|
CUSTOM
METAL PRODUCTS
A DIVISION OF THE
ROCKFORD CO.
1827 BROADWAY' ROCKFORD, ILLINOIS 61104
| Date: |
May 28, 2003 |
| To: |
International Mold
Steel |
| Subject: |
DC-53 Bending and
Flattening Die |
| From: |
Customer Metal
Products Corp. |
Thank you for your help in improving
our tool life. We have been looking for a way to improve
tool life for our flattening and bending operation.
Our current dies made of D-2 showed
dramatic wear (which does not help accuracy) and usually
did not last more than 5,000 pieces. This caused us to
make lots of adjustments during the production runs and,
of course, frequent die replacements.
The process takes place on an 800 ton
knuckle joint press. The parts are front end suspension
brackets made of ¾" diameter SAE 1541 material. The
parts are flattened to ½" thickness and also
receive a 30 degree bend over a 1" length.
Your representative suggested that we
utilize DC-53 material for improved die life.
International Mold Steel sent us a sample piece of
material. We made the die in our tool room and the
toolmakers commented that 'this really machines
well". Your representative told us that it should
machine 30% to 40% better than other steels --- we agree
that it does.
We then had the part heat treated,
ground and polished. We tried the die and did not get
any improvement. We talked to your representative and
asked how the tool was heat treated. We soon discovered
that the heat treat instructions were not followed as
recommended. We reworked the die, sent it back for heat
treatment and this time made sure that the heat treat
instructions were properly followed.
Of course, everyone now was curious
and skeptical. The die was placed back into the press
and we processed 10,000 pieces (all good) before the die
failed.
With this result, we are replacing our
dies with DC-53 material. It costs 50¢ to 60¢ (cents) more per
pound, but it machines better and a $300.00 to $500.00
tool lasts twice as long and improves quality. We will
certainly explore the use of this material in other
applications.
Thank you for your firm's help.
Joseph P. Klinck, President |
