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Hot - Work Tool Steel:
H13 Steel: This is the most commonly used material for our warm forging dies. H13 steel has excellent thermal fatigue resistance, which is crucial as the die experiences repeated heating and cooling cycles during the warm forging process. It can withstand high temperatures without significant deformation, ensuring the dimensional stability of the forged parts. Moreover, it has high toughness and wear resistance, allowing it to endure the impact and friction forces generated during forging, thus extending the die's service life.
SKD61 Steel: Similar to H13, SKD61 also offers good heat - resistance, toughness, and hardenability. It has a fine - grained structure, which contributes to better machinability and surface finish of the die.
Carbide Inserts: In some areas of the die that are subject to extremely high wear, such as the cavities for forming complex shapes or the areas in contact with hard - to - forge materials, carbide inserts may be used. Tungsten carbide inserts have extremely high hardness and wear resistance, which can significantly improve the die's performance and durability in these critical areas.
Design Phase:
Customer Requirement Analysis: Our engineering team first communicates closely with customers to understand their specific requirements for the hardware components, including the shape, size, tolerance, and mechanical properties.
CAD Modeling: Using advanced Computer - Aided Design (CAD) software, a detailed 3D model of the warm forging die is created. 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 and Optimization: Through simulation software, the forging process is simulated to predict potential problems such as metal cracking, uneven filling, or excessive stress concentration. Based on the simulation results, the die design is optimized to improve the forging quality and efficiency.
Material Preparation:
Cutting: The selected hot - work tool steel is cut to the appropriate size and shape according to the design requirements. 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 is used to relieve internal stresses and improve machinability. Quenching and tempering are carried out to achieve the desired hardness, toughness, and thermal fatigue resistance.
Machining:
CNC Machining: High - precision Computer Numerical Control (CNC) machining centers are used to perform various operations on the die, such as milling, turning, and drilling. This ensures the accurate shaping of the die 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.
Polishing:
After machining, the die surface is carefully polished to achieve a smooth finish. This not only improves the surface quality of the forged parts but also reduces friction during the forging process, making it easier for the metal to flow and the parts to be ejected.
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 allowed to leave the factory.
Fastener Manufacturing: In the production of nuts, bolts, and screws, the hardware polishing warm forging die can ensure the precise shaping of these fasteners, with excellent surface finish and high strength. The warm forging process can improve the material's grain structure, enhancing the mechanical properties of the fasteners.
Hardware Fittings: For manufacturing hardware fittings such as hinges, handles, and brackets, the die can produce parts with complex shapes and accurate dimensions. The polished surface of the die helps to create smooth - surfaced fittings that are aesthetically pleasing and functionally reliable.
Automotive Hardware: In the automotive industry, the die is used to produce various hardware components, such as engine parts, suspension components, and transmission parts. The high - precision and high - quality parts forged by our die can meet the strict requirements of the automotive industry in terms of performance and reliability.
Pre - heating: Before starting the 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.
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.
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.
Regular Inspection: Regularly inspect the die for signs of wear, cracking, or deformation. Check the critical areas such as the die cavity, edges, and corners. If any issues are detected, take appropriate measures immediately, such as repairing or replacing the damaged parts.
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.
Hot - Work Tool Steel:
H13 Steel: This is the most commonly used material for our warm forging dies. H13 steel has excellent thermal fatigue resistance, which is crucial as the die experiences repeated heating and cooling cycles during the warm forging process. It can withstand high temperatures without significant deformation, ensuring the dimensional stability of the forged parts. Moreover, it has high toughness and wear resistance, allowing it to endure the impact and friction forces generated during forging, thus extending the die's service life.
SKD61 Steel: Similar to H13, SKD61 also offers good heat - resistance, toughness, and hardenability. It has a fine - grained structure, which contributes to better machinability and surface finish of the die.
Carbide Inserts: In some areas of the die that are subject to extremely high wear, such as the cavities for forming complex shapes or the areas in contact with hard - to - forge materials, carbide inserts may be used. Tungsten carbide inserts have extremely high hardness and wear resistance, which can significantly improve the die's performance and durability in these critical areas.
Design Phase:
Customer Requirement Analysis: Our engineering team first communicates closely with customers to understand their specific requirements for the hardware components, including the shape, size, tolerance, and mechanical properties.
CAD Modeling: Using advanced Computer - Aided Design (CAD) software, a detailed 3D model of the warm forging die is created. 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 and Optimization: Through simulation software, the forging process is simulated to predict potential problems such as metal cracking, uneven filling, or excessive stress concentration. Based on the simulation results, the die design is optimized to improve the forging quality and efficiency.
Material Preparation:
Cutting: The selected hot - work tool steel is cut to the appropriate size and shape according to the design requirements. 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 is used to relieve internal stresses and improve machinability. Quenching and tempering are carried out to achieve the desired hardness, toughness, and thermal fatigue resistance.
Machining:
CNC Machining: High - precision Computer Numerical Control (CNC) machining centers are used to perform various operations on the die, such as milling, turning, and drilling. This ensures the accurate shaping of the die 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.
Polishing:
After machining, the die surface is carefully polished to achieve a smooth finish. This not only improves the surface quality of the forged parts but also reduces friction during the forging process, making it easier for the metal to flow and the parts to be ejected.
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 allowed to leave the factory.
Fastener Manufacturing: In the production of nuts, bolts, and screws, the hardware polishing warm forging die can ensure the precise shaping of these fasteners, with excellent surface finish and high strength. The warm forging process can improve the material's grain structure, enhancing the mechanical properties of the fasteners.
Hardware Fittings: For manufacturing hardware fittings such as hinges, handles, and brackets, the die can produce parts with complex shapes and accurate dimensions. The polished surface of the die helps to create smooth - surfaced fittings that are aesthetically pleasing and functionally reliable.
Automotive Hardware: In the automotive industry, the die is used to produce various hardware components, such as engine parts, suspension components, and transmission parts. The high - precision and high - quality parts forged by our die can meet the strict requirements of the automotive industry in terms of performance and reliability.
Pre - heating: Before starting the 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.
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.
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.
Regular Inspection: Regularly inspect the die for signs of wear, cracking, or deformation. Check the critical areas such as the die cavity, edges, and corners. If any issues are detected, take appropriate measures immediately, such as repairing or replacing the damaged parts.
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.
