Abstract: A forging die production method comprising a cutting step which employs, as a cutting tool, a ball end mill having a surface which has undergone a hardening treatment and in which a forging die material is cut under conditions where a length of tool extension L (mm), radius R (mm) of a cutting edge of the ball end mill, spindle speed A (rpm) and feed rate B (mm/min) satisfy (B/A)2×(L/(2×R))=0.01 to 0.05. A forging die is produced through the forging die production method. A forged article is produced through forging by use of the produced forging die.

Abstract: Honeycomb extrusion die apparatus include a die body including a first set of die pins circumscribed by a second set of die pins. At least a portion of the end face of die pins of the second set of die pins are positioned along a peripheral surface extending at an oblique angle with respect to the extrusion direction. A lateral width of the open end of a plurality of discharge slots defined by the second set of die pins is larger than a lateral width of the open end of a plurality of discharge slots defined by the first set of die pins. Methods of making a honeycomb extrusion die apparatus are also provided.

Abstract: A method is provided for making a composite part layup tool. A surface of a base is shaped and used as a tool to incrementally form a metal sheet. The formed metal sheet is friction plug welded to the shaped surface on the base to form a metal tool surface of the layup tool.

Abstract: A method of making an impression die comprises the steps of providing a substantially planar bendable bimetal plate (10) consisting of copper and steel bonded together, forming a relief pattern (14) in the surface of the copper for example by an etching process, forming the plate into a non-planar sleeve with the copper on the outside and joining the free edges of the sleeve together. Preferably the free edges of the sleeve (10) are joined together while the sleeve is mounted on a metal mandrel (15).

Abstract: A method is provided for welding a laminated metal sheet to a workpiece. The laminated metal sheet includes an outer metal sheet and an inner metal sheet bonded together by a polymer material that impedes the flow of weld current. A punch is applied against the outer metal sheet and driven through the laminated metal sheet to create a hole and also create an annular metallic burr that bridges across the polymer material layer between the outer metal sheet and the inner metal sheet. A weld electrode is positioned against the outer metal sheet at the punched hole and weld current is conducted through the first annular metallic burr to create an electric resistance weld between the laminated metal and the workpiece.

Abstract: A forging die tool set defines a cavity and includes a core rod in the cavity for shaping a void in a work piece. The core rod extends in a direction in which the work piece is introduced, compressed, and ejected from the cavity. The core rod includes an upper portion and a lower portion. The upper portion has a cross sectional shape that forms a certain shape in the work piece and a radially tapered section that tapers toward the lower portion of the core rod. The lower portion also has a cross sectional shape that forms a certain shape in the work piece, and the cross sectional shape of the upper portion differs from the cross sectional shape of the lower portion, the lower portion being a more wear resistant shape characterized by larger radii and the upper portion being a finishing shape with smaller radii for shaping the final form of the forged work piece.

Abstract: A cutting die is formed by scanning a laser beam along a path corresponding to a blade pattern, and introducing a selected powder to build up an integral blade of high grade, and hard-to-wear material on the relatively softer die body. The final blade shape is machined or produced by EDM or milling. Further hardening by heat treatment is optional. Other heat sources and cladding materials could be used.

Abstract: A terminal crimping apparatus includes an anvil for supporting a metal terminal including a base plate portion for placing an electric wire thereon and a pair of crimping piece portions extending upwardly respectively from opposite side edges of the base plate portion and a crimper which includes a press-deforming portion having a generally arch-shape formed of two arc-shaped surfaces which are opposed to the anvil. The anvil and the crimper cooperate to press the crimping piece portions for crimping the crimping piece portions to the electric wire placed on the metal terminal. The shape of the crimper satisfies a formula, Index a=c·cos ?, where c represents a length of the arc-shaped surface of the crimper, and ? represents an angle formed by a tangential line to the arc-shaped surface at a central portion of the crimper and a vertical line.

Abstract: A cutting insert kit, including a base part formed of a brittle and wear-resistant material, and a plurality of cutting insert blanks integrally formed with the base part, which are separable one by one from the base part via indications of fracture. Each insert blank includes a front end portion, a rear end portion, an upper side, an under side, and at least one cutting edge in the front end portion formed between a clearance surface and one of the upper and under sides. The base part is common to all cutting insert blanks and to which each cutting insert blank is united to the base part via an indication of fracture in the form of a weakened connection member between the base part and the rear end portion of the cutting insert blank.

