But how does one navigate the myriad options available and make the right die spring choices? Read on.

Die Spring Overview

What is a die spring? Simply put, it’s a spring that holds materials in place during manufacturing processes. Die springs are designed to perform under high compression force and apply a specific amount of pressure to compression points on the materials they hold in place. They are also designed to withstand extremely high and low temperatures.

Some common applications of die springs include metal stamping, custom machining, and plastic injection molding.

How to Choose the Right Die Springs

There are a variety of die spring options available, and selecting the right ones will depend on your use case. Some of the most important considerations for die spring selection are required functionality, material, shape, and end style.

Function: Mechanical vs. Nitrogen Die Springs

There are two main types of die springs: mechanical and nitrogen gas springs. Mechanical springs are helically coiled metal springs that work by storing and applying compressive force mechanically by expanding and contracting. Mechanical die springs are the traditional type of spring used in dies and are similar in appearance to springs used broadly in other applications.

Nitrogen gas die springs exert force using compressed nitrogen gas, which is contained in a cylinder and compressed by a piston. Such designs can produce greater force than standard mechanical die springs and are also engineered with more safety features.

When deciding between mechanical and nitrogen gas springs, it’s crucial to consider:

• Cost — Mechanical die springs will have a significantly lower upfront cost than nitrogen springs. But remember, with lower/higher cost often comes lower/higher quality.
• Longevity — Nitrogen gas springs will last much longer than mechanical springs, reducing the overall cost of the component over its lifetime
• Strength — Nitrogen die springs are capable of exerting more force than mechanical options, which means that you may need more mechanical springs to obtain the same result.
• Safety — Mechanical die springs are just springs; for extreme conditions or complex dies, nitrogen gas die springs are the only option that offers safety features.

Material

Some of the most common die spring materials include oil-tempered steel, steel alloys, chrome alloys, chrome silicon, and chrome vanadium. Chrome layers on alloys improve corrosion resistance. Chrome silicon and chrome vanadium are less common due to their increased cost, but they are much stronger than other die spring materials.

Mechanical die springs are typically coated or marked with colored vinyl that is color-coded to indicate the working load of the die springs. The working load required will correspond with the appropriate die material. Stronger materials such as chrome silicon are called for in applications requiring fewer stress points, greater accuracy, or high temperatures.

Shape: Rectangular vs. Round vs. Oval Wire

While the shape of mechanical die springs themselves is helical, there are three different wire shapes out of which die springs can be made: rectangular, round, and oval.

Rectangular wire die springs are compliant with ISO Standard 10243 and are available in inch and metric sizes. Rectangular wire produces more force than round or oval wire, and therefore, rectangular wire die springs are available with higher load capacity options. However, because the wire is rectangular, this results in the spring twisting as it moves, resulting in stress that can lead, eventually, to the failure of the spring.

Round wire die springs are commonly used in the US and are generally smaller in size and used for lighter compression applications. Round wire will withstand stress well but cannot produce the same force as rectangular wire springs of the same dimensions.

Oval wire die springs are standard in the US. Their design optimizes for the perfect compromise between the stress resistance of round wire and the load capacity of rectangular wire. Moeller Precision Tools now carries new and improved oval die springs, our R series, which include four load capacity options and are completely interchangeable with Raymond and other competing brands.

Ends: Closed vs. Open

Mechanical die springs can have either open or closed ends. Because mechanical springs are helical, their ends can terminate in one of two ways: with a complete helix, leaving an end of the spring coil unattached, or with an incomplete helix, attached to the previous helix and connecting the coil end back to the spring. Open ends result in an uneven surface unless they are grounded; depending on the application, this may or may not affect the performance of your die. Closed-ended die springs will have even end surfaces, but because the final helices are incomplete, the compression of the spring may be altered or reduced.

Get Top-Quality Die Springs From Moeller Precision Tool

Moeller Precision Tool carries an extensive variety of mechanical and nitrogen gas die springs to meet the needs of your application, including load options not carried by our competition. Learn more about our reliable, high-quality die springs, check out our die spring offerings, or contact us today.

The post The Science Behind Die Spring Selection: A Guide for Die Builders & Engineers appeared first on Moeller Precision Tool.

In this guide, we’ll explore the best practices for die maintenance, including tips, techniques, and strategies that will help you get the most out of your dies and keep your manufacturing operation running smoothly. 

What Makes a Well-Designed, High-Quality Die?

Whether you’re choosing a standard die or building a custom one, there are a few main attributes to look for in the die itself, as well as its associated tools. 

