Block E – Production Tool Design and Development

Context

Tool and die makers must be able to build production tools for the production and assembly of precision engineered products. Some tool and die makers may work in basic design of production tools.

Tool and die makers have to ensure that production tools maintain required accuracy. It is essential that they recognize the need for repair and maintenance of these tools.

New and reconditioned production tools must be proved out before being put into service. This ensures their safety, functionality and accuracy.

In some jurisdictions, tool and die makers may also be involved in building, repairing and maintaining moulds and automation tooling.

Trends

New materials and advanced coatings have been introduced. There is more high speed machining of hardened material for production tool manufacturing.

Related Components

Production tooling: jigs, fixtures, dies, moulds, cutting tools, stamping tools, automation tools.

Tools and Equipment

See Appendix A.

Task 15 Performs basic production tool design.

Required Knowledge

• K 1 types of production tools such as dies, jigs, fixtures, cutting tools and moulds
• K 2 limitations and capacity of shop equipment
• K 3 functionality, limitations and applications of various types of tooling
• K 4 strategies for supporting and retaining the part such as clamping, locating and repeatability
• K 5 ergonomic principles and safe operation of production tool
• K 6 types and availability of materials used in production tools
• K 7 material properties of the production part
• K 8 fool-proofing strategies in design
• K 9 basic drafting techniques such as first and third angle projection, isometric drawing, and GDT
• K 10 financial considerations of design in order to maintain cost-effectiveness
• K 11 machining, forming and inspection techniques

Sub-task - E-15.01 Identifies production tool requirements.

Key Competencies

• E-15.01.01 determine type of tooling required to perform the task according to part specifications
• E-15.01.02 evaluate customer’s production requirements such as volume and precision
• E-15.01.03 determine tool capability such as rigidity, accuracy, and repeatability according to industry standards and reference material

Sub-task E-15.02 Prepares shop sketches.

Key Competencies

• E-15.02.01 conceptualize design according to finished part requirements
• E-15.02.02 use required sketching resources such as sketching paper and pencils, and measuring tools
• E-15.02.03 apply sketching techniques which show all relevant features and dimensions as required for the design of the finished tool

Sub-task - E-15.03 Determines production tool material specifications and engineered components.

Key Competencies

• E-15.03.01 choose tooling component material types according to functional requirements
• E-15.03.02 determine processes that will be required for finished tooling components such as surface treatments and heat treating
• E-15.03.03 determine availability of engineered components and assess feasibility of use according to production schedule and cost-effectiveness
• E-15.03.04 select engineered components based on job requirements and component availability

Sub-task - E-15.04 Prepares information for drafting.

Key Competencies

• E-15.04.01 finalize production tool design including final dimensions and tolerances
• E-15.04.02 list engineered components by supplier and part number for drawing specifications and purchasing requirements
• E-15.04.03 list raw materials required for production tool components for drawing specifications and purchasing requirements
• E-15.04.04 communicate with drafting department in order to clarify requirements and provide context

Task 16 Fits and assembles production tools.

Required Knowledge

• K 1 types of production tools such as jigs, fixtures, dies, cutting tools and moulds
• K 2 specifications for standard assembly fits and clearances
• K 3 production tool specifications such as cutting clearances and draft angles as determined by material used
• K 4 types of fasteners such as screws and dowels
• K 5 types of adhesives such as temporary and permanent
• K 6 types of solder such as hard and soft
• K 7 types of fits such as interference and running clearance
• K 8 types of joints such as lap and dovetail
• K 9 types of dies such as cutting, forming, progressive and compound
• K 10 types of jigs and fixtures such as drill jig, weld jig and assembly fixture
• K 11 types of moulds such as injection, blow and rotary
• K 12 clearance-setting practices such as inserting material between working faces and using light source
• K 13 material properties such as composition and thickness
• K 14 types of gauging material such as plastic and metal
• K 15 types of compression aids such as springs, compressed gas cylinders and urethane
• K 16 types of non-compression devices such as punch retainers, pilots, punches and buttons
• K 17 pre-loads on die springs, compressed gas cylinders and urethane strippers
• K 18 types of mechanisms such as cams, stock lifters and slide blocks
• K 19 optimal sequence of operations for fitting and assembly
• K 20 types of production tool protection systems such as die protection and mould protection

Sub-task - E-16.01 Verifies dimensions of production tool components.

