Machining and tooling

We specialise in dies for cold stamping: we design and make cutting, forming and combination dies of any complexity, and punches and die plates for small- and large-batch production. The largest die block we can machine is 1000×650 mm in the horizontal plane.

The blank material for cold-deformation dies must be hard, wear-resistant, strong and tough (to take shock loads) while not deforming plastically. All dies are made of DIN 1.2379 alloy steel, one of the best steels for cold dies, with a high chromium content. Chromium raises cutting properties and wear resistance and increases the strength of the steel, which matters especially for large punches and die plates. Compared with carbon steels, alloy tool steels have better hardenability, greater ductility when annealed, considerable strength when hardened and better cutting properties.

The lead time for tooling depends on how busy the plant is and starts from two weeks. The cost depends on the complexity of the item; we calculate it from the drawing.

Extrusion is a complex process in which a profile of a given cross-section is formed: aluminium is pressed through a die, where it takes the required shape. The die is the tool fitted to the press that sets the configuration of the profile.

We design and make tooling for extruding aluminium profiles of various configurations and shapes. The maximum die diameter is 400 mm and the lead time from approval of drawings is 2–3 weeks. The price depends considerably on the kind of profile, open or closed. Dies are divided by complexity into categories:

• category A: for profiles of standard cross-section;
• category B: for standard profiles and profiles of medium complexity; the wall of such a product is thinner than 1.5 mm;
• category C: for profiles of higher complexity; the wall thickness of the finished profile does not exceed 1 mm.

The following data are needed to design the tooling:

• the profile (drawing);
• the press force;
• the pitch diameter of the container liner;
• how the die set is mounted in the press;
• the dimensions of the supporting tools (inserts, bolsters);
• the dimensions of the die holder;
• press-dependent die dimensions to DIN 24540, including drilled holes, keyways and marking grooves.

We design and make rolling rolls and other tooling for cold roll-forming mills that make open and closed steel sections from section stock. Our production can make rolls up to 400 mm in diameter from DIN 1.2379 steel.

The price of a roll depends on the size and complexity of the item. The lead time for tooling depends on how busy the plant is and starts from two weeks.

Heat treatment is the classic way of improving the properties of metal. Its kinds are annealing, hardening, tempering and nitriding.

• Annealing: the main aim is a uniform structure of the steel and less ductility: the steel is heated to a set temperature, held, then cooled slowly. There is annealing of the first kind (the structure of the steel does not change; it includes recrystallisation, homogenisation and stress-relief annealing) and of the second kind (aimed at an equilibrium structure through phase transformations).
• Hardening: the aim is the most non-equilibrium structure of the alloy and an untypical level of properties; it can be with or without a polymorphic transformation.
• Tempering: reducing the internal stresses of the alloy after hardening with a polymorphic transformation.
• Nitriding: thermochemical treatment in which the metal surface is saturated with nitrogen in a special medium. The surface layer with dissolved nitrides gains higher corrosion resistance and very high microhardness: in microhardness nitriding is second only to boriding, and it exceeds carburising and carbonitriding.

Machining or heat treatment can be ordered separately, without the full cycle. For machining, send a drawing with tolerances, the material grade and the number of parts: the tolerances decide whether CNC machining alone is enough or grinding or electrical discharge machining (EDM) is needed as well. For heat treatment, give the steel grade, the dimensions and weight of the blank and the hardness required: the heat treatment schedule depends on them.