• Strong material — Tool steel and high-speed steel, including those made from powdered metallurgy techniques, are popular options.
• Consistent results — Dies should yield minimal variations per finished product.
• Tight tolerances — Tool inserts should have tight tolerances for precise results.
• Repeatable design — Die designs should be easy to duplicate and promise similar end products.

By keeping each of these factors in mind, you can achieve consistent end-product quality, low waste, and reduced material and labor costs. However, even the most well-designed dies require some maintenance every now and then to maintain good operating conditions. 

How to Determine If Die Maintenance Is Needed

Proper die maintenance not only extends the life of the die but also improves the quality of manufactured products and reduces downtime caused by unexpected breakdowns. Ideally, your shop should have a preventative maintenance schedule so that no large production problems arise. But at the very least, here are a few telltale signs of die or tool wear to look out for, as they indicate maintenance is past due.

• Loose fasteners and screws
• Missing or broken components
• Debris or galling buildup
• Poor or uneven clearances and tolerances
• Worn cutting edges 
• Chips and cracking
• Burrs
• Out-of-spec hole dimensions

4 Most Common Types of Die Maintenance

If you’ve noticed any of the above issues with your die or its components, it’s time for maintenance. Below are five common types of die maintenance that should fix whatever issue you encounter.

1. Cleaning

If your die is covered in debris, such as metal slivers or buildup of stamping lubricants, a simple cleaning may do the trick and restore it to its original operating condition. There are many ways to clean a die or stamping tool, including steam, chemical solvents, gasoline, brake cleaner, and more. Ask your press lube supplier or precision tool manufacturer about their recommendation for your specific product and situation.

2. Sharpening

After a number of cycles and a certain amount of time, cutting sections and punch edges can experience normal wear. Sharpening can help. To sharpen, when possible, the working faces of punches and buttons should be ground on a surface grinder, using the appropriate wheel with caution, so as not to introduce too much heat.  Custom die sections are often welded and reworked by hand, so they continue to cut smoothly. 

3. Shimming

To make sure your die system maintains proper timing, or to compensate for length lost from sharpening, you may consider adding shims to each die section. A few things to keep in mind while doing this: 

• Remove debris and burrs from shims prior to installation
• Place and space shims appropriately
• Use the correct number of shims to achieve the proper height
• Ensure adequate clearance for fasteners

4. Tool Replacement

If any of your die tools are past the point of repair or maintenance, it’s best to replace them. If you find that you’re consistently replacing tools due to poor performance or premature wear, consider contacting a reputable manufacturer who has a product specialist on call.

How to Reduce Die Maintenance Costs & Hassle

Die maintenance will always be an important practice for extending longevity and ensuring high-caliber performance. However, there are ways to reduce maintenance efforts, while also ensuring your die and its tools last a long time. 

• Purchase high-quality dies and components — As mentioned above, higher quality products often mean less maintenance and replacement is needed. 
• Partner with a trusted manufacturer — Often, the lowest-cost option is actually NOT the cheapest option in the long run. If you constantly need to repair or replace components, find a reputable manufacturer with great customer service can help.
• Use the right tools for the right applications —  You may need custom or specialty tools of various sizes, strengths, or materials. Your purchase will be well worth the investment.
• Know when to use advanced tooling — Specific applications (e.g. high temperature or high pressure) require more toughness, wear resistance, or compressive strength than standard components can handle.

Purchase Best-in-Class Die Components at Moeller Precision Tool

Invest in high-quality die components from Moeller Precision Tool. As a trusted partner for standard and special die components, we’re proud to deliver precise, tight-tolerance tools to customers all over the world. Explore our products and request a quote today.

The post The Ultimate Guide to Die Maintenance: Tips and Techniques for Extended Die Life appeared first on Moeller Precision Tool.

Moeller Precision Tool is a US-based manufacturing leader in the punch and die component space, with headquarters in Wixom, Michigan. The company recently expanded outside of the United States with facilities in Mexico, Canada, United Kingdom, and now Italy. It’s current list of manufacturing facilities are located in: 

• Wixom, Michigan
• Antioch, Tennessee
• Queretaro C.P., Mexico
• Ontario, Canada
• Rugby, UK
• Trezzo sull’adda (mi), Italy
  

“[Moeller Precision Tool’s] rich history of comprehensive punch and die solutions, in conjunction with future expansion, will offer enhanced services, exceptional quality, and uncompromising value to our European partners,” said Frank DuQuet, President of Moeller Precision Tool.

The company extends gratitude to its European partners and is excited about more expansion opportunities in the future.

About Moeller Precision Tool

In business since 1965, Moeller’s reputation and ability to produce the highest quality stamping and die components is a reflection of our diversification and time-tested drive for excellence. The company’s commitment to quality is obtained through employee involvement and continuous improvement. For more information, visit www.moellerpunch.com. 

