Fundamentals of Tool Design, Sixth Edition

Lecture Slides

Chapter 1

Introduction to
Tool Design
Dr. John G. Nee, CMfgE

© Copyright © 2010 Society of Manufacturing Engineers

 A Word about Safety

 Safety is your responsibility.

 Read, understand, and follow all safety rules.
 The equipment you will be using is powerful and unforgiving.
 You can be killed, maimed, or seriously injured if you do not
follow the safety rules.
 A general rule: If you do not feel safe, don't touch anything. See
the instructor.

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 Course Introduction

 Syllabus
 Schedule
 Introduction: Structure and
properties of metals, tool
drafting, geometric control, See how many operations you can
tool measurements name in this video.

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 Objectives

 Reduce overall cost to manufacture a product

 Increase production rate
 Maintain quality
 Reduce cost of tooling (cost effective)
 Design safe and easy to use tools

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 Areas of Knowledge

 Cutting tools, tool holders, cutting fluids

 Machine tools
 Jigs and fixtures
 Gages and measuring instruments
 Dies for sheet-metal cutting and forming
 Dies for forging, upsetting, cold finishing, and extrusion
 Molds for plastics manufacturing
 Fixtures and accessories for welding, riveting, and mechanical
fastening

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 The Design Process

 Statement of the problem

◦ Scope
◦ Assumptions
 Analysis of requirements (constraints)
 Development of initial ideas
 Development of design alternatives
 Finalization of design ideas
◦ Iteration & finalization
 Implement
 Evaluate

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 Requirements

 Functions
 Precision
 Environment
 Costs
 Lead time
 Safety
 Adaptability, compatibility, standardization
 Working life

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 Economics of Design

 Remember to think lean

 Combined operations
 Process cost comparisons
 Break even point
 Total unit cost for a particular method
 Break even point, W&S method
 ELS (Economic Lot Size)

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Total Unit Cost

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Break Even Point

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Economic Lot Size

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Economic Lot Size (simplified)

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 Cutting tools

http://www.heinemannsaw.com/assets/pdf/US3576200.pdf

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 Typical Tooling Example

 Press tooling

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 Typical Tooling Example

CMP: Hydraulic Tube End-

form Press (EFP100)

WTM - pipe forming, pipe cutting

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Molds

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 Workholding & Inspection Tools

 Toolmaker’s tools

1-2-3 setup and tri blocks

Sine plates & vises
Spin & index fixtures
Planer gages
Bench centers
Measuring instruments

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Tooling Drawings

Tooling plates

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Tooling Drawings

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 Tooling Drawings

 Do not crowd views

 Analyze each cut
 Use standard values
 Use only the views necessary to define the part
 Realistic, thoughtful tolerances
 Shaft easier to change than hole
 Use stock sizes if possible
 Notes may be necessary

 Clarity & A Workmanlike Quality

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 Tooling Layout

 Lay out the part (red is suggested)

 Lay out cutting tools and holders
 Indicate locating requirements
 3-2-1 locating planes
 Indicate clamping requirements
 Use full scale if possible
 Indicate standard fixture parts
 Identify each item with balloons and leaders

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Tooling Materials

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Recognize any of these?

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 Material Numbering Systems

 Common numbering systems

◦ Society of Automotive Engineers (SAE)
◦ American Iron and Steel Institute (AISI)
◦ Unified Numbering System (UNS)
◦ American Society for Testing and Materials (ASTM) for cast
irons

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 UNS Numbering System

 UNS system established by SAE in 1975

 Letter prefix followed by 5 digit number
 Letter prefix designates material class
◦ G – carbon and alloy steel
◦ A – Aluminum alloy
◦ C – Copper-based alloy
◦ S – Stainless or corrosion-resistant steel

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 UNS for Steels
 For steel, letter prefix is G
 First two numbers indicate composition, excluding carbon content

 Second pair of numbers indicates carbon content in hundredths of

a percent by weight
 Fifth number is used for special situations
 Example: G52986 is chromium alloy with 0.98% carbon

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 UNS for Aluminums
 For aluminums, letter prefix is A
 First number indicates processing
 Second number indicates the main alloy group

 Third number is used to modify the original alloy or to designate

the impurity limits
 Last two numbers refer to other alloys used with the basic group
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 Some Casting Processes

 Sand Casting
 Shell Molding
 Investment Casting
 Powder-Metallurgy Process

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 Heat Treatment of Steel

 Time and temperature controlled processes that modifies

material properties
 Annealing
◦ Heated above critical temperature, held, then slowly cooled
◦ Refines grain structure, softens, increases ductility
◦ Erases memory of prior operations
◦ Normalizing provides partial annealing by adjusting time and
temperature
 Quenching
◦ Controlled cooling rate prevents full annealing
◦ Less pearlite, more martensite and/or bainite
◦ Increased strength, hardness, brittleness

