high as
possible at the rounding of the upper die but low at the rounding
of the drawing ring.
In forward extrusion operations, compressive and temperature
stresses occur at the upper die and compressive, tensile, friction
and thermal stresses at the lower die. Thermal load also develops
in cold extrusion operations as a result of the inner friction during
material flow.
The situation in the case of reverse extrusion is similar, although
the upper die is additionally affected by bending and friction
stresses.
The types of stress listed, also occur in varying degrees in other
processes such as extrusion, forging, pressure casting and shell
casting. The high operating temperatures are particularly liable to
cause stresses which are generally masked in forging operations by
additional shock stress

TOOL DAMAGE AND WEAR:

The types of damage shown in Fig., occur as a result of the types of stress
previously described. These may render the tool unfit for use and include:
1.Wear
2.Mechanical crack formation
3.Thermal crack formation
4.Plastic deformation.

CAUSES OF DAMAGE AND THEIR MECHANISMS

Since wear is the most important type of damage, it makes sense to
investigate its causes in more detail.

There is no one material characteristic which provides a conclusive

indication in itself, as to the level of wear resistance of that material. This is
because in the vast majority of cases, a number of causes interact and combine
to cause wear in the tribo-technical systems in industrial practice,

These include:
-Adhesion
-Abrasion
-Surface break-up and
-Tribo-chemical reaction

Wear inhibiting coatings are frequently equated with hard coatings. This may
be true in the case of abrasive wear, in which there is a correlation in many
cases between surface hardness and wear resistance. However, this does not
apply to other types of wear or to a combination of stresses, since factors
other than hardness, such as surface design, toughness etc. are also important.

The most important wear mechanisms and means of reducing wear, are
therefore discussed briefly in the following-

Adhesive wear: Occurs when bonding forces in the area of the atomic
lattice take effect between two metallic materials. The prerequisite for this is
that the lattices of the bodies concerned, are structurally similar and that
they approach one another until there is only a short distance between
them. Furthermore, the more the lattice structures of the materials
concerned differ; the lower is their susceptibility to adhesive wear.

Abrasive wear: Occurs when the harder of the two bodies involved in the
wear process, has pronounced roughness beaks, which tear particles of
material from the surface of the softer body. Materials which are resistant
to abrasive wear, have outstanding hardness in comparison with the
abrading material. When there is surface breakdown, the crystal and the
structural condition is damaged irreversibly as a result of alternating stresses
and which depend on the duration and level of stress involved. Surface
breakdown is reduced when the strength of a material is high, whereas
stress peaks and notch effects result in an increase.

Tribo-chemical reactions: Occur when the wear processes take place only

in the outermost boundary layer of the bodies involved. This boundary or

interfacial layer can be formed by reactions between the material and the
surrounding medium. Consequently, the wear characteristics of the base
material itself have no influence on this process. It is not possible to specify
any particular material behavior in order to avoid the tribo-chemical
reaction, since the formation and characteristics of the outer boundary layer
are determined to an equal degree by the material and by the surrounding
medium. Consequently, the lubricant is the primary determining factor. The
various types of damage sustained by tools, are illustrated in Fig by the
example of a forging die. In 70 % of all cases in which tools become unfit
for use, wear is the underlying cause. Mechanical cracking occurs in 25 %
of all cases.

In contrast, plastic deformation and thermal cracking very rarely mark the
end of tool life. These results cannot be transferred directly to other
forming operations but wear will be the most common type of wear there
too, since shock and temperature stress are generally lower in these
operations than in forging.

BASE MATERIAL AND BOUNDARY LAYER:

Requirements to be met by forming tools:
Due to the types of stress listed, there are a number of special
requirements which must be met by the base material and the boundary layer
of tools. These are shown in Fig. The focus in the following is on the
requirements to be met by the wear and strength characteristics.

Requirements to be met by the base material and the subsurface layer:

Tool materials for extrusion tools

References
1.www.nitc.ac.in/dept/me/jagadeesha/Tool...Design/CH

APTER7.pdf.
2. https://en.wikipedia.org/wiki/File:Form-tool.jpg
3.Fundamentals of Tool Design By ASTME.
4.Fundamentals of metal cutting and tools by
Ranganath.
.
Submitted By- Group 2
(Schno 121116012 -121116022)
Guided By- Dr. M.K Pradhan Sir.