INDRODUCTION TO TOOL ENGINEERING

The field of Tool Engineering takes participation in the refinementof product design and the design of machinery and also machine toolsgauges etc.
Industreis utilize millions of men,production tools,machines,processes,material handling devices, buildings,other related facilities and millions of rupeesin order to shape and produce materials to meet the needs of mankind.

The competitive system forces a methodical selection and utilization of the factors of production in the manufacture of high quality products of low cost.

The many alternative processes available to change the size and shape of materials requirecomplementary toolling. Ingenuity is required in the design of this tooling to facilitatescheduled and economic machining, casting, joining and press working of the many Engineeringmaterials. The field of tool and manufacturing engineering encompasses a wide varity of industries.It is concerned with the manufacture of airplanes, food handling equipments, glassware,refrigerators, communication equipments, textiles,electronic equipments, sewing machines, sporting goods, automobiles,machine tools, furniture, packaging equipments, missiles, farmequipments, space capsules, stores and soon.

The field of tool and manufacturing is a necessary function in unit or high volume productionand in large or small enterprises. The tool and manufacturing engineer articulates in an environment which requires a through understanding of scientific and engineering principles.The tool manufacturing engineers must understand the broad manufacturing aspects of the industryin which he is employed and he must also be able to design specific production tooling.

TOOL ENGINEERING COURSE:

Today many Engineering coruses are available for studying such as MechanicalEngineering, Electrical and Electronics Engineering, Textile Engineering, Civil Engineering,Automobile Engineering, Aeronautical Engineering, Marine Engineering etc..

Tool Engineering is one of part of the Mechanical Engineering. It is a Diploma course.It is very valuable and usuable course. This course is available in Government and Privatepolytechnic colleges.

After completion of this courses, students have a good job. And also they haveopportunities in foreign countries. Some other's to start own industries. After completion ofthis course students are positioning for the following jobs in different industries.Tool and Die maker post, Supervisor, Quality control department, Tool Room Manager, ProductionManager, Tool designer etc..
In Tool Engineering course, students have known Tool manufacturing processes and Tool designing principles. And also have knowledge on machines such as Lathe, Milling machine,Grinding machine, shaping and planner machine, Drilling machine, power hack saw cutting machineand some CNC machines.

Educational Qualification: 10th standard with good percentage of marks.

METAL FORMING PROCESSES

Introduction:

Metal forming is a process of forming the metal into the required shape. In thisprocess no chips removed from the metal. The metal is formed into shape by applying force on themetal.
A press woring operation, generally completed by a single application of pressure oftenresults in the production of a finished part in less than one second. Press working forces are setup, guided and controlled in a machine referred to as PRESS. Metal is formed in two different stages such as 1.Cold working 2.Hot working.

Cold working
In this process metal is formed in the cold condition. In cold woring the metalis pressed or cut, to get the required shape. The metal is stretched beyond its elastic limit.cold working can be done only on ductile metals. The machine used for pressing the metal in cold working is called a "cold formingpress".

Hot working:
In this process metal can also be formed in hot condition. Here the metal is heatedto a temperature, so that recrystalysation takes place. At this hot condition the metal ispressed to get the required shape. The machine used for pressing the metal in hot working is called "hot working press"

PRESS TOOLS
The tool which is used on press machines with punch and die is known as press tool.
Punch is the male part of the tool, which is fastened to the ram and forced into the die.
Die is the female part of the tool,which is rigidly held on the bed of the press machine.Die has an opening in perfect alignment with the punch.

Types of Dies:
1.Based on the operations
1.Shearing, 2.Blanking, 3.Piercing, 4.Punching, 5.Cutting off, 6.Parting off, 7.Notching, 8.Slitting, 9.Lancing, 10.Bending (angle bending and edge bending), 11.Curling,
12.Forming, 13.Drawing or cupping, 14.Plunging, 15.Squeezing, 16.Coining, 17.Embossing,
18.Deep drawing, 19.Flatening or planishing, 20.Trimming.
2.Based on construction
1.Simple die,
2.Progressive die,
3.Compound die,
4.Combination die,
5.Inverted die.

