Design and Analysis of a Flat Form Tool and its Clamping Device

Abstract

A flat form tool is a lathe cutting tool designed with a profile that matches the contour to be generated in the workpiece. As such, it can machine the full profile of the workpiece in a single pass. This paper presents the design and development of a flat form tool and its corresponding clamping device for application on a lathe machine. The objective of this study was to design a form tool of 120 mm in length and a suitable clamping device, integrating theoretical calculations, constructional evaluation as well as simulations on finite element software to ensure that the assembly works well under realistic operational loads. The findings verified that the final design satisfied the necessary requirements for rigidity, accuracy, and assembly needs. The approach also provides a valuable reference framework that can guide future tool and fixture design.