Abstract: A molten residual layer formed on a surface 26 of an electric-discharge machined portion 12 of a metal molding member 1 is eliminated by using a tool 70 made by a wire discharge grinding method. According to the wire discharge grinding method, a minute tool which high in processing accuracy and high in hardness can be obtained. Since the molten residual layer formed on a surface 26 of the portion 12 due to the electric-discharge machining is eliminated by using the tool, the molten residual layer can be eliminated uniformly with high accuracy.

Abstract: A diamond disc manufacturing process includes the following steps. Firstly, a container is provided, and an adhesion layer is formed in the container. A hollow member having a plurality of meshes is covered on the adhesion layer. A plurality of diamond particles is implanted on the hollow member and embedded into the meshes of the hollow member, so that the diamond particles are adhered onto the adhesion layer. Then, a resin material is infused into the container, so that the diamond particles are bonded on the resin material. Finally, the resin material together with the diamond particles is released from the container, so as to obtain a diamond disc base with the diamond particles having uniform distribution and orientation.

Abstract: A stamping tool and a method of making a punch assembly and a die assembly of the stamping tool. At least one of the punch and die assemblies including a plurality of laser-cut steel plates having hardened edges suitable to withstand high pressures and impacts generated during stamping operations. The assembly further including an internal passage defined by holes formed in a number of plates of the plurality of laser-cut steel plates.

Abstract: The subject invention relates to a new method for manufacturing extrusion die tools that eliminates the step of hardening the steel after cutting the steel to form the desired extrusion die tool design. The new method involves the steps of cutting and finishing steel to form the desired extrusion die tool design, coating the die tool, or parts thereof, and hardening the coated die tool. The new method for manufacturing extrusion die tools reduces the time and the cost involved in their manufacture.

Abstract: A hot forming die that includes a first die and a second die. The first die has a first die structure that is formed of a tool steel. The first die structure has a first die surface and a plurality of first cooling apertures. The first die surface has a complex shape. The first cooling apertures are spaced apart from the die surface by a first predetermined distance. The second die has a second die surface. The first and second die surfaces cooperate to form a die cavity. Related methods for forming a hot forming die and for hot forming a workpiece are also provided.

Abstract: A ferrous metal tool is provided for the forming of light metal sheet workpieces at elevated temperatures, with the forming surface of the tool prepared to minimize friction and adhesion when engaged in deformation of the hot sheet metal. The forming surface of a steel tool is nitrocarburized to form a compound layer and diffusion layer on the surface. The compound layer initially comprises an outer gamma-phase material and an underlying epsilon phase material. Gamma-phase material is removed to expose underlying epsilon phase material, and low friction particles are embedded in the modified nitrocarburized compound layer of the forming tool.

Abstract: A method to manufacture a steel die having a Physical Vapor Deposition wear resistant coating on a profile surface and a steel die formed thereby is disclosed. The steel die is subjected to quenching and tempering to achieve a Rockwell hardness in the range of about 40-45 Rc and then subjected to machining to form a profile surface. The surface is then subjected to Physical Vapor Deposition of a wear resistant coating that may be multiple layers of CrN, AlCrN, TiCrN, TiN, TiCN or TiAlN, and preferably is alternating layers of TiN—TiCN—TiN. The coating is applied at a sufficient thickness to impart wear resistance to the steel die. The steel dies are useful in sheet metal stamping operations.

Abstract: The embodiment relates generally to a stamping or draw die used for forming a workpiece into a part or component using a first die shoe, a second die shoe and a punch wherein the punch draws the material into a cavity located in the second die shoe. The force is generated during the forming operation are often unbalanced which generates an uneven stress distribution on the component of the die assembly. By varying the position and angle of the guide surfaces located on the punch, first die shoe and second die shoe the stress can be distributed across a greater area of the respective die assembly component to reduce stress concentrations in a localized area and correspondingly reduce the potential for die failure.

