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Tech 3113 Manufacturing Tooling Nageswara Rao Posinasetti
Tech 3113 Manufacturing Tooling
Nageswara Rao Posinasetti
2. Materials Used For Tooling
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Ferrous materials Tool steel, alloy steel, carbon steel, cast
iron Non-ferrous materials
Aluminum, Zinc, Lead, Bismuth Non-metallic materials
Plastics, rubbers, epoxy resins
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Tool Materials
Weight Thermal and electrical conductivity Rate of thermal expansion Melting point Strength
Tensile Compressive Shear Yield
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Physical and Mechanical Properties
Hardness Rockwell Brinell
Wear resistance Toughness Plasticity Ductility Brittleness Malleability Modulus of Elasticity
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Physical and Mechanical Properties
Conditions Hot rolled (HR) Cold rolled (CR) Ground
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Ferrous Tool Materials
Carbon steels Low carbon 0.05% to 0.30% C
Soft, Tough, Easily machined, and Welded Case hardened
Used for tool bodies, handles, die shoes, where strength and wear resistance is not required.
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Ferrous Tool Materials
Carbon steels Medium carbon 0.30 to 0.70% C
Great strength and toughness Normal heat treatment can be given
Used for tool parts such as studs, pins, axles and nuts
High carbon 0.70 to 1.50% C Wear resistance is required
Used for Drill bushings, locators, and wear pads
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Ferrous materials
Carbon steels with additional alloying elements
Expensive
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Alloy steels
Principal properties required for tool steels are: Heat Resistance Abrasion Resistance Shock Resistance Resistance to movement or distortion in
hardening Cutting ability
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Tool steels
W – water hardening tool steels Plain carbon (W1) and carbon vanadium (W2) Low cost
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Tool steels
Steel type
C Mn Si Cr W Mo V Other
W1 1.00W2 1.00 0.25
O – oil hardening tool steels Manganese oil hardening steels Better wear resistance
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Tool steels
Steel type
C Mn Si Cr W Mo V Other
O1 0.90 1.00 0.50 0.50O2 0.90 1.60O7 1.20 0.75 1.75 0.25
A – Air hardening die steels Better wear resistance
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Tool steels
Steel type
C Mn Si Cr W Mo V Other
A2 1.00 5.00 1.00A4 1.00 2.00 1.00 1.00A5 1.00 3.00 1.00 1.00A6 0.70 2.00 1.00 1.00
D – high carbon high chromium die steels Used for long run dies Tough and good wear resistance
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Tool steels
Steel type
C Mn Si Cr W Mo V Other
D2 1.50 12.00 1.00D3 2.25 12.00D4 2.25 12.00 1.00D6 2.25 1.00 12.00
S – shock resisting tool steels Low carbon and high toughness
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Tool steels
Steel type
C Mn Si Cr W Mo V Other
S1 0.50 1.50 2.50S2 0.50 1.00 0.50S4 0.50 0.80 2.00S5 0.50 0.80 2.00 0.40
H – hot work die steels Low carbon and high alloy content
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Tool steels
Steel type
C Mn Si Cr W Mo V Other
H11 0.35 5.00 1.50H12 0.35 5.00 1.50 1.50 0.40H13 0.35 5.00 1.50 1.00H21 0.35 3.50 9.00H26 0.50 4.00 18.00 1.00
T and M – tungsten and molybdenum based high speed steels Good red hardness and abrasion
resistance
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Tool steels
Steel type
C Mn Si Cr W Mo V Other
T1 0.70 4.00 18.00 1.00T15 1.50 4.00 12.00 1.00M2 0.85 4.00 6.25 5.00 5.00 5.00
CoM3 1.00 4.00 6.00 5.00 2.00M4 1.30 4.00 5.50 4.00 2.40
L – low alloy tool steels Limited application Coining and impression dies
F – finishing steel
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Tool steels
Steel type
C Mn Si Cr W Mo V Other
L2 0.35 1.00 0.20L3 0.35 1.50 0.20L6 0.35 0.75 1.50
NiF2 0.35 3.50
High compressive strength and easy casting
Large forming and drawing dies
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Cast iron
Aluminum High strength to weight ratio Corrosion resistant Supports and locators to base plates and tool
bodies Magnesium Bismuth alloys
Low melting temperature Invar
35 to 36% Ni Zero thermal expansion
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Non-ferrous Tool Materials
Removes strain after cold working Remove internal stresses after
processing Increase hardness Improve machinability Improve cutting capability Increase wear resistance Increase toughness Improve other properties
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Heat Treatment
Hardening Tempering
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Heat Treatment for Ferrous Materials
Normalizing Stress relieving Annealing Spheroidizing Case hardening
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Heat Treatment for Ferrous Materials
Cold work Precipitation hardening
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Heat treatment for Non-ferrous materials
Operations Warm forging, dies and punches Roll forging, rolling segments Upset forging, clamping tools Progressive forging, dies Axial closed die rolling, top and bottom dies Cross forming, segments Hot bending, tools Hot calibration, tools Zinc die casting, dies Al-tube extrusion.
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Hot working operations
Properties required Wear resistance Toughness High hot wear resistance Very good high temperature properties High resistance to thermal fatigue Very good temper resistance Very good thermal conductivity.
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Hot working operations
Operation Cold Forging Cold Rolling Cold Extrusion Sheet metal operations
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Cold working operations
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Properties required high hardness high volume of carbides high hardness of the carbides large carbide size Wear resistance Toughness
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Cold working operations
