Die is a cavity in which the hot piece is placed in forging & by the application of force the hot metal is given the required shape. So the die is the exact shape of the original component.
Dies are of two types: -
1. Rough blocker: - Blocker is the die which has the larger dimensions so that more metal flow is incorporated in first blows. 2. Finisher: - Finisher is the die which has the exact dimensions
including tolerances used to give the product during forging whole of metal not flows in the cavity. Some of it comes out to counter it a hollow portion is incorporated around die & this portion is called gutter.
Die is the most important tool for closed die forging. Making a die as per design specifications is most essential work in automobile industry. Die manufacturing is a completely sequential process, due to this there is a separate die manufacturing section is provided in the factory.
Die making machines: -
The machines which are involved are as under: - 1. Lathe machine
2. Milling machine 3. Power hacksaw 4. Grinding machine 5. Drilling machine
6. Electric discharge machining (EDM) machine 7. CNC wire cut (for rimming dies)
8. Shaper
9. Electric arc welding set-up
Composition of the die materials used is as under:- 1. DIN 2713
Carbon – 0.55 Silicon – 0.30 Manganese – 0.66
Phosphorus & sulphur – 0.035 Chromium – 0.70 Molybdenum – 0.30 Nickel – 1.70 Vanadium – 0.10 2. DIN 2714 Carbon – 0.56 Silicon – 0.30
Phosphorus & sulphur – 0.035 Molybdenum – 0.50
Nickel – 1.72 Vanadium – 0.10
Die making procedures:-
• Block selection: - Here we have to select the size of the die block. For this we have to check the number of cavities. Approximately 20 mm of gutter is provided around a cavity of size 100 – 125 mm. next thing is to check the thickness of the block for general pieces 70 mm thickness & half the clearances.
• Block preparation: -
- Automatic hand raw cutters are used to cut the blocks. - Both sides are given reference
- Dove tail marking & machining is done. - No tool mark should be there.
- Impression marking & marking of other location is done by choosing one machined surface as datum surface.
• Primary machining: -
- Facing is done on lathe machine
- Impression turning is done on milling machine
- A hole is machined on both sides which are known as tong hole. Tong bars are put into these holes & die can be easily lifted.
- Then marking is done. Marking means drawing up the marks where machining is done. It is done with the help of height gauge & surface plate.
- The cavity can be made by either machining on a milling machine or by the help of an electrode on the EDM machine.
• Pressing & polishing: - By using a hand grinder the grinding is done. Also the tool marks are removed. Carbide cutter is used. Polishing is done with iron stone to have better surface finish & also easy withdrawal.
• Final inspection: -
- Dove-tail parallelity check - Dove-tail alignment check - Top surface level check - Dove-tail reference check
2). Shafts Power Take off Shafts Hollow Shafts Hydraulic Lift Shafts Live Power Take Off Shafts Drive Shafts Tie Rod Assembly
(i)Power Take off Shafts for Transmitting power from tractor to implements.
(ii)Hollow Shafts for transmitting power in the tractor and off highway
vehicles. Utility Applicable Automobile - Off Highway Agri Machinery
(iii)Hydraulic Lift Shafts for transmitting power to lift arms.
Utility Applicable Automobile - Off Highway - Agri Utility Applicable Automobile - Off Highway Agri Machinery
3). Spur and Helical Gears
Bull Gears Bull Pinion Shafts Gears for Gear Boxes
(i) Bull Gears for torque transmission in off highway and tractors.
Utility Applicable
Automobile - Off Highway
Agri Machinery
Bull Pinion Shafts
(ii) Bull Pinion Shafts for transmitting torque in off highway vehicles.
Utility Applicable
Automobile - Off Highway
Agri Machinery
(iii) Gears for Gear Boxes Utility Applicable Automobile - Off Highway - Agri Machinery
4). Epicyclic Reduction Gears
Ring Gears Spur Satellite Gears Flanges
(x) Ring Gears for Epicyclic Reduction in off highway
vehicles and tractors.
Utility Applicable
Automobile - Off Highway
Agri Machinery
Spur Satellite Gears
(ii) Spur Satellite Gears for Epicyclic Reduction.
Utility Applicable
Automobile - Off Highway
Agri Machinery
Flanges
(iii) Flanges for off highway transmission.
Utility Applicable Automobile - Off Highway Agri Machinery -
5). Hypoid and Bevel Gears
Crown Wheel & Pinion for Trucks
Crown Wheel & Pinion for Off Highway
Crown Wheel & Pinion for Cars and SUV
(i) Crown Wheel & Pinion for Trucks
Utility Applicable Automobile Off Highway - Agri Machinery -
(ii) Crown Wheel & Pinion for Off Highway
Utility Applicable
Automobile - Off Highway
Agri Machinery
(iii) Crown Wheel & Pinion for Cars and SUV
6).Right Angle Drive Gear Boxes
Right Angle Drives with 1 & 2 outputs in different gear ratio for various
agriculture and other implements.
Utility Applicable Automobile - Off Highway - Agri Machinery Utility Applicable Automobile Off Highway - Agri Machinery -
7). Propeller Shaft Assy & Components
Propeller Shaft Assy. Various components
(xi) Propeller Shaft Assy. Of various sizes suitable for
Cars, SUV’s, LCV and heavy trucks upto 20 tonnes.
Utility Applicable Automobile Off Highway - Agri Machinery Various components
(xii) Various components like U.J. Cross, Splined yokes
etc. Utility Applicable Automobile Off Highway - Agri Machinery
8). Steering Column Assy.
Steering Column Assemblies for LCV’s, HCV’s. Also available for various
tractors. Utility Applicable Automobile Off Highway - Agri Machinery