Key Competencies

• E-16.01.01 select measuring instruments based on tolerances required and application such as internal and external measurements
• E-16.01.02 take measurements using standard and specialized measuring instruments
• E-16.01.03 compare measurements to drawings and sketches to ensure conformity, fits and clearances
• E-16.01.04 record critical dimensions as required by workplace procedures

Sub-task - E-16.02 Positions production tool components.

Key Competencies

• E-16.02.01 kit production tool components and engineered components in organized manner, in order to facilitate assembly and ensure all required parts are present
• E-16.02.02 develop special tooling aids such as clamps and fasteners
• E-16.02.03 install required engineered products according to drawing or sketch
• E-16.02.04 fasten production tool components temporarily as required to permit adjustments for alignment and fit
• E-16.02.05 make necessary adjustments for fit, clearance and function according to specifications
• E-16.02.06 fasten or clamp production tool components temporarily as required for final assembly

Sub-task - E-16.03 Performs final assembly.

Key Competencies

• E-16.03.01 drill, tap and ream locating holes as required to permanently locate components
• E-16.03.02 fasten components permanently using methods such as using engineered fasteners, applying adhesives, soldering and brazing
• E-16.03.03 verify final dimensions and fit to ensure functioning of production tool

Sub-task - E-16.04 Sets production tool timing.

Key Competencies

• E-16.04.01 adjust final height of cutting punches to achieve required punch penetration
• E-16.04.02 adjust final height of forming punches to achieve required form of the part
• E-16.04.03 adjust cam engagement of stamping dies to achieve required lateral punch penetration or form
• E-16.04.04 adjust cam engagement of moulds to achieve required seal
• E-16.04.05 adjust stripper plates, ejectors, compression springs and shut-height to achieve required functioning of the tool
• E-16.04.06 set up the die protection and calibrate the sensors

Task 17 Proves out production tools.

Required Knowledge

• K 1 safety considerations for operating production equipment
• K 2 types of presses such as punch press, brake press and hydraulic press and their operation
• K 3 types of moulding equipment and their operation
• K 4 types of machine tools and their operation
• K 5 production part material specifications such as composition, thickness, hardness, ductility and malleability
• K 6 material classifications such as ANSI, SAE and Universal Numbering System (UNS)
• K 7 production part geometry according to specifications
• K 8 types of dies, jigs and fixtures such as draw dies, form dies, trim dies, checking fixtures, assembly fixtures and drill jigs
• K 9 strip layout, stock progression and feed mechanism
• K 10 production tool’s intended function and operation such as volume of production part and consistency in quality
• K 11 critical areas to check for damage
• K 12 stock handling equipment such as coil feeders, cradles, bar feeds, straighteners and material hoppers
• K 13 types of production tool protection systems such as die protection and mould protection

Sub-task - E-17.01 Sets up production tools.

Key Competencies

• E-17.01.01 determine equipment required for operation of production tool
• E-17.01.02 install, align and secure production tool to equipment according to type of tool
• E-17.01.03 connect press accessory systems such as stock feeders, hydraulic lines and pneumatic clamps
• E-17.01.04 connect mould accessory systems such as water lines, misters, parts catchers and conveyor systems

Sub-task - E-17.02 Verifies production part material.

Key Competencies

• E-17.02.01 ensure that material conforms with the design specifications
• E-17.02.02 interpret material identification such as conformance documents, trace identification tags and markings on the material
• E-17.02.03 identify materials by physical properties
• E-17.02.04 ensure that feed stock is free from damage, foreign matter or other contamination that may impact final product quality or damage the tool

Sub-task - E-17.03 Develops blank.

Key Competencies

• E-17.03.01 calculate amount of material required for finished shape by using applicable tables and formulas
• E-17.03.02 select press and settings required according to material and product
• E-17.03.03 perform circle grid analysis to assess inconsistent material flow
• E-17.03.04 develop draw radius and adjust clamping force on the blank using draw beads to achieve uniform material thickness
• E-17.03.05 evaluate material changes such as thinning, thickening, folding and flow in order to maintain dimensions to specifications
• E-17.03.06 verify profile geometry against customer-supplied specifications using CMM
• E-17.03.07 record final blank dimensions to manufacture production blanks

Sub-task - E-17.04 Cycles equipment with production tools.

