Raya University

TOOL AND DIE DESIGN

Daniel Aregawi
Materials and Manufacturing Engineering profession
Manufacturing Engineering department
Engineering and Technology college
Raya university
E-mail:-Danielaregawi04@gmail.com; Office No:B.7- R.204
CHAPTER - ONE
2

TOOL DESIGN
1.1 Introduction to tool design
3

• Tool design is a critical aspect of the manufacturing

process, involving the creation and development of tools
and equipment used in various industries to produce
goods.
• It is a specialized field that requires a deep understanding
of engineering principles, materials, manufacturing
processes, and product requirements.
• The primary objective of tool design is to design and
develop efficient and effective tools that enable the
production of high-quality products while optimizing
productivity and minimizing costs.
Types of tools
4

 Cutting tools
 Dies
 Work-Holding Tools
 Injection Mould Tools
1.2 Tooling
5
• Tooling refers to the collection of tools, equipment, and
machinery used in various manufacturing processes to
produce parts, components, or finished products.
• It encompasses a wide range of tools, including cutting
tools, molds, dies, jigs, fixtures, gauges, and other
specialized equipment.
• Tooling plays a crucial role in manufacturing industries as
it directly impacts product quality, production efficiency,
and overall cost-effectiveness. The design and selection of
appropriate tooling are essential for achieving desired
manufacturing outcomes.
Cont…
6

• The design and development of tooling involve factors such

as material selection, dimensional accuracy, durability,
ease of use, and compatibility with manufacturing
processes.
• The use of computer-aided design (CAD) software and
advanced manufacturing techniques, such as computer
numerical control (CNC) machining and additive
manufacturing, has revolutionized tooling design and
production, enabling more complex and precise tooling
solutions.
Requirements of a tool designer
7
To be a successful tool designer, there are several key requirements and
skills that are beneficial in performing the job effectively. These include:
 Technical Knowledge: A tool designer must have a strong
foundation in engineering principles, materials science, and
manufacturing processes.
 Design and Drafting Skills: Proficiency in computer-aided design
(CAD) software is crucial for creating accurate and detailed tool
designs.
 Knowledge of Manufacturing Processes: Tool designers need to
have a comprehensive understanding of various manufacturing
processes and their implications on tooling design.
 Material Selection Expertise: A tool designer should have
knowledge of different materials and their properties, including metals,
plastics, composites, and coatings.
Cont…
8

 Communication and Collaboration: Effective

communication skills are essential for collaborating with
various stakeholders, such as product designers,
manufacturing engineers, and quality control personnel.
 Attention to Detail: A tool designer should have a
meticulous approach to design, paying close attention to
dimensions, tolerances, clearances, and other critical
details that impact the performance and functionality of
the tool.
 Knowledge of Industry Standards and Regulations:
Tool designers should be familiar with relevant industry
standards, regulations, and safety guidelines.
 1.3 General tool design procedure
9
The tool design procedure typically involves several stages and iterative
steps to ensure the development of efficient and effective tools that meet
the required specifications. While the specific details may vary depending
on the industry and application, the following is a general overview of the
tool design procedure:
1. Understand the Requirements: The first step is to gather and
analyze the requirements for the tool. This includes understanding the
product that the tool will be used to manufacture, its dimensions,
tolerances, production volume, and any specific performance or quality
criteria.
2. Conceptual Design: Based on the requirements, the tool designer
develops initial conceptual designs. This involves generating ideas and
exploring different design possibilities. Sketches, CAD models, or
prototypes may be created to visualize and evaluate the design
concepts. Factors such as ergonomics, ease of use, manufacturability,
and maintenance requirements are taken into consideration.
Cont…
10

3. Detailed Design: Once a suitable conceptual design is selected, the

tool designer proceeds with detailed design development. This involves
creating detailed 2D or 3D CAD models of the tool, specifying dimensions,
clearances, tolerances, and other critical design parameters.
4. Material Selection: The appropriate materials for the tool are
selected based on factors such as strength, wear resistance, heat
resistance, and cost.
5. Manufacturing Process Selection: The tool designer determines
the most suitable manufacturing processes for producing the tool. This
includes considering factors such as cost, lead time, tool complexity, and
the capabilities of the manufacturing facility. Common processes include
machining, casting, forging, and additive manufacturing.
6. Validation and Prototyping: Before proceeding to full-scale
production, it is often beneficial to create prototypes or small-scale
models of the tool to validate its design and functionality.
Cont…
11

