Die Science: The science

Some of you may disagree with its content and find that very little of what I am about to share is true in your community. If so, my response to you is a sincere congratulations! I hope your community is the catalyst for change. I am on your side, and you are the exception to the rule.

The purpose of this article is not to criticize, condemn, or complain, but to expose the truth behind the new, advanced, and ever-changing tool and die industry.

A Discouraging Stereotype

I find it discouraging and sometimes even irritating that high school guidance counselors consider the pursuit of a tool- and die making apprenticeship as a less than professional career path.

More often than not special career centers that focus on industrial trades become the dumping ground for underachievers and students with behavioral problems. Counselors often encourage and direct their brighter students to attend to a four-year college and oven on to become “professional,” while they point their lower perfumers to the industrial trades learning center.

The mindset is, “If Johnny isn’t smart enough to become a doctor or lawyer, he might as well do that factory tool and die thing, whatever that is. At least he will make good money.”

Sound familiar?

Americans have seriously stereotyped manufacturing jobs, often viewing them as far less professional than jobs that require a four-or six-year degree. I am a tool and die journeyman and have in my possession a piece of paper stating that I have achieved this status. The reality of this accomplishment? 50 cents and my document will get me a cup of coffee, providing the coffee is not 75 cents.

The true value of an individual lies in his or her ability to perform and add value to the bottom line, not a piece of paper. Education comes in many factors, and just because you don’t have a four-, six, or eight-year college degree doesn’t mean you are not a professional.

Don’t get me wrong: I am in noway discouraging education or college. After all, I’m an educator. However, we need to focus on practical ability, not how many degrees we have.

So what is the typical stereotype? That tool and die is an art form. It’s a factory-style job requiring individuals with limited mechanical and engineering skills. Tool- and diemakers and technicians work in a dirty, greasy, dark, loud, and undeducted environment. They work a lot of overtime some make pretty good money. They use a lot of expensive precision tools. Toolmakers often use trial-and-error methods for problem solving.

The Truth About Tool and Die

Actually, tool and die is a physics based science. Die designers, makers, and troubleshooting technicians, and designers often have the following skills:

• They fully understand sheet metal formability. The work-hardening exponent and the plastic strain ratio are common words in their vocabulary. The anisotropy of the sheet material and its surface topography are their concerns. They fully understand the advantage of biaxial stretch and use this unique property to solve splitting problems. They understand the effects of poor strain distribution with regard to elect recovery.

• They use sophisticated measurement tools to predict product failures. Tool and professionals commonly use forming assessment tools such as circle grid analysis and thinning strain analysis and thinning strain analysis. They measure different strain types and the deformation of each strained area to assess the forming severity of a part.

• They understand tool steel. Tool and die professionals understand toughness, hardness, and wear resistance as well as the importance of pre- and postheating for welding. They understand how too steel selection affects the die coating process and can determine whether chemical vapor disposition or physical vapor deposition will be best-suited to the tool steel selection.

• They understand metal forming. They consider radial compression and the effects of radii during die design and troubleshooting. They perform draw ratios and reductions calculations.

• They are experts in the use of hand grinders and other tools. Toolmakers are very precise in their grinding and metal finishing techniques.

• They conduct data-based experimentation to produce a hypothesis before taking corrective action. They compare their collected data with the desired results and create a good plan for executing die changes that will produce immediate positive results.

• They understand metal cutting theory. Tool and die professionals have a good understanding of what happens during metal cutting to make a good, data-based decision regarding items such as burr control and punch and button wear.

• They understand the importance of precision measurement and accurate of die conditions. Toolmakers and technicians use number of precision tools and often must be able to measure to as little as 0.0001 inch. Precision instrument reading and calibration are critical in the tooling industry.

These are just a few of literally hundreds of skills sets tool and die professionals require. I think you would have a hard time convening anybody that these are the skill sets of a typical factory worker.

Very simply, the tool and die profession is a career path that requires a much greater knowledge base than the public often perceives. We need to encourage bright students to pursue manufacturing and lose the mentality that they must have at least a four year college degree to survive.

If you are a tool- and diemaker, designer, or technician, be proud of what you are. I tip my hat and toast my beverage to you! It doesn’t matter to me if you have a sixth-grade education or a Ph.D from Harvard. What really matters is what you can do with what you have learned.

If I had to start all over again, you guessed it—I would be a tool-and diemaker.

Until next time… Best of Luck!