Question

how these Die-tools are traditionally manufactured.

6 types of Traditional manufacturing methods relevant to die manufacture e.g laser jet cutting, water jet cutting, milling, lathing etc? (should cover following information and no more than 300 words for each method) Your discussion in this section should include the following information regarding.

1. how method creates die/part and what materials can it use

2. what are the tolerances and finish of die/part

3. what are the material properties/strength of the final product

4. how long does it take to produce the desired die/part and approx cost.

5. Advantages and disadvantages.

Answer 1

How the Die - tools are traditionally manufactured?

1. Laser Jet Cutting Method :
   • Laser cutting is a very precision working. In this process laser beam is used to cut the material. In this Laser cutting, the final part/Die will be produced exactly as per drawing. All alloy steels, stainless steel, Die steels can be cut in this laser cutting process. Laser machined get operated through Computer aided design program.
   • Tolerances and Finish : Though this laser cutting the part/die can be manufactured within +/- 0.0005 inches. Surface Finish - Generally the surface roughness would be between 125 to 250 micro-inches.
   • Material Properties/Strength of finished Die/Parts: Due to heat generation, material tends to thermal affects, so that a HAZ will form around the holes. Thermal shocks may develop so that micro cracks may present in the part/die.
   • Time - Laser cutting does not take long time. Very fast, say in few hours the desired die/part can be produced.
   • Advantages & Disadvantages: Advantage is - High precision part can be produced within the given tolerances. Disadvantage is - Very expensive process, approximately $1 per minute.
2. Water Jet Cutting Machine:
   • When compared to Laser cutting, this water jet cutting process is not so precision. This process can be used for prototype works with low quality. Material like alloy steels, stainless steel, Die steels can be processed on the water jet cutting method.
   • Tolerance & Finish - Part/Die can be produced within +/-0.05 mm. Surface roughness will be 3.2 to 50 µm.
   • Material Properties/Strength of finished Die/Parts: Due to heat generation, material tends to thermal affects, so that a HAZ will form around the holes. Thermal shocks may develop so that micro cracks may present in the part/die
   • Time - Laser cutting does not take long time. Just it takes few hours to produce the part/die.
   • Advantages & Disadvantages: Advantage is less expensive than Laser Jet Processing. Disadvantage is - low quality when compared to Laser Jet Cutting process.
3. Milling :
   • This is not a finished process to compete the part/die. Just to produce bore or hole this milling process is useful. All the alloy steels, stainless steels, Die-steels can be processed.
   • Possible accuracy from CNC milling process is +/-0.005". Surface roughness will be between 0.8 to 6.3 µm
   • Material Properties: Grain Size and structure get impacted in milling process.
   • Time - It depends upon the size of the job. Generally it takes a few hours to complete the job.
   • Advantages: Very precise job work can be processed in milling. Economical. Disadvantage - NIL.
4. Lathing:
   • For some parts, this is finished process, for some parts this is semi-finished process. All the alloy steels, stainless steels, Die-steels can be processed.
   • Process accuracy will be 0.005". Surface roughness will be 0.4 to 6.3 µm.
   • Grain size and structure get impacted in the lathing process.
   • Time : Time will be depend upon the size of the job work to perform. Normally a few hours will take to complete the job.
   • Advantages and Disadvantages - High accuracy and precision jobs can be performed. This process is not much expensive, almost more or less to milling cost. Disadvantageous - NIL.