strong>In-Depth Guide to Filling Out Non-Standard Cutting Tool Design Request Forms
In the realm of custom cutting tool manufacturing, a well-completed request form is the crucial link between design and production. Vague parameters and missing application details frequently lead to delays, quality disputes, or even batch scrapping. This is especially problematic in export trade, where hidden requirements—such as standard mismatches or material restrictions—may trigger cross-border conflicts. Based on over 20 years of experience in the metalworking tool industry, this guide provides a systematic approach to completing the entire form—from basic specifications to detailed working condition matching. It includes practical details such as material conversion, failure prediction, and cost coordination, helping professionals avoid common pitfalls and efficiently convert technical needs into production-ready solutions.
Why Standardize the Request Form?
1. Avoid Production Errors
Example: The client requests an "M6 tap" without specifying metric or UNC thread, leading to return or rejection.
2. Accelerate Communication
A complete form minimizes repeated confirmations between the technical team and the customer.
3. Protect Both Parties' Interests
Clear documentation helps avoid future quality disputes.
Three Key Points to Note
1. Basic Information is Essential
- Tool type (e.g., tap, drill bit, milling cutter)
- Application scenario (e.g., machining stainless steel parts, aluminum alloy molds)
- Export destination (affects standards, e.g., DIN for Germany)
2. Fill Out Key Parameters Completely
| Parameter Type | Correct Example | Incorrect Example |
|---|
| Dimension | "Diameter 6mm ±0.01" | "About 6mm" |
| Material | "M35 High-Speed Steel" | "Some good steel" |
| Coating | "TiN coating, 2μm" | "Anti-rust coating" |
3. Clarify Special Requirements Separately
- Rust-proof packaging needed?
- Inspection reports required?
- Acceptable substitutes if raw material is unavailable?
Step-by-Step Filling Tutorial
Step 1: Define the Tool’s Purpose
E.g., “For CNC machining of 304 stainless steel screw holes in batch production.”
Step 2: Select Basic Parameters
- □ Tool Type: □ Tap □ Drill □ End Mill
- □ Material: □ HSS □ Cobalt HSS □ Carbide
- □ Workpiece Material: □ Cast Iron □ Stainless Steel □ Aluminum Alloy
Step 3: Provide Detailed Specs
- Diameter: ______ mm | Total Length: ______ mm
- Tolerance: ±______ mm
- Special Processing: □ Coating □ Polishing □ Other ______
Step 4: Confirm Additional Clauses
- □ Material certification required
- □ 3–5 days confirmation period accepted
- □ Minimum order quantity: ______ pcs
Universal Request Form Template
Advanced Tips for Parameter Input
1. Material Hardness Conversion
Avoid mismatches between Rockwell and Brinell values:
HRC ≈ HB/10 + 3 (Valid for HRC 20–60 range)
2. Quick Reference for Cutting Parameters
| Material | Drill Speed (Carbide) | Feed per Tooth (HSS-E End Mill) |
|---|
| Aluminum Alloy | 200–300 m/min | 0.1–0.2 mm/tooth |
| Stainless Steel | 30–50 m/min | 0.05–0.1 mm/tooth |
| Titanium Alloy | 15–30 m/min | 0.03–0.06 mm/tooth |
3. Special Symbol Interpretation
- "▽": Surface roughness (e.g., ▽3 = Ra1.6μm)
- "◎": Coaxiality (common for step drills)
- "⌒": Arc transition (used to prevent stress concentration)
Advanced Requirement Modules
1. Working Condition Checklist
- □ Max machine spindle speed: ______ rpm
- □ Tool holder type: □ BT30 □ BT40 □ HSK
- □ Cooling method: □ Oil □ Air □ MQL
- □ Cycle time requirement: ______ sec/part
2. Failure Mode Prediction Table
| Failure Mode | Recommended Design Adjustment |
|---|
| Chipping | Increase rake angle, reduce hardness by 2 HRC |
| Built-up Edge | Add chip groove, polish cutting edge |
| Chatter | Shorten overhang, apply unequal flute spacing |
3. Cost Control Considerations
- Material Utilization: Rod diameter should be 1.2× tool diameter (e.g., use Φ12mm rod for a Φ10mm end mill)
- Alternate Material Suggestion: “If M42 is out of stock, accept ASP23 powder steel? □ Yes □ No”
In-House Quality Acceptance Standards
1. Mandatory Tap Inspection Items
- Thread pitch diameter measured by 3-wire method (±0.005mm tolerance)
- Torsion test: M6 tap must withstand ≥15 N·m torque
2. End Mill Quality Checkpoints
- Runout: ≤0.015mm (measured in BT40 holder)
- Dynamic Balance: G6.3 (G2.5 required for RPM >8000)
3. Drill Life Testing Method
- Continuous drilling into 45# steel, hole size Φ6 × 30mm
- Failure criteria: Hole diameter enlarged by 0.05mm or torque increase ≥20%
Frequently Asked Questions
- Q: What if I’m unsure about certain parameters?
- A: Refer to existing tool samples or provide photos of the workpiece.
- Q: How to request a special tool shape?
- A: Attach a sketch or annotated image with key dimensions.
- Q: What drawings are required for non-standard tool design?
- A: At minimum: 2D dimensioned drawing (with tolerances), material spec, and surface treatment details.
Conclusion
A well-structured non-standard cutting tool request form is both a technical document and a quality contract. Through precise parameter definition, working condition mapping, and failure risk assessment, companies can greatly improve the reliability and efficiency of custom tooling solutions. This guide, with acceptance standards, quick-reference charts, and smart templates, transforms abstract technical needs into quantifiable and verifiable benchmarks. Whether you're a new engineer or a seasoned buyer, standardized request forms reduce communication friction and serve as a reusable methodology for tackling complex requirements—paving the way for more efficient collaboration in the customized manufacturing sector.
