At a glance
Four times longer between service interventions.
- approximately 200,000 parts with NC11LV working components
- punches and dies hardened to 65 HRC
- detailed analysis of a multi-stage tool
- approximately 800,000 parts after introducing cemented carbide
The challenge
Working components required service after approximately 200,000 parts.
The customer requested engineering support for a multi-stage die affected by rapid punch wear and chipping of die components.
The original NC11LV tool-steel components, hardened to 65 HRC, produced approximately 200,000 parts before requiring sharpening or replacement. The tool’s multi-stage operation required more than simply reproducing the worn parts.
Technical approach
Changing both the material and its integration into the tool.
Tool analysis
The construction and operating sequence of the multi-stage die were examined.
Material selection
Cemented carbide was selected for the most highly loaded components because of its greater wear resistance.
Design modification
New insert, punch and die seating arrangements were designed for the existing tool.
Manufacture and fitting
The new components were manufactured and fitted to the remaining die assembly.
Outcome
Service life increased from approximately 200,000 to 800,000 parts.
The cemented-carbide components operated for around four times longer before sharpening or replacement was required.
Relative to the earlier result, this represents an increase of approximately 300%. The project shows that effective tool modernisation may require root-cause analysis, a more suitable material and a design change in the most highly loaded components.
The figures relate to this specific project. Cutting-component life depends on tool design, processed material, operating conditions and maintenance.