Abstract: A method to manufacture a steel die having a Physical Vapor Deposition wear resistant coating on a profile surface and a steel die formed thereby is disclosed. The steel die is subjected to quenching and tempering to achieve a Rockwell hardness in the range of about 40-45 Rc and then subjected to machining to form a profile surface. The surface is then subjected to Physical Vapor Deposition of a wear resistant coating that may be multiple layers of CrN, AlCrN, TiCrN, TiN, TiCN or TiAlN, and preferably is alternating layers of TiN—TiCN—TiN. The coating is applied at a sufficient thickness to impart wear resistance to the steel die. The steel dies are useful in sheet metal stamping operations.

Abstract: A method is provided for cutting beaded fabric that includes a bead attached to cloth-like material. According to one embodiment, a continuous length of the beaded fabric is fed through a guide into a die-cutting press and is die-cut via a soft anvil die while the material is retained in the guide. A guide is also provided for retaining the beaded fabric during die-cutting operations. Pre-cut beaded fabric is also provided that is easily separated into tie-downs. A continuous cutting method is also provided for forming individual tie-downs from a combination of fabric and plastic material used to form a bead on the fabric. The continuous cutting method may include die-cutting beaded fabric, placing a mark on a bead of the beaded fabric, and severing the bead at the mark.

Abstract: A process for geometrical construction of a flash land is provided for a flash land that is to be provided in a die for forging of a turbomachine vane, in accordance with determined parameters, where the vane includes a blade. The process includes choosing at least three reference planes corresponding to a root, middle and tip of the blade. At least three reference sections of the blade in reference planes corresponding to the root, middle and tip of the blade are chosen in the reference planes. A length of the flash land and a shrinkage distance for the three reference sections are determined in the reference planes. Intermediate sections of the flash land and the corresponding flash gutter of the flash land from the reference sections are constructed by interpolation in the predetermined planes.

Abstract: An apparatus for maintaining alignment between precision ground plates includes a first plate including a main body portion having plurality of passages. The first plate also includes a first heating device mounted to heat the main body portion to a selected temperature. A second plate including a main body portion having a plurality of passages is positioned adjacent the first plate. The second plate includes a second heating device mounted to heat the main body portion to a selected temperature. A controller operatively connected to the first and second heating devices selectively establishes a desired temperature in each of the first and second plates to facilitate a desired alignment between the plurality of passages in the first plate and the plurality of passages in the second plate.

Abstract: A cemented carbide tool containing tungsten carbide, titanium carbide, niobium carbide, possibly TaC, cobalt, chromium and possibly nickel, iron, molybdenum is disclosed. The composition of the materials provides a lighter material than usual, combined with a good resistance to corrosion as well as high hardness and wear resistance. These properties are particularly interesting for the manufacture of punch tools for cold forming operations. Cold forming tools made with these materials will have much better performance, particularly more steady performance and much longer lifetime. A method of cold forming and drawing, particularly deep drawing and ironing process of aluminum and steel beverage can manufacturing, is also disclosed.

Abstract: Interference surfaces are constructed on inner transition surfaces between wings of a fastener having a spiral recess. A portion of the transition surface is tapered to provide the interference. A standard driver for a spiral recess will engage the interference surface to create a “stick fit” engagement. The punch is formed using a wire EDM operation to construct tapered surfaces within the die cavity of a hob. The hob is machined down to obtain the desired depth, which is measured up from a gage spot indicative of the sticking point.

Abstract: A modular/configurable rotary die and a rotary die cutter (4) incorporating the die for making a corrugated carton blank (2) are disclosed. The rotary die comprises a plurality of die components (6,7,8) each having at least one blade (43-48) thereon for at least one of scoring, creasing and cutting a corrugated sheet (13) to cooperatively form a corrugated carton blank. With reference to the three dimensions of a carton (1) to be erected from the corrugated carton blank, the die components include at least one length die component (6), at least one height die component (7) and at least one width die component (8). By replacing at least some of the die components with different sizes/types of die components different sizes/types of carton blanks can be produced without requiring the use of dedicated rotary dies for each size/type of carton blank.

Abstract: Tools with a thermo-mechanically modified working region and methods of forming such tools. The tool includes a working region containing steel altered by a thermo-mechanical process to contain modified carbide and/or alloy bands. In use, a surface of the working region contacts a workpiece when the tool is used to perform a metal-forming operation.

