Major Defects in Tool 1

Design
AN OVERVIEW
Causes of Tool Failure 2

 Manufacturing defects, operating errors and unforeseen events.

 Heat treatment an important impact factor.
 Failure minimized in production steps and proper usage ensured.
 Lack of structural toughness tool breakage/fracturing
 Quenching method deviating from brine hardening to vaccum
hardening method.
 Premature tool failure more critical in high performance tools
Significance of Tool Failures 3

 Perspectives of Tool Failure

 Economic loss of Tool failure more significant due to added costs.
 20%-25% improvement performance increase can be factored in
service life improvement potentials for all tools.
 Manufacturing failures trackable to the source.
 Zero-defect manufacturing
Elaboration on Tool Failure Causes 4

 Manufacturing Failure Most critical: tool production

 Operating Error
 Unforeseen Events: Least Occurrence

Defective materials account for no more than 5% of all

failures.
Execution (finishing) and heat treatment emerge as most
common failure sources.
Influences On Tool Service Life 5

 Tool service life from design to use:

• Design: load bearing capability is determined via shape and load rating
calculations.
• Material: steel grade selected, finishing and working hardness
• Manufacturing: machining and heat treatment (design specs put into
use)
Investigation of Tool Failures 6

 Macroscopic Analysis
 Metallographic Investigation
• Hardness Testing
• Material properties
(carbide distribution,
cleanliness, grain size)
• Material defects (porosity,
shrinkage holes, excessive
segregation, inclusions)
 Machining Defects
• grinding or erosion faults
Classification of Tool Failures By 7

Defect Types
 sharp edged: high notch stress

 Material: internal and surface defects

Classification of Tool Failures By 8

Defect Types
Grinding Failure: martensite susceptible to cracking

Erosion machining with excessive power inputs

nitrided to increase the wear resistance

Classification of Tool Failures By 9

Defect Types
Quench stress cracking

Retained austenite
Lab Task 10

 Make a table of prominent tool failures describing the name, type,

cause and remedy for the said failure along with the relevant
sketches.