Tool and die design: Introduction

•THE ROLE OF ENGINEERING DESIGN in a manufacturing firm is

to transform relatively vague marketing goals into the specific
information needed to manufacture a product or machine that will
make the firm a profit. This information is in the form of drawings,
computer-aided design (CAD) data, notes, instructions, and so forth.

Engineering design as a part of the product realization process

 Cont’d
• The design of a part involves selection of a material and a
complementary manufacturing process;
• The majority of parts used in products today are either injection
molded plastics, stamped ferrous metals, or die-cast nonferrous
metals;
• Many other material-process combinations are also in use;
• Some parts are made by a sequence of processes, such as casting
followed by selective machining;
• A great deal of varied knowledge is needed to perform design
competently and quickly;
• Design is usually a team effort involving people from marketing,
several branches of engineering, and manufacturing.
 Procedures of tool and die design
Tool design objectives
• The main objective of tool design is to improve efficiency and
production quality and to minimize cost;
• To accomplish this objective the following must be fulfilled:
• Provide simple to operate easy tools for maximum efficiency;
• Reduce manufacturing cost by producing components by possible
lowest costs;
• Design tools that consistently produce high quality products;
• Increase the rate of production with existing machine tools;
• Design the tool to make tool proof and to prevent improper use;
• Elect material that will give adequate tool life;
• Provide protection in the design of the tools for maximum safety of
the operator;
 Tool Design in manufacturing
• As important part of manufacturing tool design occupies a position
between product design and product production;
• First the need for a product is determined;
• The drawings and specifications are developed;
• Then forward this information to the planning engineer;
• The process planning engineer working closely with the product
designers and tool designers, plans the method that will be used to
produce the parts;
• Modify the design if necessary and speed up the production;
• The planning engineer sets the production rate and product design and
choose the machine tools;
• Dead lines are scheduled and budget is set up;
• The tool designer must plan with in this frame work.
 Planning the design
• The amount of planning in a tool’s design greatly affect its
success or failure;
• All of the information pertaining the proposed products are
evaluated so that the most efficient and cost effective tool design
can be selected.
 Cutting Tools
• One of most important components in machining process;
• Performance will determine efficiency of operation;
• Two basic types (excluding abrasives);
– Single point and multiple point
• Must have rake and clearance angles ground or formed on them;
Cutting-Tool Materials
•Tool bits generally made of seven materials
High-speed steel
Cast alloys (such as stellite)
Cemented carbides
Ceramics
Cermets
Cubic Boron Nitride
Polycrystalline Diamond

6
CUTTING TOOL
TECHNOLOGY
Introduction: Machining is accomplished by cutting tools.
• Cutting tools undergo high force and temperature and temperature
gradient.
Tool life
Three modes of failure
– Premature Failure
• Fracture failure - Cutting force becomes excessive and/or dynamic, leading
to brittle fracture
• Thermal failure - Cutting temperature is too high for the tool material
– Gradual Wear
• Gradual failure
Tool wear: Gradual failure
– Flank wear - flank (side of tool)
– Crater wear - top rake face
– Notch wear
– Nose radius wear
 Possible Wear Mechanisms
Abrasion – Flank and Crater wear
• Hard Inclusions abrading Cutting tools
• Hot Hardness Ratio
• Erosion
• Attrition
• Adhesion
• Compatibility chart
Diffusion/Dissolution – Crater wear
• Chemical solubility
• Diamond dissolves into iron.
• Oxide coating resists crater wear.
• Plastic deformation
 Tool life
Tool life – the length of cutting time that the tool can be used
– Break-in period
– Steady-state wear region
– Failure region
Tool Life Criteria in practice
1.Complete failure of cutting edge
2. Visual inspection of flank wear (or crater
wear) by the machine operator
3. Fingernail test across cutting edge
4. Changes in sound emitted from operation
5. Chips become ribbony, stringy, and difficult to dispose of
6. Degradation of surface finish
7. Increased power
8. Workpiece count
9. Cumulative cutting time
 Tool Materials
• Important properties
– Toughness – avoid fracture
– Hot hardness – resist abrasion
– Wear resistance - solubility
Cutting tool materials
– Plain carbon and low alloy steels
– High-speed steels
– Cemented carbides, cermets and
coated carbides
– Ceramics
– Synthetic diamond and CBN
 Cont’d
• Plain Carbon and Low Alloy Steels
– Before High Speed Steels
– Due to a high carbon content, heat treated to R=60
– Poor hot hardness
• High-speed steels (HSSs)
– tungsten type (T-grade)– 12-20% of W
– molybdenum type (M-grade)- 6% W and 5% Mo
– Other elements: Tungsten and/or Molybdenum,
• Chromium and Vanadium, Carbon, Cobalt in some grades
– Typical composition: Grade T1: 18% W, 4% Cr, 1% V, and 0.9% C
HSSs
•Still used extensively for complex geometry such as drills
• Heat treated to Rc=65
• Re-grinded for reuse
– Thin coating
 Cont’d
• Cast Cobalt Alloys
– 40-50% Co, 25-35% W, 15-20% others
– Casting in a graphite mold and grind
– Toughness is not as good as HSS but hot hardness is better.
– Not so important
• Cemented Carbides
• Advantages (Cemented Carbide, Cermets & Coated Carbides)
– High compressive strength and modulus
– High room and hot hardness
– Good wear resistance
– High thermal conductivity
– Lower in toughness that HSSs
Grades
– Nonsteels grade – WC-Co
– Steel grades – add TiC and TaC due to the high solubility of WC into
steels resulting in extensive crater wear
 Cont’d
Cemented Carbides – Mainly WC-Co
– As grain size is increased, hardness decreases but TRS increases.
• – As the content of cobalt increase, TRS increases but hardness
decreases.
– For roughing or milling, high cobalt is desirable
– For finishing, low cobalt is desirable.
Cermets
• Cermets – TiC, TiN and TiCN with Ni or Mo as binders
– Applications: High speed finishing and semi finishing of steels,
stainless steels and cast iron
– Higher speeds than carbides
– For better finish, low feed
Coated carbides

