Customized Hot Forging Hexagonal Die

I. Product Overview

II. Product Materials

1. Hot - Work Tool Steel:

• H13 Steel: This is a popular choice for hot forging dies. H13 offers excellent thermal fatigue resistance, which is crucial as the die is exposed to repeated heating and cooling cycles during the hot forging process. It can withstand high temperatures without significant deformation, maintaining the die's shape and dimensional accuracy. Additionally, it has high toughness and wear resistance, enabling it to endure the high impact forces and friction associated with hot forging.

• SKD61 Steel: Similar to H13, SKD61 provides good heat - resistance, hardenability, and toughness. It has a fine - grained structure, which contributes to better machinability and a smoother surface finish on the die. This results in improved surface quality of the forged hexagonal parts.

2. Carbide Alloys: For areas of the die that experience extreme wear, such as the corners of the hexagonal cavity where the metal flow is more complex, carbide alloys may be used. Tungsten carbide, for example, has extremely high hardness and wear resistance. Inserting carbide in these critical areas can significantly extend the die's service life and improve the quality of the forged parts.

III. Product Processing Process

1. Design and Customization:

• Customer Consultation: We start by engaging in in - depth discussions with customers to understand their specific requirements for the hexagonal parts, including dimensions, tolerances, surface finish, and production volume.

• CAD Design: Using advanced Computer - Aided Design (CAD) software, our engineers create a detailed 3D model of the hot forging hexagonal die. The design takes into account factors such as the metal flow during forging, the ejection mechanism for the forged parts, and the necessary clearances to ensure smooth operation.

• Simulation: Through simulation software, we simulate the hot forging process to predict potential issues such as metal cracking, uneven filling, or excessive stress concentration. Based on the simulation results, we optimize the die design to improve the forging quality and efficiency.

2. Material Preparation:

• Cutting: The selected hot - work tool steel or carbide material is cut to the appropriate size and shape according to the design specifications. This may involve sawing, shearing, or other cutting methods.

• Heat Treatment: The cut material undergoes a series of heat treatment processes, including annealing, quenching, and tempering. Annealing relieves internal stresses and improves machinability. Quenching and tempering are carried out to achieve the desired hardness, toughness, and thermal fatigue resistance.

3. Machining:

• CNC Machining: High - precision Computer Numerical Control (CNC) machining centers are used to perform operations such as milling, turning, and drilling on the die. This ensures the accurate shaping of the hexagonal cavity and other features, with tight tolerances.

• EDM (Electrical Discharge Machining): For complex shapes or fine details that are difficult to achieve by conventional machining, EDM is employed. It uses electrical discharges to erode the material and create the required geometry.

4. Surface Treatment:

• Polishing: The die surface is carefully polished to achieve a smooth finish. This not only improves the surface quality of the forged hexagonal parts but also reduces friction during the forging process, facilitating the metal flow and part ejection.

• Coating: In some cases, a coating such as titanium nitride (TiN) or chromium nitride (CrN) may be applied to the die surface. These coatings enhance the wear resistance and release properties of the die, further improving its performance and longevity.

5. Quality Inspection:

• The completed die is thoroughly inspected using a variety of measuring instruments, such as coordinate measuring machines (CMMs) for dimensional accuracy, and hardness testers for hardness verification. Only dies that meet our strict quality standards are approved for delivery.

IV. Product Usage Scenarios

1. Fastener Industry: The customized hot forging hexagonal die is widely used in the production of hexagonal nuts and bolts. These fasteners are essential in various industries, including automotive, construction, and machinery. The die ensures the precise shaping of the hexagonal head, with high strength and excellent surface finish.

2. Aerospace and Defense: In the aerospace and defense sectors, hexagonal components are used in critical applications. Our hot forging die can produce high - quality hexagonal parts that meet the strict requirements for strength, precision, and reliability in these industries.

3. Power Generation: For power generation equipment, such as turbines and generators, hexagonal parts are often required. The die can be customized to produce these parts with the necessary dimensional accuracy and mechanical properties to ensure the efficient operation of the equipment.

V. Product Usage Precautions

1. Pre - heating: Before starting the hot forging process, the die must be pre - heated to an appropriate temperature. This helps to reduce thermal shock when the hot metal comes into contact with the die, preventing cracking and extending the die's service life. The pre - heating temperature should be determined according to the material of the die and the forging process requirements.

2. Lubrication: Use high - quality forging lubricants to reduce friction between the die and the metal. Proper lubrication not only improves the surface quality of the forged parts but also reduces wear on the die. The lubricant should be applied evenly on the die surface before each forging operation.

3. Operating Parameters: Adhere to the recommended operating parameters, such as the forging temperature, pressure, and speed. Exceeding the recommended parameters can cause premature wear or damage to the die, while operating below the parameters may result in incomplete forging or poor - quality parts.

4. Regular Inspection: Regularly inspect the die for signs of wear, cracking, or deformation. Check the critical areas such as the hexagonal cavity, edges, and corners. If any issues are detected, take appropriate measures immediately, such as repairing or replacing the damaged parts.

5. Cooling and Storage: After use, allow the die to cool gradually in a controlled manner. Avoid sudden cooling, which can cause thermal stress and damage to the die. When storing the die, keep it in a dry and clean environment to prevent corrosion.