Abstract: A method of manufacturing a honeycomb structure-body molding die formed with material feed holes and slit recesses formed in a lattice pattern in communication with the material feed holes, respectively, for molding the material into a honeycomb shape is disclosed. The method comprises a preparing step, a feed-hole forming step and a slit-recess forming step. In the slit-recess forming step, grinding work is conducted using a disc-like thin-blade grinding stone to form non-communication slit recesses on the slit-processing surface each in a depth not to communicate with the material feed holes (in a non-communication grinding process). Then, the grinding work is further conducted to grind the non-communication slit recesses into the slit recesses until the slit recesses are brought into communication with the material feed holes (in a communication grinding process).

Abstract: A self-attaching fastener and panel assembly wherein the free open end of the tubular barrel portion is coined, collapsed axially, flattened and deformed radially inwardly and outwardly and axially against a panel surrounding the panel opening. The method of installation includes driving the free end of the tubular barrel portion against a substantially planar die surface, deforming an end portion radially, then collapsing an intermediate portion over the radially deformed end portion, flattening the end portion, substantially thickening the tubular barrel portion and forming an annular surface engaging and supporting the panel surrounding the opening. The die member includes an annular moat surrounding a central die post and a planar die surface extending generally perpendicular to the axis of the die button.

Abstract: A system and process for stamping parts having tolerances below 1000 nanometers. The inventive system and process is particularly suited for producing optoelectronic parts. The system includes a stamping press and one or a progression of stamping stations for supporting a punch and die. The stamping stations are designed to maintain substantial alignment of the punch and die with minimal moving components. The stamping station includes a shaft for rigidly guiding the punch to the die. The stamping press is capable of providing the punch with the necessary force to perform the stamping operations. The system includes an interface system for interfacing the force of the press with the punch, while simultaneously structurally decoupling the press from the punch. The system also includes a locating sub-plate, for locating the stamping station in alignment relative to each other, and means for in-line machine stock material before entry into the stamping stations.

Abstract: A press molding die capable of preventing a workpiece from moving is provided. The press molding die includes a punch for pressing a workpiece; a molding die having a molding surface on which the workpiece is placed and a concave portion which is formed on the molding surface and which has a shape corresponding to the punch; a pad for pressing a part of the workpiece placed on the molding surface and which is on the periphery of the concave portion; and a micro-rough layer which is formed by performing a particulate coating process on at least one of a portion of the pad, for pressing the workpiece, and a portion of the molding surface, corresponding to the portion of the pad. Preferably, the height of roughness of the micro-rough layer is 0.01 to 0.06 mm, and the particulate coating process is performed using a silicofluoric chrome plating solution.

Abstract: A diamond disc manufacturing process includes the following steps. Firstly, a container is provided, and an adhesion layer is formed in the container. A hollow member having a plurality of meshes is covered on the adhesion layer. A plurality of diamond particles is implanted on the hollow member and embedded into the meshes of the hollow member, so that the diamond particles are adhered onto the adhesion layer. Then, a resin material is infused into the container, so that the diamond particles are bonded on the resin material. Finally, the resin material together with the diamond particles is released from the container, so as to obtain a diamond disc base with the diamond particles having uniform distribution and orientation.

Abstract: To obtain a push-cutting blade 2, a flexible base 1 and a projection (trapezoid-section projection 21) protruding from this base are formed by etching. Then, a lateral surface or surfaces of the projection 21 is cut into a vertical projection 2b. Lastly, the tip of the vertical projection 2b is sharpened to give a double (or single) cutting edge 2a.

Abstract: It is an object to realize and establish new extrusion technology for manufacturing a light-metal hollow member (product) having excellent mechanical properties with constant stability and also efficiently manufacturing the product having a strength satisfying a required level at low cost, by using a hollow die such as a bridge die. The object is achieved by dividing and joining/welding a light-metal material with a hollow extrusion die and then extruding the light-metal material to form in a desired cross-sectional shape through a die opening, wherein the strain level applied to the light-metal material after the joining/welding is maintained at 1.8 or more and the extrusion is performed.

Abstract: The object of the invention is a hot-forming tool (1) having an upper die and a lower die (1a, 1b), the upper as well as the lower die (1a, 1b) each consisting of a base plate (2) having a forming cheek (3) fixed thereto and a core (4) which is also fixed to the base plate (2), and a duct system (5) for the guiding-through of a coolant being constructed between the core (4) and the backside of the forming cheek (3) facing the core (4). In this case, at least the forming cheeks (3) are constructed as cast parts. As a result of this manufacturing method relating to the forming cheeks (2) (3? translator), the manufacturing costs of the hot-forming tool (1) can be significantly lowered because a high-expenditure mechanical cutting machining of the forming cheeks is only still required in the area of the mounting surfaces (3a) as well as the mutually facing exterior sides (3b).

