10 Skills of a Tool and Die Maker

This article is written for “SKILLS AHEAD” Magazine; Sept. 2011 issue. By Mr. K VENUGOPAL Director Trg&COO- NTTF

A tool is a hardware to produce a particular product. A tool maker is a generalist. His work varies from job to job. Tool making profession is a highly skilled activity with many accessories, tools and machines named after this profession, like tool maker’s square, tool maker’s hammer, tool maker’smicroscope and tool maker’s buttons.There are only few institutions in India giving specified training in tool maker trade. NTTF is one amongst them involved in this grade since 50 years.It is difficult to pinpoint the qualities of a tool maker. However, reviewing the success stories of persons engaged in the profession, it is inferred that inbuilt traits along with acquired skill and knowledge lead to successful tool making profession.

1.      APTITUDE.

         Does the person have aptitude for creating new things to specific stipulated norms? Only a few individuals are born artisans. The ability to create or rebuild to perfection is not a common quality. As listed above, tool makers keep on innovating new tools to the needs of the user from time to time.

2.      CREATIVITY.

       By creativity, we mean an ability to visualize objects in three dimensional styles and make alterations in a user-friendly manner. In fact, tool design for a mould or die-casting involves three dimensional viewing of the product and creating a counterpart as a tool. This skill helps the tool maker to understand the engineering graphics easily.

3.     ANALYTICAL ABILITY.

         This ability is needed while creating a tool, especially while programming the CNC machines for three dimensional objects. Also, optimum of costly machines involves analytical calculations. This ability can be again used while inspecting objects of odd shapes and forms. This, along with the above two traits, it to be tested through aptitude and skill test while selecting a candidate for tool & die making course as they are inborn in an individual.

4.      PATIENCE AND PERSEVERANCE

       Like a goldsmith or an artisan, a tool maker needs to have patience and perseverance. The high speed machines and fast manufacturing process can supplement production of parts of a tool. However, the final assembly involves a patient activity. Repeated trials and corrections should not dishearten him.

5.      KNOWLEDGE OF ENGINEERING GRAPHICS

       This is coupled with the ability to interpret the designs created and supplied by the design group. Tool makers create objects based on the design supplied by the tool designers. As we advice the designers to have the mastery in drafting practice and graphic standards, a tool maker needs to be on same wavelength to understand the intentions of the tool designer depicted in the drawing.

Occasionally the tool maker needs to create enlarged views of elements of tools for better understanding and needs to have CAD and software knowledge in the relevant area. In fact engineering drawing and design concepts have to be known

A good Tool Designer needs to be a good tool maker. The vice versa also holds good.

6.      HAND SKILLS.

            This is coupled with machining skills to produce parts in close tolerance, for example single digit micron tolerance. Extension of the knowledge should be in respect to latest tool making practices. The hand skill and the machining ability of a tool maker makes him smart.

Production of parts to close tolerances is expected by the machinist. However many a times the tool maker needs to demonstrate his skill tom the machinist to achieve the desired result.

The latest tool making practices on conventional machines, precision machines like jig boring and jig grinding, CNC machining and also high speed machining needs to be familiar to him.

7.      CONCEPT OF QUALITY.

       A tool maker should\d be absolutely clear about how to measure dimensions, forms and shapes. He rarely depends on a quality person to inspect the dimensions of the parts produced by him. He should know the use of all conventional and special measuring equipment. He needs to know the capabilities and limitations of universal height masters, profile projecting equipment and also the three coordinate measuring machines.

8.      KNOWLEDGE OF SPECIAL MATERIALS.

       A tool maker deals with a variety of special materials (tool steels). The steel used for a mould or a die-casting tool or even a press tool are different. The parameters for the machining of this tool steel and its heat treatment processes vary. The finishing operations done on tool elements also vary with base material. A mirror finish is a must in a mould part, whereas a sharp cutting edge is a requirement in a press tool. Hence, a tool maker must understand the metallurgical aspect of tool steels.

9.      COMFORT WITH PRODUCT.

       A tool maker should have the ability to assemble parts, feel the function of every element and the function of the total tool as a creator. The precision of a tool comes from the assembly done by a tool maker utilizing the piece parts or elements gathered by him. A lot of touch-ups are needed to mating parts of a tool. We name it as assembly skill. Of course, it is an acquired shill by the tool maker.

10.    ABILITY TO SATISFY CUSTOMER.

       Finally, he should know how to take trials of his tools on appropriate machines and make necessary corrections and modifications to produce the part to customer’s specification. The duty of a tool maker ends only after the tool produces an acceptable product. A mould for a plastic component is loaded on a moulding machine and the product needs to come out from the mould without flashes, mismatch or sharp edges. The setting parameters for the moulding machines for the specific material and the time controlled for every stage in moulding process.

This is not conclusive because many more skill requirements of tool makers can be listed. It is practically impossible to have a tool maker with excellence in all above skills. However, we suggest that a professional tool maker needs to be excellent in 3-4 avenues from among the above list, good in a few other skills and well aware of the remaining traits. A professional tool maker should also be able to transfer these skills to many other interested persons. Sure, a person of this nature is a unique creator and a resource person. He recalls and rejoices many of his creative works when aged.

This article is written for “SKILLS AHEAD” Magazine; Sept. 2011 issue. By Mr. K VENUGOPAL Director Trg. NTTF.