|
The manufacture of Tools and Dies
has become a more difficult task than ever before. The dies are
more intricate, larger and the production quantities more demanding
of the Toolmaker than ever before. Lead times for delivery have
been compressed to such an extent that welding has become an
integral part of the tool and die manufacturing process.
Imagine having a facility available
that will enable you to replace missing tool steel, regardless of
whether you have removed too much in machining, the tool has worn
or your client has modified his original requirement. Imagine
having a welder at your disposal that understands toolmaking and
all the constraints that face you every day. Imagine having a
welder that understands the metallurgy of tool steels and can give
you exactly what you want. Imagine having a welder that understands
‘just in time’ and the urgency of your particular
problem.
A H13 core for a gearbox extension
housing required modifications.
This required a weld deposit of 3mm over 50% of the die casting
area.
Click image to enlarge!
The oldest profession
in the world is Toolmaking. Cavemen revered the clan chief, the
medicine man and the toolmaker. Stone, such as flint was used and
excess material was removed until the required tool was made. If
too much was removed, the tool was set aside for some other use, (a
knife became a scraper) or it was thrown away. When the art of
joining things together was developed, (a technique used only by
mankind) toolmakers made tools with handles such as spears and
axes. In the 1950's, tools were made by nesting inserts into a
holder block. With the advent of the E.D.M. and Copy Mills, we have
gone back to the original method of making tools by removing excess
material. It’s just a little more difficult to throw away a modern
tool or die than a lump of flint! What it means is that your
biggest problem is a lack of material. To put it simply, we can
replace it.
The technology in toolmaking is
advancing very quickly. As new materials and techniques are
developed, we are researching new processes to enable us to service
your requirements.
These photographs shows a core
from a die. It molds a fine filter mesh for a dish washer. Base
material is Thyssen 2379 hardened to 60 HRC. The areas broken can
be measured against the metric rule showing 1mm graduations. The $2
coin is 20mm (3/4 inch) in diameter.
Click image to enlarge!
- We weld ferrous and non-ferrous materials.
Hardness ranging from 20 HRC to 62 HRC can be deposited if
required.
- We use the same method to replace steel that is
used to make the steel. This allows us to match the base metal
perfectly.
- The weld can be polished, etched, cased, or
machined in the same way as the base material.
- Razor sharp edges and sharp corners are
maintained. Thin sections can be welded.
- Nitrided dies can be welded if nitriding depth
conforms to the steel manufacturers recommendations.
- Steel can be welded at any stage of heat
treatment.
- The weld is visually melted into the base metal
and will not chip, peel or crack.
- In most cases, dies can be welded without
stripping ejectors, etc
- The process does not produce spatter. No masking
is required
- Water galleries don't present
problems.
- Down time is minimised. We understand the
problems caused by J.I.T. and our turnaround times are usually same
day.
- An on-site service is available on application,
usually for dies in excess of 5 tonnes. We have a 5 tonne crane and
have welded components up to 10 tonnes with the assistance of
mobile cranes.
- As tool rooms become more efficient in removing
metal, we have become more efficient in replacing it.
- Robotics enable us to control welding parameters
and real time welding conditions can be logged for Q.A.
- An assesment of wear factors (abrasion, impact,
corrosion or combinations of these factors) enables us to provide
the optimum surfacing material.
- We provide a daily pick up and delivery of dies
in the Melbourne Metro area.
- An obligation free assessment and quote can be
provided. (On-site if required.)
Back to the Top >>
|