Career Opportunities

As one of the most important metal cutting trades, tool and die making requires manual dexterity, good math skills and consistent attention to detail. This program covers all the core competencies including operation of computerized numeric control machines, increasingly in use in today's tool and die making industry. Upon completion of your tool and die maker apprenticeship, you can seek provincial certification and pursue employment in: Aircraft, appliance or automotives manufacturing Electrical machinery or plastics manufacturing Tool and die, mould-making and machine shops .

Apprenticeship :

*Flexible hours, earn while you learn

*The province is facing a large shortage for skilled labour ; in the Niagara Region, 10,000 new skilled trades workers will be required

*The government is committed to increasing apprenticeship programs *An apprenticeship trade offers satisfying work

*A certified journeyperson earns a good wage Approximately 18 per cent of skilled workers are self-employed

*There is, and will continue to be, a demand for highly qualified, highly skilled trades people.

Niagara

Apprentices complete 720 hours of college instruction and about 3.5 years of on-the-job training as paid trainees Outstanding levels of student satisfaction Highly experienced and supportive professors State-of-the-art facilities for your practical experiences Small class sizes where you will receive individual attention from the professor More than three decades of apprenticeship in-school training experience .

Tool and die makers:

Tool and die makers are among the most highly skilled workers in manufacturing. These workers produce and repair tools, dies, and special guiding and holding devices that enable machines to manufacture a variety of products we use daily—from clothing and furniture to heavy equipment and parts for aircraft.Toolmakers craft precision tools and machines that are used to cut, shape, and form metal and other materials. They also produce jigs and fixtures—devices that hold metal while it is bored, stamped, or drilled—and gauges and other measuring devices. Die makers construct metal forms, called dies, that are used to shape metal in stamping and forging operations. They also make metal molds for diecasting and for molding plastics, ceramics, and composite materials. Some tool and die makers craft prototypes of parts, and then, working with engineers and designers, determine how best to manufacture the part. In addition to developing, designing, and producing new tools and dies, these workers also may repair worn or damaged tools, dies, gauges, jigs, and fixtures.To perform these functions, tool and die makers employ many types of machine tools and precision measuring instruments. They also must be familiar with the machining properties, such as hardness and heat tolerance, of a wide variety of common metals, alloys, plastics, ceramics, and other composite materials. Tool and die makers are knowledgeable in machining operations, mathematics, and blueprint reading. In fact, tool and die makers often are considered highly specialized machinists. The main difference between tool and die makers and machinists is that machinists normally make a single part during the production process, while tool and die makers make many parts and assemble and adjust machines used in the production process. While many tools and dies are designed by engineers or tool designers, tool and die makers are also trained to design tools and often do. They may travel to a customer's plant to observe the operation and suggest ways in which a new tool could improve the manufacturing process.Once a tool or die is designed, tool and die makers, working from blueprints, plan the sequence of operations necessary to manufacture the tool or die. They measure and mark the pieces of metal that will be cut to form parts of the final product. At this point, tool and die makers cut, drill, or bore the part as required, checking to ensure that the final product meets specifications. Finally, these workers assemble the parts and perform finishing jobs such as filing, grinding, and polishing surfaces. While manual machining has declined, it is still used for unique or low-quantity parts that are often required in building tools and dies. Tool and die makers use computer-aided design (CAD) to develop products and parts. Specifications entered into computer programs can be used to electronically develop blueprints for the required tools and dies. Numerical tool and process control programmers use computer-aided design or computer-aided manufacturing (CAD/CAM) programs to convert electronic drawings into CAM-based computer programs that contain instructions for a sequence of cutting tool operations Once these programs are developed, computer numerically controlled (CNC) machines follow the set of instructions contained in the program to produce the part. Computer-controlled machine tool operators or machinists normally operate CNC machines, but tool and die makers are trained in both operating CNC machines and writing CNC programs, and they may perform either task. CNC programs are stored electronically for future use, saving time and increasing worker productivity.After machining the parts, tool and die makers carefully check the accuracy of the parts using many tools, including coordinate measuring machines, which use sensor arms and software to compare the dimensions of the part to electronic blueprints. Next, they assemble the different parts into a functioning machine. They file, grind, shim, and adjust the different parts to properly fit them together. Finally, tool and die makers set up a test run using the tools or dies they have made to make sure that the manufactured parts meet specifications. If problems occur, they compensate by adjusting the tools or dies.