The post Moeller Precision Tool Expands to Serve European Market appeared first on Moeller Precision Tool.

What Is a Punch Stripper?

A punch stripper is a part of a die assembly that holds a workpiece in place. It’s typically placed over a punch and attached to the retainer. However, each die assembly is designed differently.

A punch stripper’s function is to generate enough holding pressure to hold the workpiece in place while the punch retracts from it. There are two objectives here:

1. To create a clean, defined punch or shape in the workpiece.
2. To cleanly retract the punch from the workpiece after stamping.

To achieve these objectives, it’s critical to choose the type of punch stripper that suits your application best. We’ll help you understand and narrow down your choice below.

Mechanical vs. Urethane Punch Strippers: Which Is Best for Your Application?

There are two main types of punch strippers on the market: mechanical and urethane. Below we’ll describe each of them, along with their respective advantages and disadvantages.

Mechanical Punch Strippers: Pros & Cons

Mechanical punch strippers are an assembly of a tool steel body, a bronze stripper, and a mechanical die spring.

Pros

Mechanical strippers are known for their high strength and extended lifespan. Below is a closer look into their top benefits:

• High strength — Mechanical strippers offer stronger and more consistent stripping forces than urethane strippers, increasing strength and ensuring top performance even in advanced stamping applications.
• Long service life — Mechanical strippers offer longer service and punch life than their urethane counterparts, largely thanks to their pre-loaded springs. Mechanical strippers are also rebuildable, unlike urethane strippers.
• Load versatility — Mechanical strippers offer multiple spring options, which enables versatility with desired stripping force..
• Sustainability — Due to their material makeup and increased service life, mechanical strippers are a more sustainable and cost-effective stripping option in the long term.

Cons

The most common complaint about mechanical strippers is that they can cost more than other stripping solutions. However, their upfront cost does pay off for many customers in the long term, leaving them happy with their purchase.

Urethane Punch Strippers: Pros & Cons

Urethane punch strippers have rubber-like bodies with vertical tunnels. They generally look like this:

Pros

Urethane strippers are known for their simplicity and affordability. The most common benefits of using them are:

• Affordable — Urethane strippers are often cheaper than mechanical strippers.

Cons

Urethane strippers’ convenience and affordability come at a cost, however. Common customer complaints regarding urethane stripping solutions include:

• Short service life — Urethane strippers are highly perishable and require more regular replacement.
• Limited pressure — Urethane strippers have limited stripping pressure options and do not have as much load-bearing versatility.
• Higher damage risk — Urethane strippers can fall into the die and cause damage or breakage.
• Low sustainability & cost-effectiveness — Due to their urethane composition and frequent replacement requirements, urethane strippers aren’t as sustainable or cost-effective in the long term.

Moeller’s Industry-Leading Mechanical Stripper Solution: True Strip

In most cases, mechanical punch strippers are the best choice. Their improved strength and increased lifespan make them a powerful and cost-effective solution for various metal stamping applications, and Moeller has created the best of them all: True Strip.

True Strip is the industry’s strongest and most accurate off-the-shelf mechanical stripper. Built with pre-hardened steel and finished with black oxide for corrosion resistance, it’s built to perform and built to last — even in the most extreme applications. Our customers needed a better solution that made assembly, disassembly, and replacement easier, so we developed it.

Other key features and benefits of True Strip include:

• Dual gliding condition to guarantee stability
• No special tools required, unlike imitation products
• Pre-loaded spring that’s threaded to a positive stop
• Eliminates the need for custom stripper plates
• Special multi-hole True Strip designs available upon request

True Strip is an exclusive, patented product from Moeller. While other industry manufacturers have tried to replicate our design, none have successfully come close. Rival mechanical stripping solutions just don’t perform as well or outlast the True Strip.

Discover the Benefits of True Strip For Yourself

If you’re searching for a durable, high-quality mechanical stripper solution, look no further than Moeller’s True Strip. Get in touch with one of our representatives to learn more about its unique features and benefits.

The post Mechanical vs. Urethane Punch Strippers appeared first on Moeller Precision Tool.

What Is Quality Control for Precision Tooling?

Quality control (QC) is defined as a method of ensuring that a manufactured product complies with a particular quality standard or customer requirement. By testing a sample of the product against the standard or specification, manufacturers can guarantee top quality, repeatability, and satisfactory performance of products.

In a precision tooling environment, quality control helps to:

• Improve end product quality and performance
• Reduce tool wear and improve longevity
• Boost cost-effectiveness of tool room inventory

3 Quality Control Systems for Precision Tooling

A quality control system, also known as a quality management system (QMS), is a collection of specifications, standards, processes, and responsibilities that set the foundation for quality control efforts. There are various quality control systems out there, each established by an organization and with its own product, service, topic, or industry of interest.