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 Heat Treatment of Steel

 Tempering
◦ Reheat after quenching to a temperature below the critical
temperature
◦ Relieves internal stresses
◦ Increases ductility, slight reduction in strength and hardness

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Effects of Heat Treating

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 Case Hardening

 Process to increase hardness on outer surface, while retaining

ductility and toughness in the core
 Addition of carbon to outer surface by exposure to high carbon
solid, liquid, or gas at elevated temperature
 Can also achieve case hardening by heat treating only the outer
surface, e.g. induction hardening or flame hardening

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 Alloy Steels

 Chromium
 Nickel
 Manganese
 Silicon
 Molybdenum
 Vanadium
 Tungsten

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 Corrosion-Resistant Steels

 Stainless steels
◦ Iron-base alloys with at least 12 % chromium
◦ Resists many corrosive conditions
 Four types of stainless steels
◦ Ferritic chromium
◦ Austenitic chromium-nickel
◦ Martensitic
◦ Precipitation-hardenable

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 Casting Materials

 Gray Cast Iron

 Ductile and Nodular Cast Iron
 White Cast Iron
 Malleable Cast Iron
 Alloy Cast Iron
 Cast Steel

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 Nonferrous Metals
 Aluminum
 Magnesium
 Titanium
 Copper-based alloys
◦ Brass with 5 to 15 percent zinc
 Gilding brass, commercial bronze, red brass
◦ Brass with 20 to 36 percent zinc
 Low brass, cartridge brass, yellow brass
 Low-leaded brass, high-leaded brass (engraver’s brass), free-
cutting brass
 Admiralty metal
 Aluminum brass
◦ Brass with 36 to 40 percent zinc
 Muntz metal, naval brass
◦ Bronze
 Silcon bronze, phosphor bronze, aluminum bronze, beryllium
bronze
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 Plastics

 Thermoplastic – any plastic that flows or is moldable when heat

is applied
 Thermoset – a plastic for which the polymerization process is
finished in a hot molding press where the plastic is liquefied
under pressure

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Thermoplastic Properties (Table 1)

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Thermoset Properties (Table 2)

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 Composite Materials

 Formed from two or more dissimilar materials, each of which

contributes to the final properties
 Materials remain distinct from each other at the macroscopic
level
 Usually amorphous and non-isotropic
 Often consists of laminates of filler to provide stiffness and
strength and a matrix to hold the material together
 Common filler types:

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Material Families and Classes (Table 3)

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Material Families and Classes (Table 3)

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Material Families and Classes (Table 3)

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Material Families and Classes (Table 3)

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 Physical Properties

 Weight
 Color
 Thermal and Electrical Conductivity
 Coefficient of Thermal Expansion
 Melting Point

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 Mechanical Properties

 Strength
◦ Tensile Strength
◦ Compressive Strength
◦ Shear Strength
◦ Yield Strength
 Coefficient of Friction

Trying to crush the mighty

bearing ball with hydraulic
press

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 Hardness

 Rockwell
 Brinell

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 Wear Resistance/Resistance to Galling
See ASTM G98 - 02(2009)
Standard Test Method for Galling Resistance of Materials

 Galling is adhesive wear or cold welding

of one material to another that is sliding
across it.
 Especially a problem with austenitic
stainless steels and aluminum.
 Factors affecting Galling
◦ design (avoid small friction areas)
◦ applied load
◦ contact area and degree of movement
◦ lubrication
◦ material properties (surface finish,
hardness and steel microstructure).

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 Toughness

 Toughness
◦ Brittleness
◦ Plasticity
◦ Ductility
◦ Malleability

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 Stiffness, Modulus of Elasticity

 Slope of linear section is

Young’s Modulus, or
modulus of elasticity, E
 Hooke’s law

 E is relatively constant for a

given type of material (e.g.
steel, copper, aluminum)

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 The Big Tradeoff

Hardness Vs. Toughness

Other main factors:

 Service temperature
 Hot hardness
Two pieces of the exact
 Thermal shock resistance same material (O1)
 Stability in heat treating
 Cutting speed
 Cost

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 Ferrous Tooling Materials

 Carbon Steel - CRS, HRS,1018, A36

 Alloy Steel - e.g., 4140 (chromoly)
 Tool Steel
◦ W – Water Hardening
◦ O – Oil Hardening (O1)
◦ A – Air Hardening (A2)
◦ D – High-Carbon, High Cr Die Steels
◦ S – Shock Resisting (S7)
◦ H – Hot Work Die Steels
◦ T & M – HSS
◦ L – Low Alloy Tool Steels
◦ F – Finishing Steels

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Identification and classification of tool steels (Table 2-2)

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 Identification and classification of tool steels (Table 2-2)

 The steels listed in Table 2-2 will adequately serve 95% of all
metal-stamping operations. The list contains 31 steels, nine of
which are widely applied and readily available. The other steels
represent slight variations for improved performance in certain
instances. Their use is sometimes justified because of special
considerations.
 Tool steels are identified by letter and number symbols. All the
steels listed, except those in the S and H groups, can be heat-
treated to a hardness greater than Rockwell C 62 and, accordingly,
are hard, strong, wear-resistant materials.

