Tool management

Tool management is needed in metalworking so that the

information regarding the tools on hand can be uniformly
organized and integrated. The information is stored in a
database and is registered and applied using tool management. Tool data management consists of specic
data elds, graphics and parameters that are essential in
production, as opposed to managing general production
equipment.
Unlike hand tools, a tool in numerically (digitally) controlled machines are composed of several parts. Putting
the parts together accurately into an assembly is required
to achieve error-free production.
Processing a part with a CNC (computer numerically
controlled) machining operation requires several tool assemblies that are documented in a list. Each component, each assembly and each list has an identier under which the specications are found. Tool management
is divided into documentation (master data) and logistics (transaction data). The documentation includes information needed for a trouble-free and a comprehensible
production process. Spare parts, experiences in production and the corresponding data can be managed. Several functions are available to manage, process, print and
combine with other applications.

Outline sample for chamfer tools.

ited. They are often acquired together with a new machine. (Clamping equipment is handled like non-cutting
components.)
Header data is uniformly structured and contains information such as name, supplier product code and
a unique item number. Each component is assigned
a specic tool type, which denes the number and
description of the required data elds. Each component is also linked to a tool category that belongs
to a user specic tree structure, which serves to nd
the tools according to their technical criteria without
indicating the number.

Logistics deals with demand planning, supplies and tool

location. This includes, on one hand, the location in the
warehouse and the purchasing of individual parts with
the corresponding consumption report. It also allows the
planning and coordination of the movements of the assemblies within the shop oor.

Descriptive data (geometrical value) vary depending on the type of tool. The data elds are specied
in the class list of characteristics. The meaning of
the geometrical data elds is illustrated in diagrams
and pictures. DIN 4000 recommends diagrams and
pictures for their explanation. Varying graphics for
dierent functions are stored either in the database,
or with the components through data links.

Master Data

Master data describes tools geometric characteristics,

composition and usage. The information is divided into
specications and usage instructions. Master data describes the tool in its qualitative aspects, but does not provide quantities and locations.
Generally, four types of graphic illustrations are used:

1.1

1. 2D drawings, for example, in DXF format according

to the ISG/BMG standard for geometrical information,

Components

The components are individual elements that can be combined into an assembly. Components are purchased as
a unit and stored in tool release.confusing Cutting components (ex.: inserts) wear out during use and therefore must be purchased and replaced periodically. Noncutting components (ex.: collets) are practically unlim-

2. PDF data of the tool manufacturer as a data sheet

with exploded view,
3. 3D data (ex.: STEP or STL) for the use in CAM
systems,
1

MASTER DATA

uation for the assembly. The specications are improved with the help of practical experience and are
automatically made available for NC programming
in the CAM system.

1.3 Tool lists / manufacturing operation

DXF according ISG/BMG Standard.

4. Photos (ex.: JPG) as graphical information

Cutting data (speed and feed) is stored for the cutting components for optimal chipping eciency.
The dierent data for varying materials and processing methods, number of revolutions, progressive
feed, cooling and production method.

1.2

Tool Assemblies

The tool assembly is built using several components. The

component at the rear end must connect the machine tool,
and the cutting component is found on the other end (ex.:
drill or insert). Varying components are used intermediately (ex.: extension, collets) to reach the desired geometry. The assembly documentation describes how the
components are assembled, to ensure that the applied geometry in the CAM system matches that of the real tools
in the CNC machine.
Header data contains information such as identication, a specic number and the allotted tool class.

The tool list includes all tool assemblies needed for a

machining operation. It is printed as a pick list and is
used for commissioning and providing advice for assembly setup. Often instructions and information are not directly related to the tools (e.g. clamping, clamping xtures, the name of the NC program, etc.) to ensure that
all documents for an operation can be viewed together.
Header data includes information such as name,
unique identication and the allocation to the right
machines. The combination of part number +
operation, drawing number + operation can be
used.
Assembly list contains all the assemblies needed for
the operation, along with the designated pocket in
the machine (T number, Turret). That list includes
those requirements for the assembly, valid for this
specic operation only (such as minimum cutting
length). The assemblies are listed in the order in
which they are used in the NC program.
The print edition (picking list) is used for the picking
of components and assembly of the complete tools
in the tool output. It includes the necessary components and their storage location and the important geometric details and tolerances of the complete
tool.

1.4 Auxiliary Tables

Geometric elds are computed directly through the
data of the applied components. Adjustable tools
(ex.: ne drill tools with adjustable diameter) are
stored in addition to the assembly data.
Assembly instructions contain the bill of material as
well as the data for the parts assembly that is important for the specic assembly (ex.: adjusting tolerance + 0.03/0.01 mm).
Nominal values for the presetting serve as a default
in the measuring process with a tool presetting machine. The exact position of the tool and the measuring method can be specied, in addition to the
nominal values of the geometry, so that, for exam- Match conditions for tool components.
ple, the left or right corner has to be measured for a
grooving tool.
In addition to the main tool data, auxiliary data tables simplify data acquisition, using values selected from a table.
Cutting data is typically used as a recommendation Compared to manual input, this ensures more comfortfor the assembly and is adjusted to the specic sit- able and consistent data collection.