Below are three common quality control systems used in the precision tooling industry.

1. ISO

ISO is short for International Standards Organization, which is an organization with a membership of over 160 national standards bodies. The organization brings experts in various industries together to develop consensus-based standards that support quality, consistency, and innovation across the globe.

There are ISO standards for many industries and issues — from environmental management to risk management, food safety, and more. In the precision tooling environment, ISO 9001:2015 is of the most importance.

ISO 9001: 2015 dictates specific requirements for quality management systems when an organization:

1. Needs to show its ability to consistently manufacture products that meet regulatory and customer requirements, and;
2. Wants to improve customer satisfaction through innovation and continuous improvement.

At Moeller Precision Tool, our headquarters in Wixom, Michigan, was the first domestic punch manufacturing facility to achieve ISO 9001:2015 certification. Our other locations are not ISO certified but follow the same procedures outlined in our HQ’s quality manual.

2. Six Sigma

Six Sigma (6σ) is another quality control system that imposes a number of tools and techniques for process improvement. It uses data and statistical analysis to identify causes of defects, minimize variability, and create strategies to improve quality in manufacturing and business processes.

There are five key principles of Six Sigma:

1. Focus on the customer
2. Use data to identify process defects or variations
3. Continuously improve to eliminate defects and variations
4. Include people from different teams and levels of management
5. Be flexible and thorough

The many tools and techniques provided by Six Sigma help businesses ensure these five principles are executed. From there, each business can earn a Six Sigma certification. Certification tiers are listed similarly to karate belts: white belt (lowest), yellow belt, green belt, black belt, and master black belt (highest).

3. Die Standards

There are various quality control systems that set forth standards specific to die assembly and metal stamping. One of the most common is NAAMS (North American Automotive Metric Standard) Global Standard Components for Assembly and Stamping.

NAAMS standards are produced and maintained by Chrysler, Ford, General Motors, and their suppliers. They define approved components and their specifications to ensure consistency among automotive parts and how they’re engineered. At Moeller Precision Tool, our standard die punches, buttons, and retainers conform to NAAMS.

Original equipment manufacturers (OEMs) also have approved vendor lists that direct whose die products a die builder is allowed to purchase. Any punch manufacturer on that list has been verified to meet the necessary standards set out by the OEM. If a punch manufacturer is not on the list, an OEM is not likely to purchase from them. This is the case for OEMs in many industries — not just automotive.

Pictured: Moeller Precision Tool’s team verifying parts coming off the machine.

Quality Control Processes for Precision Tooling

At Moeller Precision Tool, we hold our tooling up to incredibly tight tolerances of .0002”. In order to maintain those tolerances and adherence to required quality standards, we employ the following quality control processes and efforts.

Visual Product Inspection

Our production staff and quality control team visually inspects product samples for assembly errors and cosmetic defects. First piece inspection is a critical step in the manufacturing process. Moeller can offer inspection reports that articulate square root quantity, critical dimensions, and/or certificates of conformance for inspected products.

Equipment for Inspection

Our team uses a variety of tools to inspect and verify that products conform to customer prints. These tools need to be calibrated regularly (usually monthly or quarterly) in order to ensure reliable results during inspection.

• Calipers, micrometers, and other manual tools
• Optical comparators
• CMM inspection devices
• Opticline inspection devices
• Profile measurement systems

Environmental Control

We maintain strict environmental control over our manufacturing environment to ensure no external factors affect end results. This includes:

• Temperature control
• Cleanroom usage for high-risk procedures
• Regular equipment calibration and maintenance

Continuous Improvement Committee Meetings

We have a Continuous Improvement Committee that meets quarterly to review key performance metrics, discuss new technologies and capital equipment, and create new or update existing policies and procedures to ensure we provide the highest quality tooling and unparalleled service to our customers.

Automation and Programming

As part of our commitment to innovation, we use automated and programmed equipment to our advantage. Automated procedures eliminate risk and ensure repeatability, so they are put in action whenever possible. Along with the programs and processes used in manufacturing, Moeller has also implemented automation programs in our shipping department, on our CNC machines, and in our order entry departments for accuracy.

For Top-Quality Precision Tools, Trust Moeller.

At Moeller Precision Tool, we provide unsurpassed quality and innovation for the special tooling required in metal stamping, forming, piercing, and trimming industries. Our quality control processes apply to standard and custom detail tooling — providing cost-effective manufacturing and world-class performance from every part produced.