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 Comparison of basic characteristics of steels (Table 2-3)

Table 2-3 lists basic

characteristics of
steels used for press
tools

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Hardening and tempering treatments (Table 2-4)

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Hardening and tempering treatments (Table 2-4)

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 Applications of tool steels (Table 2-5)

Table 2-5 lists typical applications of various steels.

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Cold Work Tool Steels

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Hot Work Tool Steels

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Shock Resisting Steels

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 Tool Steel Recommendations

 First rule: Use what works!

 FTD, Table 2-3, 2-4, 2-5
 Carpenter Tool Steels

water-hardening tool steels - plain carbon (W1)

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 Powder Metallurgy

PM Tool Steels

 Improved Cracking and Fatigue Resistance

 Better Dimensional Stability during Heat Treatment
 Small, uniform carbide structure
 Potential for Increased tool life

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 Heat Treating

 Hardening
◦ Quenching
◦ Case Hardening
 Softening
◦ Normalizing
◦ Stress Relieving
◦ Annealing
◦ Tempering
◦ Spheroidizing Goodwin Steel Castings Ltd

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 Heat Treating of Nonferrous Metals

Nonferrous Metals
 Solution heat treatment - Dissolving alloy in elements
 Quench, in order to form a supersaturated solid solution
 Aging controlled precipitation of the supersaturated solid
solution. This can occur at any temperature below the solvus,
even at room temperature.

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 Other Ferrous Alloys

Stainless Steels (440C) (see AZOM for reference)

Austenitic
Nickel stabilizes austenite

Ferritic
Chromium stabilizes ferrie

Martensitic

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 Cutting Tool Materials

CBN

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 Carbides (cemented carbide)

 Tungsten Carbide (sometimes combined with Titanium and/or

Tantalum carbide) in a cobalt binder.
 ISO Machining Groups
 P (Blue) Steel, Cast Steel
 M (Yellow) Steel, Cast steel, austenitic steels
 K (Red) Cast iron, hardened steel, nonferrous metals
 N (Green) Aluminum and some nonmetals
 S (Orange) Titanium and High temperature alloys
 H (Grey) Hard Steel, other Cast Iron

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 Carbides & Cermets

Carbide Grades
Manufacturers have their own grades
C grade systems

SAE j1072

Cermets (TiC and TiN) in a cobalt binder

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 Carbide Inserts

ap = cutting depth

fn = feed per revolution

vc = cutting speed

sandvik.coromant.com 70
How Carbide Inserts are Made

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 Material Coatings

Two methods of applying: Chemical Vapor Deposition and

Physical Vapor Deposition.
CVD
 Thick, durable
 TiN - Golden, resists edge buildup best
◦ Lower speeds
 TiC - Hard, abrasion resistant
◦ Wear resistance
 Al2O2 - Alum oxide, Heat resistance
◦ Insulates the tool, Chemical stability

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 Material Coatings

PVD
 Thin, edge toughness, sharper edges
 For Stainless, Superalloys, Titanium
 TiAlN - Titanium Aluminum Oxide
◦ Combination of heat resistance and hardness
 TiN, TiCN - Hard, abrasion resistance

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 Other Cutting Tool Materials

 Cermets
 Ceramics
 Polycrystalline Diamonds

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 Non-ferrous Tool Materials

 Aluminum
 Magnesium
 Bismuth & Low Temperature Alloys
◦ Field's Metal
◦ Woods' Metal

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 Low Melting Temperature Alloys

 Field's Metal and Wood's Metal

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 Nonmetallic Tool Materials

 Wood
◦ Hardboard
◦ Densified Woods
◦ Plywood
◦ Particleboard/MDF

 Inexpensive, useful, flammable!

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 Polymers and Composite Materials

 Plastics Including 3D Printed Polymers & Metals

◦ Acetal
◦ ABS
◦ Nylon
◦ HDPE
◦ PTFE
◦ Radel
 Epoxy Resins
 Rubber
 Polyurethane
 See Machinable polyrethane foam (thermoforming molds,etc).

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