Abstract: A hot forming tool is heated with multiple electrical resistance cartridge heaters. The heaters are located in the body of the tool so as to maintain the entire forming surface within a predetermined temperature range. Numerical thermal and optimization analyses direct the placement of the heaters so that when each heating element is simultaneously powered on for an identical fraction of the time, an acceptable temperature distribution will be produced within the tool at the tool operating temperature.

Abstract: A cold or hot-forging heading die used in metalworking to form a “head” on the end of a metal rod is configured to provide two heading cavities formed in opposite ends of the carbide insert. The heading die of the invention comprises a hardened steel ring with a cylindrical carbide insert having a through bore with a first cavity machined concentrically with the bore in one end of the carbide insert. The die is then inverted and a second cavity formed in the opposite end of the insert. The second cavity can be identical to the first cavity or provide the shape for an alternate head configuration.

Abstract: A metal-forming die according to the present invention includes die blades with convoluted opposed side surfaces that correspond to variable-width features on the working surface of the die. The convoluted side surfaces and variable-width working surface features permit the impression left by one die blade to fill space taken from an impression made by a laterally adjacent die blade. Such a die permits formation of working surface shapes not possible with flat-sided die components. The die is manufactured in discrete longitudinally extending components, or blades. Dividing the working surface of the die into longitudinally extending portions, each carried by a die blade allows conventional machining processes to be employed in forming the working surface on each die blade. An additional machining process cuts complementary shapes on the sides of the die blades. The die blades and their corresponding working surfaces interfit, or nest together.

Abstract: Mold apparatus for molded wood strand three-dimensionally carved articles of manufacture using at least one hole punch comprised of a base and a funnel shaped hole-defining portion having a funnel angle of 20 degrees or greater to vertical for producing molded holes at angles of 20 degrees or greater to vertical, to facilitate insertion of items such as a T nut within the molded hole in an assembly-line like fashion.

Abstract: A steel rule cutting die is provided and includes a baseboard, and cutting knifes including an integral cross member having holes having a first diameter. The cutting knifes may be bent to form an enclosed cavity. Fasteners including a head and a shaft having second and third diameters, respectively, are provided, and are disposable within the hole in the cross member for connecting the cutting knife to the baseboard. Washers including a fourth outer diameter and a hole having a fifth diameter, are provided. The first diameter may be greater than the third diameter, the second diameter may be greater than the fifth diameter, and the fourth diameter may be greater than the first diameter, such that, when the washer is disposed under the fastener head, the washer prevents the head from entering the hole in the cross member, and facilitates translation of cavities parallel to the baseboard.

Abstract: A press die for molding a sipe blade is provided, including a pair of divided parts. A material for the sipe blade is interposed and pressed between the pair of divided parts to mold a sipe blade. Portions of the divided parts of the press die to which a load is applied by molding pressure in contact with the material to give a desired shape to the sipe blade have shapes corresponding to the desired shape of the sipe blade, and portions of the divided parts of the press die to which a load is not applied are provided with first relief parts which do not correspond to the desired shape of the sipe blade and do not substantially contact the molded sipe blade.

Abstract: A cover for a rotary die is centrifugally cast with multiple layers to substantially eliminate stress when the cover is cast in an arcuate shape for use in a die cutting system. A locking mechanism attached to ends of the cover is designed to be convenient to install on and remove from a cutting cylinder.

Abstract: A die and a method for forming a die to produce optically varying effects in a light reflective surface. A design generally formed as a plurality of parallel grooves of varying widths and depths are engraved in a soft metal foil adhered to a substrate. A hard metal coating is formed on the engraved soft metal foil in a metal plating bath. The hard metal coating, removed from the soft metal foil provides a die formed as a mirror image of the grooves engraved in the soft metal foil. The die is used to deform a reflective surface such that the surface produces optically varying effects. A die formed in the same manner with further processing is used to both deform a reflective surface and hot stamp it to a substrate.