For more information on what parts we can manufacture for you, contact our team.

The post Quality Control Systems & Processes for Precision Tooling appeared first on Moeller Precision Tool.

If you’re new to metal stamping, you might be surprised by the number of everyday items made through the process. Here’s a look at some of them.

8 Everyday Products Made From Metal Stamping

Metal stamping has roots dating back to the 1800s, when it started to replace inconsistent and time-consuming manufacturing processes like die forging. Fast forward to today, and you’ll find metal-stamped products of all shapes and sizes everywhere — some of which you use on a daily basis.

*The metal-stamped products listed below are examples of components we manufacture every day at Moeller Precision Tool.

1. Washing Machines

Washing machines, along with other large household appliances known as “white goods,” are manufactured with metal-stamped parts. Inner and outer drum punches create stamped holes inside the washing machine’s drum. Fan blades and brackets are also stamped.

2. Alkaline Batteries

The next time you need to replace the batteries in your TV remote so you can binge your favorite Netflix series, you can thank metal stamping. Alkaline batteries (AAA, AA, C, D, etc.) consist of various metal-stamped components.

Compression tooling, such as core rods and core pins, are used on the chemicals inside the batteries. Battery cans and anode caps are also made from metal stamping.

3. Pegboard

Have you used a pegboard to organize or store something? It’s likely metal stamping tools were used to make it, even if it wasn’t a metal board. Punches can also be used to perforate other materials like high-density fiberboard (HDF), medium-density fiberboard (MDF), composites, and wood.

4. Food and Beverage Cans

If you enjoy ice-cold cans of Coca-Cola® or steamy pots of chicken noodle soup, you enjoy foods and beverages stored in cans made from — you guessed it — metal stamping.

Metal stamping and deep drawing help produce components like blanks for cups and cans. Metal stamping is also used to manufacture vending machine components.

5. HVAC Components

From fin die tooling to slitter blades, enhancement blocks, and more, metal stamping plays a huge role in the manufacture of HVAC components. These smaller components are part of the manufacturing process for larger HVAC devices like evaporators, condensers, heating coils, exchangers, and busbars.

6. Construction Brackets

Stamped metal parts are a big part of common wood frame construction. Truss plates, gang nail plates, joist hangers, and many other kinds of metal construction brackets and supports are made in metal stamping presses. We also have metal stamping to thank for beam connectors and metal wall studs.

Unless you work in construction, you probably don’t technically use these products every day, but you can still thank them for keeping your home’s structure sturdy!

7. Grills

Charcoal and gas grills, while having some stamped holes for venting and assembly purposes, are an example of what is called “draw forming.” The large rounded forms of the grill body are “drawn” from a flat steel strip in the stamping press, while the venting and assembly holes are stamped out at another operation in the same press.

8. Metal Shelving

If you experienced an empty toilet paper supply at a grocery store during the height of the COVID-19 pandemic, you got an undisturbed view of a shelf made from metal stamping. That’s right — the store shelves you pick your favorite cereals and snacks off of are punched and formed through this process.

Other Products Made From Metal Stamping

There are also some metal-stamped products that you probably don’t use every day but are equally as important to the innovation of society. Manufacturers around the globe regularly employ metal stamping practices to produce products for the following industries:

• Automotive
• Aerospace
• Fluid power (things like hydraulic and pneumatic valve components, mounting flanges)
• Medical/pharmaceutical (during the height of the pandemic, Ford made respirators and masks in their metal stamping plants)

High-Quality Metal Stamping Starts With High-Quality Precision Tools. Contact Moeller.

Whatever your metal-stamped product may be, you need the right tools to get the job done. For standard and special die components, you can trust our team at Moeller Precision Tool to deliver every time. For over 55 years, we’ve been a leading precision tool manufacturer on the cutting edge of the world’s most advanced manufacturing technologies.

For more information on how we can help you, contact our team.

The post Everyday Products You Probably Didn’t Know Were Metal Stamped appeared first on Moeller Precision Tool.

What Is Die Clearance?

Die clearance, typically expressed as a percentage per side, is the distance between a punch’s cutting edge and a die button’s cutting edge. It’s the amount of extra space that’s needed to provide the leverage to shear and break the stock material to create a hole. The percentage per side relates to the thickness of the workpiece material.

Why Is Calculating Die Clearance  Necessary?

Die clearance is an incredibly important specification to get right. That’s why our engineers at Moeller Precision Tool have put lots of time and effort into researching and testing how different clearance values affect different stamping applications.

