Not sure why it happens, but it's been happening with my phone too. First try sending it a bunch of times and hopefully one will actually get through. Today, I made a tone and had to send it over 10 times, but at least it got there.
You can also...
Try playing with the audacity software and see if there is a function in there where you can add Tags to the phone; hopefully Tag 1 and Tag 2.
If there is, try adding separate tags (1 or 2) and also to both at the same time. Try sending to your phone again and keep track of which one works, and do the extra step after you make the tone, before you email to your phone.
After I make my tone(s), I open them in WinAmp, right click on them and there is a prompt that says View File Info. It is in ID3v1 and ID3v2 that you make the tags. All you have to do is check where it says include ID3v1 tag in file and in comments, I just put anything, usually just a period (.).
Mess with that and see if it helps at all...