Work environment.

Tool and die makers usually work in toolrooms that are normally quieter than typical manufacturing production floors because there are fewer machines running at once. Toolrooms also are generally kept clean and cool to minimize heat-related expansion of metal workpieces. To minimize the exposure of workers to moving parts, machines have guards and shields. Most computer-controlled machines are totally enclosed, minimizing workers' exposure to noise, dust, and the lubricants used to cool workpieces during machining. Tool and die makers also must follow safety rules and wear protective equipment, such as safety glasses to shield against bits of flying metal, earplugs to protect against noise, and gloves and masks to reduce exposure to hazardous lubricants and cleaners. These workers also need stamina because they often spend much of the day on their feet and may do moderately heavy lifting. Companies employing tool and die makers have traditionally operated only one shift per day. Overtime and weekend work are common, especially during peak production periods.

EMPLOYMENT:

Tool and die makers held about 101,000 jobs in 2006. Most worked in industries that manufacture metalworking machinery, transportation equipment such as motor vehicle parts, fabricated metal products, and plastics products. Although they are found throughout the country, jobs are most plentiful in the Midwest and the Northeast, where many of metalworking companies are located.

Tool and Dye Maker Career and Job Description

Some of the most skilled employees in production are tool and dye makers. They make tools, dyes, and customized guiding and holding devices that allow production equipment to produce many different kinds of products, from clothes and furniture to heavy components used in airplanes.Tool makers make a variety of tools and machines that must be utilized in the cutting, shaping, and forming of metals and other supplies. Additionally, toolmakers make jigs and fixtures, which are tools that hold metal while boring, stamping, or drilling is being done, as well other devices used to make measurements like gauges. Dye makers produce metal forms (dyes) which are utilized thin shaping metal for stamping and forging tasks. Additionally, dye makers produce metal molds for dye casting or molding plastics, ceramics, and composite substances. To decide the best way to produce a part, some tool and die makers will design and create prototypes of components. Besides the working on the development, design, and production of tools and dies, these employees might also make repairs on old or broken tools, dies, jigs, fixtures, and gauges.Tool and dye makers must use a variety of different tools and measuring equipment to carry out their work. Additionally, workers need to have familiarity with machining properties, like heat tolerance and hardness, as well as an array of other normal metals and alloys. Thus toolmakers must have and understanding of machining operations, mathematics, and blueprint reading. Typically, tool and dye makers are though of as greatly specialized machinists. The big difference between a regular machinist and tool and dye makers is that machinists tend to produce just one part throughout manufacturing while tool and dye makers produce parts and machines utilized in manufacturing.Tool and dye makers utilize blueprints to outline the order of steps needed to produce the part or dye. Then tool and dye makers must make measurements and label the metal that is going to be cut and used in the formation of the end good. Nest workers must perform cutting, drilling, or boring of the part as planned, making sure that the finished good is produced properly and to the required specifications. Lastly, tool and dye makers put the parts together, and file, grind, and polish the part as needed.New technological advances have helped revolutionize they way these workers carry out their tasks. Now tool and dye makers utilize computer-aided design (CAD) to design and create new products and parts. Workers can input specifications into the computer, which in turn can electronically produce drawings for the needed tools and dyes. Numerical tool and process control programmers utilize computer-aided manufacturing (CAM) programs to convert electronic drawings into computer programs that include directions for an outline of cutting tool steps. After the program has been created, computer numerically controlled (CNC) machines adhere to the guidelines and specifications inputted into the program and form the desired part. While typically computer-controlled machine tool operators or machinists run CNC machines, tool and dye makers are taught how to operate CNC machines and write CNC programs, and