7. Tool Production: Once the design is finalized and validated, the tool
is manufactured according to the selected manufacturing processes. This
may involve machining, casting, assembling components, or other
fabrication techniques. Quality control measures are implemented to
ensure that the tool meets the required specifications.
8. Testing and Evaluation: The manufactured tool is tested and
evaluated to ensure that it functions as intended. This may include testing
its performance, durability, and reliability under realistic operating
conditions. Any necessary adjustments or improvements are made based
on the test results.
9. Documentation and Maintenance: Comprehensive
documentation, including design drawings, specifications, and
maintenance guidelines, is prepared for the tool. This documentation
serves as a reference for future production runs, tool maintenance, and
potential modifications or repairs.
1.4 Economics of tool design
12

 The economics of tool design refers to the cost

considerations and financial implications associated with
the design and development of tools. Here are some key
economic factors to consider in tool design:
1. Initial Tooling Costs: The design and production of
tools involve upfront costs, including material costs,
manufacturing expenses, and design and engineering fees.
2. Tool Life and Durability: The durability and lifespan
of a tool significantly impact its economic viability. Tools
that wear out quickly or require frequent repairs or
replacements can lead to increased downtime, production
interruptions,
Cont…
13

3. Production Efficiency: Tool design plays a crucial role in

production efficiency. Well-designed tools can improve
manufacturing processes by increasing production speeds,
reducing cycle times, and minimizing errors or defects.
4. Scrap and Waste Reduction: Ineffective tool design can lead
to increased scrap generation and material waste.
5. Maintenance and Repair Costs: The maintenance and
repair requirements of tools impact their long-term economics.
1.5 Tool Materials
14

A wide range of materials can be used for tooling, depending

on the specific application, desired properties, and
manufacturing processes involved. Here are some commonly
used materials for tooling:
1. Tool Steels: Tool steels are a popular choice for tooling
due to their excellent combination of toughness, hardness,
and wear resistance.
2. High-Speed Steels (HSS): High-speed steels are alloy
steels that can withstand high temperatures and retain
their hardness and cutting ability even at elevated
temperatures. They are often used for cutting tools such as
drills, milling cutters, taps, and reamers.
Cont..
15

3. Carbide: Carbide tools are known for their exceptional hardness and
wear resistance. They consist of hard particles, typically tungsten carbide
(WC) or titanium carbide (TiC), embedded in a metallic binder such as
cobalt. Carbide tools are widely used for cutting, drilling, and milling
operations.
4. Ceramics: Ceramics offer high hardness, heat resistance, and
chemical stability, making them suitable for tooling applications that
involve high-temperature environments or abrasive materials. Common
ceramic materials used for tooling include alumina (Al2O3) and silicon
carbide (SiC). Ceramics are often used for cutting tools, wear-resistant
parts, and abrasive machining.
5. Aluminum Alloys: Aluminum alloys are lightweight, corrosion-
resistant, and offer good machinability. They are commonly used for
tooling applications where weight reduction is important, such as in the
aerospace and automotive industries. Aluminum alloys can be used for
molds, jigs, fixtures, and certain forming tools.
 Cont…
16

6. Copper Alloys: Copper alloys, such as bronze and brass, are used for
tooling applications that require good thermal conductivity, electrical
conductivity, and corrosion resistance. They are often used for electrodes,
heat exchangers, and certain forming tools.
7. Plastics and Composites: In some cases, plastics and composite
materials are used for tooling, particularly for low-volume production or
prototyping applications. For instance, epoxy-based resins, reinforced
with fiberglass or carbon fiber, can be used to create molds or patterns for
casting processes or composite part production.
Requirement of tool materials
17

 Red Hardness (Elevated temperatures)

 Toughness (Impact forces on tool in interrupted
operations)
 Wear resistance (tool life to be considered)
 Chemical stability or inertness (to avoid adverse reactions)
 Adequate mechanical strength
 Resistance to thermal shock
 Ease of fabrication
 Economical