Having the correct die clearance will help you:

• Get a cleaner, more accurate result and ensure the quality of the stamped part
• Reduce the possibility of galling and adhesive wear
• Extend the life of your precision tools

On the flipside, having an incorrect die clearance calculation could result in:

• Excessive burrs
• Out-of-tolerance holes
• Cracks and breaks in punches, buttons, and other precision tools
• Increased tonnage and punch force requirement

How Is Die Clearance Determined?

An industry rule of thumb is for die clearance to be about 10% of the punched material’s stock thickness. However, it’s important to know further research has proven that increasing that percentage up to 11-20% can greatly reduce the strain on punch tooling.

But it’s usually not as simple as that. Determining die clearance can be very confusing because you need to consider many variables — so many variables that even within the same die, there are often different clearance percentages for every hole in the stamped part! Below, we’ll list some of those variables and die clearance estimates.

Factors That Affect Die Clearance

These are the main factors determining how much die clearance is required for safe, consistent, high-quality stamping operations.

• Punch & workpiece material type
• Punch & workpiece material thickness
• Punch & workpiece material hardness
• Punched hole size & geometry and tolerancing
• Anticipated tool life

Example Die Clearance Values

After taking all of the factors listed above into consideration, you can then formulate an equation to determine the correct die clearance for your application. As an example, we’ve included a chart below with various materials and hardness characteristics, as well as their recommended die clearance values for general-purpose holes using non-ejector punches.

Get the Details Right. Choose Standard & Special Die Components From Moeller Precision Tool.

With technologically advanced equipment and a staff that’s fully committed to its customers, Moeller Precision Tool continues to lead the industry in high-quality precision tool manufacturing. When die clearance questions and issues arise, our team is eager and ready to cater a specific solution to your tooling needs.

To learn more about us and how we can help you, contact us online.

The post How to Determine Punch and Die Clearance appeared first on Moeller Precision Tool.

Why Is Precision Tool Material and Coating Selection Important?

All metals have unique properties related to toughness, wear resistance, compressive strength, and more. If you understand those properties well, you can use them to your advantage and create the most suitable tool for your application.

The right tool material and coating will help your tools last longer and perform better, which in turn can help you:

• Reduce production downtime
• Lower replacement tool costs
• Achieve higher-quality results

3 Common Precision Tool Materials

Precision tools can be made of hundreds of different materials. Most of them are not “better” or “worse” than any of the others — the right choice depends on what your particular application requires. As examples, here are three of the most common materials we work with at Moeller Precision Tool.

1. Carbon Tool Steel

Carbon tool steel is one of the most popular precision tool materials, mostly because it’s affordable and works great for low-speed stamping applications. It’s composed of 0.6-1.5% carbon and less than 0.5% manganese and silicon. It can reach hardness ratings up to 65 on the Hardness Rockwell C (HRC) scale.

Although carbon tool steel works great for low-speed stamping applications, it should be kept to that. It’s not a good material choice for higher-speed operations.

2. High-Speed Tool Steel (HSS)

High-speed tool steel is similar to carbon tool steel, except it’s modified to be more durable and perform better in stamping applications that standard carbon tool steel just can’t handle. Alloying elements like tungsten, chromium, and more are added to carbon tool steel for increased hardness (up to HRC 67), abrasion resistance, and durability.

Due to added elements, hardness, and durability, high-speed tool steel is often a bit more expensive than standard carbon tool steel. However, that extra cost is well worth it if your application requires it.

3. PM-Grade Steel

PM-grade (short for “powder metal grade”) steels are the most versatile of all material options listed here. Wrought tool steels are manufactured using ingot metallurgy. PM-Grade steel is made using particle metallurgy processing. This includes hot isostatic pressing (HIP), which compresses the materials at high temperatures and high pressures to forge. The end result is an improved microstructure that offers incredible wear resistance and toughness (or both), as well as improved tool life.

Although PM-grade steels are more expensive on the front end, they’re worth the investment if you need their strength and versatility.

M2 vs. PM-M4

As an example of how strong PM-grade materials are over standard ones, let’s take a quick look at the differences between M2 (the tried-and-true material for standard punching applications) and PM4 (its stronger alternative).

• M2 is a high-speed tool steel made of a tungsten-molybdenum blend. It has good abrasion resistance and can withstand high temperatures without softening.
• PM-M4 is a high-vanadium special-purpose high-speed tool steel. It’s the right choice if you need higher levels of durability, toughness, wear resistance, and impact resistance.

You can learn more about M2 material in our Inch and Metric catalogs, and you can learn more about PM-M4 material in our Advanced Stamping catalog.

4 Common Precision Tool Coatings

Often, the right tool material is just one aspect of improving tool life. If you want the greatest longevity and performance from your tools, you may want to apply a performance enhancement coating. While there are many good surface treatments to choose from, physical vapor deposition (PVD) coatings are typically the best suited for precision slip and press-fit punch components.