2.1

Stock control of Components

On both sides of a component, match conditions

indicate the geometric condition another component
must meet to be connected. If a component has on
the right side matching conditions such as a next
component on the left side, the two can be assembled. The use of match conditions makes searching
for matching components easier and more secure.
When entering the component into the database, for
both sides the right match conditions are selected
from a table.
A list of the work materials is required for the as- Tool Components on stock.
signment of cutting conditions. Dierent qualities
and additional terms for the materials are contained 2.1 Stock control of Components
in the list, and extended by the individual designations as used by the respective enterprise.
The logistics of components includes primarily inventory
management, requirements planning monitoring of min The tool classication is used to organize the tools imum stock levels. When reaching the minimum level,
in technical terms. All tools assigned to the same tool management triggers a procurement process. The
tool class are suitable for the same task, but they logistics of tool management use a workplace-tuned user
have dierent sizes. The tool classes are organized interface and interfaces to storage systems and other fain a tree, which is adapted and expanded by the user. cilities within the shop oor. Requirement for coordinated component inventory is a central tool organization
in which all components of a production unit are stored
The tool types with the corresponding images deat one location, and each withdrawal is recorded reliably.
scribe the required geometric values and where they
are measured. Each tool type is assigned to a class
list of characteristics that dene the components 2.2 In-house logistics of Components
data elds.
The locations are used to specify the location of the
assemblies and components in logistics. They are
a reection of the manufacturing environment and
include all stands where tools and equipment could
stay. They are divided into storage locations, intermediate locations, preparation- and production units
(machines). Several locations are grouped into departments. The locations themselves can be divided
into individual places. The level of detail and depth
of the structure are dened only as far as the logistcal
aspects are actually necessary.

In-house logistics is mainly interested in where a wanted

component currently is, and at what cost center it is consumed. This method only consumes wear parts (cutting), the other components (holders, clamping devices)
are moved between toolroom, storage places and machine tool. Component booking at the individual cost
centers and locations occurs simultaneously when withdrawn/restored to the toolroom. The preparation of tools
and resources is triggered by a production order. It refers
to a tool list in the master data, that lists required components. Prior to usage in the machine tool, the components
are assembled, according to the specications and work
instructions in the tool list. When scheduling production
orders, inventory for each component will be checked.

The cost centers are used in logistics to evaluate the

use of tools in dierent departments (e.g. turning).
With the removal of a component from storage, an 2.3 In-house logistics of Assemblies
indication is specied at its cost center. The cost
centers of the tool management must be adjusted Assemblies are built from components, and after usage
with those in the PPS system.
usually disassembled into components and restored again.
From one assembly, multiple copies can be assembled
simultaneously, if the components are available in sufcient numbers. The logistics of assemblies refers to the
2 Transaction Data (logistics)
condition and location of these copies.
Logistics is concerned with inventory, storage areas and Each copy of an assembly can typically be in one of three
purchasing. Within logistics, the components and the as- states:
semblies are separate. The components dierentiatie be Not yet assembled (the components are available as
tween internal material ow and purchasing goods from
external suppliers (stock control).
individual parts)

3 INTEGRATION OF TOOL DATA

requested in production from tool management. Integration guarantees availability of the information in tool
management. The basic objective for integration is a systematic numbering of documents and resources.

3.2 ERP (purchasing)

tool Assemblies loaded.

Assembled in intermediate storage (e.g. on a shelf)

Assembled on the CNC machine
When scheduling a production order, the relevant tools,
for the work are known, based on the tool list. Also,
known is which assemblies, required for the machining
process, are already located on the machine tool. Necessary, but not yet available assemblies are calculated and
printed in a net loading list. They either have to be assembled or removed from the intermediate storage. With a
coordinated logistic of the assemblies it is possible to reduce the time required for providing and replacement of
assemblies at the machine.

Integration of Tool Data

Tool management guarantees ecient and faultless order

processing. Existing knowledge is made generally available and the guidelines stated in the master data are noticed. The integration of tool data enables other applications to use the tool data which is maintained with tool
management. Applications either fall back on the tool
management database, or the data will be replaced by the
interfaces. Especially in CNC manufacturing where several persons are involved in the production process, integration avoids faults, delays and duplicate data recording.

3.1

PDM (documentation)

In product data management (PDM) systems every products work plan is saved which comprises CAD Models, the description of working steps and a list of needed
equipment. The detailed description of the equipment
takes place in tool management because the PDM system
does not oer functions and data elds do describe them
in detail. It typically oers links to external data. Production orders are generated with the ERP system which
links to the work plan in the PDM system. Needed resources such as NC programs, tools, and instructions are

The ERP system plans raw material, consumable items

and other resources. It closely connects with PDM and
assumes the tasks of materials management and logistics.
Related to the tools, this concerns the consumable components. If the component inventory is conducted with
tool management, purchase orders will be transmitted as
purchase requisitions to the ERP system which issues the
actual order. This requires that the products be registered in both systems with the same number. Additionally
all internal stock movements of tool components for the
costing can be handed to the ERP system with the integration.