Since 1970, they improve machinability.

• One or more layer of thin layers of wear resistance CVD or PVD
coating such as TiC, TiN,Al2O3, ZrN, CrC or Diamond.
• Coating thickness = 2.5 - 13 µm (0.0001 to 0.0005 in)
• Applications: cast irons and steels in turning and milling operations
• Best applied at high speeds where dynamic force and thermal shock
are minimal .
 Ceramics, Synthetic diamond and CBN
Ceramics
• Fine alumina powder is pressed and sintered at High pressure and
temperature.
– Other oxide such ZrO2are added.
– Used in finishing of harden steels, high v, low d and f and rigid work
setup;
-Not for heavy interrupted cutting
-Other ceramic tools:Si3N4 ; sialonSi3N4-Al2O3 Alumina and TiC and SiC
whiskers-reinforced alumina
Diamond – the hardest material
– Usually applied as coating (0.5 mm thick) on WC-Co insert
– Sintered polycrystalline diamond
– Applications: high speed cutting of nonferrous metals
Cubic Boron Nitrides (CBN)
– For steels and Nickel alloys
– Expensive
 Tool Geometry
-Back rake angle (αb)
-Side rake angle (αs)
-End relief angle (ERA)
– Side relief angle (SRA)
– Side cutting edge angle(SCEA)
– Nose radius (NR)
– End cutting edge angle(ECEA)
Cutting edge for a single-point
tool
 Cont’d
Chip Breakers
– For single-point tools, chip breaker forces the chip to curl so that
it fractures
– Groove and obstruction types
Effect of Tool Material
– Positive rake angle -> reduce cutting force, temp.and power
consumption
– HSS: +5°< rake angle<+20°
– Carbides: -5°< rake angle <+10°
– Ceramics: -5°< rake angle <-15°
– The cutting edge: solid, brazed insert and clamped insert.
 Twist Drills

The most common cutting tools for hole-making Usually made of high
speed steel
 Twist Drill Operation
Rotation and feeding result in relative motion between cutting edges
and workpiece
– Cutting speed varies along cutting edges as a function of distance from
axis of rotation
– Zero Relative velocity at drill point (no cutting)
– A large thrust force to drive the drill forward
• Chip removal
– Flutes allow chips to be extracted
• Friction makes matters worse
– Rubbing between outside diameter and wall
– Delivery of cutting fluid to drill point
• Principal types: Milling Cutters
– Plain milling cutter
– Peripheral or slab milling
(can be Helical)
– Form milling cutter –
Peripheral milling cutter
in which cutting edges
have special profile to be
imparted to work
• Important application 18-teeth Plain Milling Cutter
gear-making, in which Used for Peripheral or Slab Milling
the form milling cutter is
shaped to cut the slots
between adjacent gear
teeth
-Face milling cutter
– End milling cutter
Four-tooth Face Milling Cutter
 End Milling Cutter
• Looks like a drill bit but designed for primary cutting with its
peripheral teeth
• Applications:
– Face milling
– Profile milling and pocketing
– Cutting slots
– Engraving
– Surface contouring
– Die sinking
Milling cutters
 Broaches and Saw Blades

Saw Blade (Straight & Undercut tooth or Straight & Raker sets)