August 2026 Volume 8

MATERIALS

BEYOND THE DIE STEEL The Materials Behind Modern Forge Tooling By Bailey Taylor

W hen the conversation turns to forging materials and tooling, it is only natural that attention gravitates toward the materials that ultimately become the finished die. Tool steels such as H13, FX, ForgeDie, and many other familiar grades have earned their reputation through decades of successful application, and discussions surrounding heat treatment, hardness, toughness, and wear resistance remain as relevant today as ever. In fact, many of these topics have been covered extensively within the forging industry, including in previous articles. Yet, from our perspective as a forge tooling manufacturer, there is another side of the conversation that often receives less attention. While the steels used to manufacture forging dies have remained relatively consistent, many of the materials and consumables required to transform those steels into finished tooling have changed considerably. These changes may never be visible once a die is installed in a press, but they have become an increasingly important part of the manufacturing landscape for both dedicated tooling suppliers and the many forging companies that maintain in-house machining capabilities. The tooling itself may look much the same as it did years ago, but the environment required to produce it continues to evolve. One of the most noticeable examples is the continued evolution of cutting tools. Anyone involved in machining has witnessed just how quickly cutting tool technology advances. End mills, drills, inserts, and specialty cutters that were considered state-of the-art only a few years ago have often been replaced by improved geometries, more advanced carbide grades, and coatings designed to push performance even further. This constant development is one of the strengths of our industry. Cutting tool manufacturers continue investing heavily in research and development, producing tooling capable of higher metal removal rates, improved surface finishes, greater dimensional consistency, and longer tool life. Modern CAM software and machining strategies have evolved alongside these advancements, allowing shops to take advantage of capabilities that simply were not available a decade ago. For those of us manufacturing forging tooling, this creates an interesting dynamic. The steels we machine may remain largely unchanged, but the methods used to machine them are in a continual state of refinement. Shops are constantly evaluating new tooling, testing different strategies, and determining whether the latest generation of cutting tools provides measurable improvements over previous solutions. Sometimes the gains are significant. Other times, the existing process continues to be the better choice. In either case, continuous evaluation has become part of everyday manufacturing. Of course, advances in cutting tool technology also come with another reality; carbide has become an increasingly valuable resource. The conversation surrounding carbide often focuses on cost, and understandably so. Most machining operations have experienced noticeable increases in cutting tool prices over the past several

years. However, focusing solely on price overlooks a broader trend that many shops have experienced firsthand. Availability has become just as important as cost. Whether operating a captive toolroom inside a forging facility or an independent tooling shop, production schedules depend on reliable access to cutting tools. Delays in receiving a specific cutter, insert, or replacement tool can quickly become production issues, particularly when machining large or complex tooling where alternative tooling may not be readily available. Most shops have experienced situations where preferred tooling simply could not be sourced within the desired timeframe, requiring adjustments to machining strategies or substitutions that may not have been considered under normal circumstances. Much of this reflects the increasingly global nature of the cutting tool supply chain. While there continues to be strong domestic innovation and support throughout the industry, many of the raw materials, carbide processing operations, tool blanks, coatings, and finished cutting tools ultimately rely on international manufacturing and distribution networks. As those global networks experience disruptions, whether from transportation constraints, geopolitical events, raw material shortages, or changing trade conditions, the effects eventually work their way onto shop floors across North America. This is not unique to forging tooling. It is a reality shared by manufacturers across countless industries. However, because forging tooling often involves highly specialized machining operations with demanding delivery schedules, these supply chain fluctuations can have an outsized impact. They influence purchasing decisions, inventory strategies, and even how machining processes are planned long before the first chip is made. One response many shops have adopted is placing greater emphasis on flexibility. Standardizing tooling platforms where practical, qualifying multiple cutting tool options, and maintaining more strategic inventories have become increasingly common approaches to reducing risk. While every operation is different, the overall objective is similar: build resilience and redundancy into the manufacturing process without sacrificing quality or productivity. Another interesting shift has been the changing perception of carbide after it has reached the end of its useful cutting life. Historically, most machine shops understood that worn carbide retained value. Used inserts and end mills were rarely thrown away without a second thought, and many operations maintained some level of recycling program. Today, however, the economics surrounding carbide recycling have changed enough that many shops are placing renewed attention on these efforts. With scrap carbide values significantly higher than historical norms, used tooling is increasingly viewed as a recoverable material rather than simply worn-out consumables. Collection containers that may once have been an afterthought are now managed more intentionally, ensuring inserts, end mills, drills, and other carbide tooling are properly segregated and returned through recycling programs.

34 FIA MAGAZINE | AUGUST 2026