Below are four examples of common PVD tool coatings.

1. Titanium CarboNitride

Titanium CarboNitride (TiCN) is becoming incredibly popular due to its broad range of stamping applications. It’s great for piercing and forming carbon steel, stainless steel, nickel, and copper.

• Thickness: 2-4 μ
• Hardness: 3,000 HV
• Coefficient of friction: ~0.6
• Maximum service temperature: 400°C or 752°F

These characteristics give TiCN great wear resistance, excellent toughness in high-pressure conditions, and great lubricity.

2. Titanium Aluminum Nitride

Titanium aluminum nitride (TiAlN) offers improved wear resistance and heat resistance. Its specifications are as follows:

• Thickness: 3-6 μ
• Hardness: 3,400 HV
• Coefficient of friction: 0.3-0.35
• Maximum service temperature: 900°C or 1652°F

Because of these features, TiAlN has amazing wear resistance on cutting edges and is ideal for high-heat applications and high-stressed components. It can also be used with minimal lubrication.

3. Chromium Nitride

Chromium nitride (CRN) is the best tool coating choice when hard chrome is preferred, but you need something a little harder and with better coating adhesion. It has these features:

• Thickness: 2-5 μ
• Hardness: 2,000 HV
• Coefficient of friction: ~0.5
• Maximum service temperature: 700°C or 1,292°F

As a superior substitute to hard chrome, CRN is a great choice for forming low-strength steels and copper. It’s also resistant to corrosion and harsh chemicals.

4. Diamond-Like Carbon

Diamond-like carbon (DLC) is your go-to tool coating for applications that incur the most extreme wear and galling. It’s commonly used for aluminum applications and has the following specifications:

• Thickness: 1-3 μ
• Hardness: 2,500 HV
• Coefficient of friction: 0.1-0.2
• Maximum service temperature: 300°C or 572°F

As mentioned above, DLC is excellent for piercing and forming aluminum, as its resistance to abrasive wear and galling is unmatched. It also has an incredible coefficient of friction.

High-Performance Precision Tool Materials and Coatings at Moeller Precision Tool

At Moeller Precision Tool, we offer a wide variety of tool materials and coatings. Even if you need one we don’t have listed we can lead you to our coating partner, Oerlikon Balzers, that can help you.

To list a few, we offer all of the materials and coatings listed above, plus other coatings like:

• Titanium carbonitride
• Aluminum chromium nitride-based
• Oerlikon Balzers coatings
• DLC coatings

View our full list of coatings in our Performance Enhancement Coatings catalog, or check out our Performance Enhancement Coatings Selection Chart below.

For High-Quality Precision Tool Materials and Coatings, Choose Moeller.

If you need help finding the right tool material or coating for your application, contact Moeller Precision Tool. Our engineers are happy to guide you in the right direction or refer you to one of our industry partners that specializes in material and coating selection.

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What Is CNC Machining?

CNC (short for “computer numerical control”) machining is a manufacturing process where automated software controls and machine tools work together to remove material from a workpiece, resulting in a custom part. It’s a subtractive manufacturing method, which means material is removed from the workpiece. This is the main differentiator from other manufacturing methods like 3D printing (additive) and injection molding (formative). 

CNC machining can be done to many different materials, like metals (the most common), but also plastics, wood, and even glass. It’s an important process for our team at Moeller, as it’s how we manufacture our standard and custom die components.

What Is a CNC Machine?

A CNC machine is a programmable machine that can autonomously perform CNC machining tasks. In other words, it can cut or change a workpiece material based on the coded, programmed instructions entered into it without a manual operator.

6 Benefits of CNC Machining

CNC machining is a popular manufacturing method for a reason. It brings many advantages to plants and production floors across the globe. Some of the key benefits of CNC machining are:

• Automated processes — CNC machines complete jobs without a manual operator directly controlling them, streamlining processes and reducing labor costs.
• Quick & efficient production — CNC machines are faster than manual machines. Some manual machines that have undergone a CNC retrofit have been proven to produce parts 75-300% faster.
• Accurate & consistent results — For precise, repeatable results, there’s no better choice than CNC machining. Programmed code ensures parts are made accurately every time.
• Minimal material waste — Due to accurate and consistent results, the CNC machining process can significantly reduce material waste.
• Safe operations — Since CNC machines can function autonomously, operators can stand back and stay safe.
• Cost-effective solutions — With reduced labor needs and minimal product errors, CNC machining has proven itself to be one of the most cost-effective manufacturing methods available.

