Tool with breakage sensor and method

A tool comprising:

• a shank including a trailing end configured to operably engage a tool holder;
• a tip extending from said shank and configured to form a hole in sheet material, said tip and said shank defining a passageway;
• an electrical conductor located in said passageway in said tip;
• and
• a circuit including said electrical conductor, said electrical conductor including a first portion insulated from said shank and a second portion electrically connected to said tip at an extremity of said tip, said electrical conductor being configured to break and interrupt the continuity of said circuit when said tip breaks, whereby the continuity of the circuit can be used to determine when said tip breaks so that a press running a die incorporating said tool can be stopped before a significant number of defective parts are made.

An apparatus comprising:

• a press including press controls;
• a die configured for manufacturing parts in said press, said die including a punch holder;
• and
• a die punch comprising:
• a shank configured to operably engage said punch holder on said die;
• a tip extending from said shank, said tip being configured to punch a hole in sheet material being formed on said die, said punch including a passageway extending axially in said shank and said tip;
• and
• an electrical circuit defined in said tip including a conductor extending from said shank to said tip and located in said passageway, said conductor including a first portion insulated from said die punch and a second portion electrically connected to said tip at an extremity of said tip, said electrical conductor being operably connected to said press controls and being configured to interrupt the continuity of said circuit when said tip breaks, so that, when said tip breaks and said continuity of said electrical circuit is broken, said press controls generate a signal indicating that said tip has broken, whereby said press can be immediately stopped before a significant number of defective parts are made.