3.3 CAM
CAM systems generate the G-Code commands (NC program) for the CNC machine. Geometry, description and
cutting conditions are selected and received directly from
tool management. This ensures that all tools used are documented and consistent with the reality in the workshop.
From the CAM system, all tools used in an NC program
are automatically saved as tool lists in tool management.
This ensures the correct use of the tools during the preparation of the work process.

3.4 Storage systems

Besides conventional tool cabinets, storage systems that
provide the operator with the shelf containing the desired product are often used. The relationship between
the item number and the storage location is saved in tool
management. When booking a tool removal in the logistics area of tool management the storage system is operated automatically. Alternatively, assignment of storage
locations can be congured in the storage system. The
removal is then performed on the storage system and the
inventory change is transmitted to tool management.

3.5 Presetting
At the processing to the tools positioning the CNC machine needs their exact measurements. Therefore, the
length and diameter of the complete tools must be entered when connecting them to the machine. These settings of the tools can be measured with an external presetter. Convenient pre-setters assume the nominal values, tolerances and designation from tool management

4.3

Make Information Available.

and pass the measured values directly to the CNC machine. The integration of tool management with the presetters takes place in the exchange format of the respective equipment manufacturers and includes graphics and
information about the measurement method.

4.3 Make Information Available.

Tool and production data is managed within a company

database and in a specic format. For this purpose
a software application provides accessed across all departments and used without registering duplicate data.
Such data can be utilized by other software applications
(i.e. CAM-Systems, tool pre-setters, shop oor logistics).
3.6 Tool catalogues
Suitable interfaces are integrated to secure smooth, seamTo reduce the cost of initial data acquisition of the com- less workows. Central data management reduces errors
ponents in tool management, tool manufacturers provide and production stoppages.
the data and graphics in appropriately conditioned form.
For technical data, the DIN 4000 and the ISO 13399 ex4.4 Value
change formats are currently used. Where required, 2D
graphics are provided in accordance with the ISG / BMG
The importance of exchanging information between opDXF standard. For 3D graphics no standard is dened.
erational areas varies according to type of company. GenNormally, STL and STEP format are oered and axis poerally it can be said that missing or unclear information
sition is chosen according to the application on the mais the source of errors that cost capacity and generate dechine.
lays and inecient work ow. Manual interfaces and information passed by word of mouth are potential error
sources and obstacles. Especially important are binding
4 Motivation for Tool Management specications that are involved in complex work situations to reduce the chance of machine damage as well
as the risks involved with defective deliveries.

4.1

Utilization of New Technologies

Rising demands in design and quality, combined with

time and cost pressures, force companies to regularly invest in more ecient equipment and procedures. Modern CNC-Machines (i.e. Mill-Turn-Machines) are highly
productive, however they demand rigorous preparation
and application. A prerequisite for their successful use
is therefore the simultaneous adaptation of the organization together with the management of necessary operational information. The knowledge can subsequently be
included in operational procedures and made available for
each necessary task. This avoids the awed or incomplete
information that can interrupt production.

4.2

Supplying the Right Information

Newly purchased equipment is supplied with specic usage information (i.e. cutting data with tools). This information is found in supplier specic documentation (i.e.
maximum allowed diameter of a ne boring tool). Before the new acquisition can be used, the data must be
integrated in the company-specic task format. (i.e. The
exact setup values for a required ne boring tool). Furthermore, this information must be made available to all
participating work areas. (i.e. the exact adjusted diameter must be made known to the NC programming and
tool store departments). Processed company information
is then made available as part data instructions (i.e. appropriate cutting values for a particular tools usage with a
specied material) and must be managed and integrated
within workows to prevent production capacity loss or
shortening tool life.

5 References
Hans B. Kief, Helmuth A. Roschiwal: NC/CNC
Handbuch 2007/2008. Hanser, Mnchen 2007,
ISBN 978-3-446-40943-9.Leseprobe
Dr. Steen Lang: Tool Management: Intelligente Konzepte zur Kostenreduzierung rund um die
Werkzeugverwaltung. VDI-Z 147

6 TEXT AND IMAGE SOURCES, CONTRIBUTORS, AND LICENSES

Text and image sources, contributors, and licenses

6.1

Text

Tool management Source: https://en.wikipedia.org/wiki/Tool_management?oldid=651582812 Contributors: Giraedata, Lfstevens,

Anna Frodesiak, Kierkkadon, FrescoBot, Keri, Shop-Floor-Manager, Magister Scienta, Jeraphine Gryphon, ChrisGualtieri, Ginsuloft and
Anonymous: 8

6.2

Images

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6.3

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