Key Competencies

• E-17.04.01 check clearances and interferences between equipment, production tool and workpiece
• E-17.04.02 operate machine tool at reduced rate if required to verify function and minimize risk of damage to equipment and production part
• E-17.04.03 verify and adjust timing as required to optimize tool performance
• E-17.04.04 perform adjustments to die components such as stripper plate and die springs
• E-17.04.05 perform adjustments to accessories such as feeders, coils and straighteners
• E-17.04.06 perform press adjustments such as shut height, pressure pads, limit switches and counterbalance
• E-17.04.07 assess production at normal conditions to ensure that part volume and consistency are optimal and to observe trends in production

Sub-task - E-17.05 Evaluates production part.

Key Competencies

• E-17.05.01 examine part visually for deficiencies such as poor surface finish, burrs and part damage
• E-17.05.02 measure part dimensions to confirm that measurements conform to specifications
• E-17.05.03 document the results of the evaluation including data such as critical dimensions, surface finish and tolerances

Sub-task - E-17.06 Checks production tool for damage.

Key Competencies

• E-17.06.01 visually inspect tools for damage such as cracks, breaks and deformities
• E-17.06.02 use optical aids such as loupe eyeglasses and magnifiers

Sub-task - E-17.07 Modifies production tools to enhance productivity.

Key Competencies

• E-17.07.01 adjust mechanisms such as stock feeders and limit switches
• E-17.07.02 recommend surface treatment coatings such as nitride, plating or anodizing to enhance the productivity and wear resistance of production tool
• E-17.07.03 streamline load and unload processes to reduce cycle time
• E-17.07.04 change tool materials to optimize tool life and cycle time

Task 18 Repairs and maintains production tools.

Required Knowledge

• K 1 application, function and original specifications of production tools such as jigs, fixtures, dies and moulds
• K 2 production tool component properties such as material type, hardness and surface finish
• K 3 production part specifications such as material types, properties, finish and dimensions
• K 4 types of production tool defects such as worn bushings, broken clamps and worn surfaces
• K 5 methods and sequence of production tool assembly/disassembly
• K 6 types of engineered components such as bushings, hinges, screws and dowels
• K 7 types of accessories such as hydraulic and pneumatic
• K 8 types of production tool mechanisms such as cams, strippers and stock pushers
• K 9 cleaning agents such as solvents and degreasers
• K 10 cleaning tools, techniques and procedures
• K 11 types of production part defects such as burrs, cracks, flash and dimensional non-conformities
• K 12 repair procedures such as disassembling, resurfacing, polishing, adjusting timing of die mechanisms and sharpening
• K 13 machine tools and hand tools used to recondition faulty components
• K 14 current production values such as batch sizes and sharpening cycle
• K 15 types of production tool protection systems such as die protection and mould protection

Sub-task - E-18.01 Identifies condition of production tools.

Key Competencies

• E-18.01.01 monitor and evaluate production part for non-conformance to specifications
• E-18.01.02 observe operation of production tool to evaluate need for repair, adjustment or reconditioning
• E-18.01.03 compare condition of production tools to original specifications using measuring instruments such as vernier calipers and micrometers
• E-18.01.04 record production tool defects according to company policies and procedures

Sub-task - E-18.02 Identifies repair procedures.

Key Competencies

• E-18.02.01 analyze information recorded during part and tool evaluation
• E-18.02.02 develop a repair procedure based on defect and tool type
• E-18.02.03 use reference materials to determine possible repair procedures

Sub-task - E-18.03 Adjusts production tool components.

Key Competencies

• E-18.03.01 perform adjustments to jigs and fixtures such as shimming, realigning, levelling and relocating stops
• E-18.03.02 perform adjustments to dies such as shimming, peening and realigning
• E-18.03.03 perform adjustments to moulds such as shimming and realigning
• E-18.03.04 verify that production part conforms to specifications
• E-18.03.05 record production tool adjustments according to company policies and procedures

Sub-task - E-18.04 Reconditions production tool components.

Key Competencies

• E-18.04.01 remove residues such as grease, dirt and oil from component surfaces
• E-18.04.02 remove excess production part material using equipment such as abrasive stones and polishing media
• E-18.04.03 determine reconditioning methods such as machining, applying surface treatments and replacing components
• E-18.04.04 repair components by machining or applying surface treatments
• E-18.04.05 fabricate new components for production tools when components are damaged beyond repair
• E-18.04.06 replace engineered components for production tools as required
• E-18.04.07 inspect reconditioned component to confirm completeness of repair
• E-18.04.08 record production tool reconditioning according to company policies and procedures
• E-18.04.09 perform sharpening of dies and resurfacing of moulds