they can carry out both duties. CNC programs can help save time and money while improving productivity since they are electronically saved and can be used again.Tool and dye makers must first machine the product, then inspect it for precision by utilizing different tools such as coordinate measuring machines (CMM), which incorporate software and sensor arms that inspect the dimensions to determine if they match electronic blueprints. Then the parts must be assembled into a working machine. To get the parts to fit together as need, workers must perform filing, grinding, shimming, and adjustments on the parts. Lastly, to ensure that parts meet all required specs, the workers must design a test run using the produced tools and dyes. Finally, the tool and dye makers set up a test run using the tools or dies they have made to make sure that the manufactured parts meet specifications. Adjustments to tools and dyes must be made when errors arise.
Tool and Dye Maker Training and Job Qualifications
The majority of tool and dye makers acquire training through 4 or 5 years of education and training in formal apprenticeships or postsecondary programs. Apprenticeship programs combine in class teaching with real work experience, frequently requiring 10,400 hours, or close to 5 years to finish. Most employees consider apprenticeships the best method to becoming qualified for work as a tool and dye maker. The amount of workers receiving training via community and technical colleges is increasing, and sometimes it is combined with an apprenticeship program.Most tool and dye makers will still need more work experience to become highly skilled, even after finishing up an apprenticeship program. The majority will finds areas of specialization, be it in tools, molds, or dyes.Some of the tasks learned by tool and die makers includes operation of milling machines, lathes, grinders, wire electrical discharge machines, and various other machine tools. Too and die makers will learn how to utilize different hand tools used to fit and assemble gauges or other mechanical and metal-forming equipment. Additionally, these workers must learn the metalworking processes, like heat treating and plating. In class instruction typically involves mechanical drawing, tool designing, blueprint comprehension, tool programming, and courses in algebra, geometry, trigonometry, and basic statistics. Since tool and dye makers work with CAD technology, CNC machine tools, and computerized measuring machines they must also have sound computer skills.Those who don’t enroll in apprenticeships normally will learn their skills via work experience and taking courses at a vocational school or community college. These workers might start as machine operators and eventually be assigned harder tasks. Also, a lot of machinists become tool and dye makers. The job of tool and dye makers necessitates workers be highly skilled with precision measuring equipment, and be very detailed and patient since most of the work done must meet precise specs, such as precision to one ten-thousandth of an inch. Good vision is a must. Tool and dye makers must also have mechanical aptitude, be problem solvers, have and have the capacity to be extremely focused while exerting physical effort.There are many different ways for promotion. Some workers will become supervisors or administrators for their employers. Others may work towards their college degree and become engineers or tool designers. Still others may start their own business.
Tool and Dye Maker Job and Employment Opportunities
Those with the necessary knowledge and skill set will have good prospects for jobs. There is expected to be fewer qualified applicants than the number of job positions made available through retirement and transfers to other jobs. Employers are relaying it is their experience that is hard to replace highly skilled workers who retire with comparably qualified workers. Perhaps the biggest problem is that the most of the nation’s youth that have the required education and background for tool and die making decide to go to college or enter different occupations.Even though job prospects are expected to be great, very little if any growth in employment of tool and dye makers is expected over the 2002-12 timeframe since improvements in automation, such as CNC machine tools and computer-aided design, will increase worker productivity, thereby limiting employment. However, tool and dye makers are vital to the building and maintenance of sophisticated manufacturing systems. Companies will be forced into reliance on skilled tool and dye makers to provide their retooling expertise as these companies bring in new equipment, change production processes, and implement product design changes.