Abstract: The screw has two or three non-circular super-imposed recesses. The depth of each recess is less than 1.2 mm and there is a less than 1° of draw in each recess. The screw head recess is formed using a punch (10) in a cold-heading process. The punch is formed in a profilating CNC machine, cutting the profiles (12,14,16) of the punch to a tolerance of better than ±0.025 mm. A method of manufacture of a cold-forming punch for such a screw comprises providing a profilating head as one of the tools on a turret mounted adjacent the chuck in the CNC machine. The profilating head has several cutting elements, each being adjustable with respect to one another: axially, radially and angularly.

Abstract: In order to produce precision optic elements using injection molded plastic, a metal mold is fabricated from two positive masters comprising exact metallic reproductions of the desired plastic part and on which a metal shell has been electroformed or otherwise plated. Two positive masters are required for each mold, one being formed to define the upper part of the mold and the other the lower part of the mold. Each positive master is scribed with an axial line and with a cutting line slightly offset from the axial line, the cutting line for the upper part of the mold being below the axial line and the cutting line for the lower part of the mold being above the axial cutting line. The positive masters are then cut along their cutting lines, the metal shells removed, and the portion of the remaining metal shells between their axial lines and their cutting lines is then trimmed. The upper and lower parts of the mold are then combined to define the complete injection mold.

Abstract: The life of ceramic SPF dies can be enhanced significantly by plasma spray application of a cordierite glaze on the forming surface. The preferred glaze has a coefficient of thermal expansion close to or matching with the ceramic of the die, and, typically, is a 2•2•5 MAS system including 2-10 mol % TiO2 (or above 8 wt %).

Abstract: A method for manufacturing a cutter mold for use on a cutting machine to cut articles includes the steps of: preparing a metal plate, coating a printing ink layer on the surface of the metal plate to form a printing ink area and a non-printing ink layer, drying the printing ink layer on the metal plate, submerging the metal plate in an etching agent to etch the non-printing ink layer to form a cutter with a tapered top end, and finally grinding the tapered top end of the cutter to form an edge to complete the cutter mold.

Abstract: An improved rotary die cutting apparatus and method for removing scrap material from work pieces such as paperboard blanks. One of the dies of a pair of rotary cutting dies is provided with gripper elements that extend over at least a portion of the area of the die corresponding to the areas over which the scrap portions are generated. The gripper elements grip, without piercing completely through, the scrap portions generated by the cutting operation of the dies. A stripping knife extends across the die carrying the scrap portions at a height above the gripper elements that provides clearance between the gripper elements and the stripping knife but contacts the scrap portions retained on the gripper elements.

Abstract: A tool and its finishing method of surface for center fin member of an air conditioning apparatus for a vehicle. The tool includes a plurality of fin blades each having a circular cutter shape and being provided at a periphery thereof with a plurality of cutting teeth and at a central portion thereof with a central hole. The fin blades are stacked on one another in such a fashion that the central holes are aligned together, and a pair of jig discs are arranged in a coaxial and integral fashion with the fin blades. The tool serves to form louvered center fins having a plurality of continued flat wall portions formed by bending a thin strip in a desired pitch in a zig-zag fashion, each of the flat wall portions having a plurality of louvers extending in perpendicular to the flat wall portion.

Abstract: A die cutting block for forming die cuts from paper and other materials includes a base portion having a recess formed therein having a desired shape formed therein, an insert portion having an outer contour which substantially matches the contour of the recess and a blade interposed between and tightly held between the base portion and the insert portion. The blade extends above the base portion and insert portion to provide an exposed edge for cutting paper and the like into a desired shape.

Abstract: The invention provides a ball-lock insert assembly adapted to be mounted axially in a mount opening formed in a holder plate having a desired thickness. The ball-lock insert assembly comprises an insert body having an axis and an elongated interior recess extending at an angle relative to this axis. The elongated interior recess is configured to house a resiliently-biased engagement member. The invention also provides retainer assemblies that include ball-lock assemblies, as well as methods of producing retainer assemblies, which methods include providing ball-lock assemblies.

Abstract: The life of ceramic SPF dies can be enhanced significantly by plasma spray application of a cordierite glaze on the forming surface. The preferred glaze has a coefficient of thermal expansion close to or matching with the ceramic of the die, and, typically, is a 2•2•5 MAS system including 2-10 mol % TiO2 (or above 8 wt %).