Overview of the CNC Machining Process

The CNC machining process can look a bit different each time, depending on which specific services and operations are needed for a particular application. However, most jobs follow the same four basic stages, which are listed and explained below. 

Stage 1: CAD Model Design

CAD (computer-aided design) is the process of using computer software to create, modify, analyze, or optimize a design. It replaced manual drafting. 

That said, this step of the CNC machining process involves a designer creating blueprints for a component using CAD. Since it’s a draft, they’ll include tolerances, which are acceptable ranges of dimensional variation that would still allow the part to function properly.

Stage 2: CAD File Conversion

During this stage, the designer converts the CAD file using CAM (computer-aided manufacturing) software. This extracts the part’s geometrical characteristics and generates G-code that will control the CNC machine to produce the part in the most efficient way possible.

Stage 3: CNC Machine Setup

From there, the CNC machine is set up for operation. This involves programming the machine with code created in the last stage, then inserting the workpiece material into the machine and attaching any special fixturing for part to part consistency.

Stage 4: CNC Machine Operation

Production starts! The code automates the CNC machine to remove or modify particular layers of workpiece material until the finished product is complete.

6 Common CNC Machining Operations

There are many specific operations that a CNC machine can perform to create a part. Here’s  a look at six of the most common, or standard: 

• Drilling: uses drill bits to create cylindrical holes in the workpiece material.
• Turning: uses single-point cutting tools to remove material from a rotating workpiece. 
• Milling: uses multi-point cutting tools to remove material from a workpiece.
• Jig grinding: specialty grinding process used to make precise holes, slots, pockets, and contours in a workpiece.
• Profile grinding: specialty grinding process used to achieve precise inside and outside diameters of cylindrical parts. 
• Wire EDM: short for “electrical discharge machining,” it uses a thin strand of wire and de-ionized water to conduct electricity and allow the wire to cut through the workpiece, using the heat from electrical sparks.

CNC Machining Services at Moeller Precision Tool

At Moeller Precision Tool, we’re familiar with all of the CNC machining processes and services listed above. Every day, we use advanced CNC machining techniques to produce standard and special die components for metal stamping applications. We also have a climate-controlled inspection department with CMM (coordinate measuring machine) equipment, SPC (statistical process control) equipment, and quality control certification experts.

We’re committed to being the most technologically advanced in the industry, offering modern capabilities that are proven to deliver high-quality results. Some of our main CNC machining capabilities include: 

• Wire EDM
• Multi-axis
• Hard turning
• Hard milling
• Turning
• Milling
• High-speed milling
• Jig grinding
• Profile grinding

Moeller is always looking for ways to expand and improve those capabilities to better serve our customers. If we don’t already have a solution for what you need, we’re happy to either figure one out or direct you to one of our partners that can service you better. 

For Quality, CNC-Machined Die Components, Contact Moeller Precision Tool.

Want to learn more about how our advanced CNC machining capabilities can benefit your metal stamping application? We’d love to talk. Contact our team online today.

The post CNC Machining 101: Services, Processes & Quality Control appeared first on Moeller Precision Tool.

7 Things to Look For in a Reputable Custom Die Component Manufacturer

Let’s start with some key traits to look for in a quality custom die component manufacturer. Here are seven important factors to consider, so you can narrow down the list to figure out which company will be the best partner for you.

1. They Have the Die Components You Need

This one’s pretty straightforward but arguably the most important factor in your decision. Can they make the die components you need? Have they created the same, or similar, parts before? Draw on their experience in the industry and learn what kind of fit they may be at the most basic level: product.

At Moeller Precision Tool, we’re a global manufacturer of standard and custom die components. Our specialties include die punches, buttons, springs, retainers, and intricate, complex, per-print details. We have many international partners that create other components (plates, guide pins, bushings, etc.) as well.

2. They Can Customize Die Components to Meet Your Non-Standard Specifications

Some die component manufacturers can only produce standard parts. While these options work for many applications, they won’t for new projects that require customized solutions. Find a supplier that has advanced machining capabilities and experience making non-standard, per-spec die components. That way, you always have that option when you need it.

After 50+ years in the industry, Moeller’s become a global leader in cutting-edge precision manufacturing techniques. We create some of the most precise, complex, custom tooling components in our shops every day. Some of our capabilities include:

• High-capacity CNC conventional/wire EDM
• CNC turning and milling
• CNC jig grinding
• Complex 3-7 axis precision grinding
• CMM equipment
• 3D laser scanning and part digitizing

3. They Make Product and Service Information Easy to Find

The tool and die world can be technical and difficult to navigate. A great custom die component manufacturer will provide ample resources for you to get all the information you need about their products and services. Whether that be through customer service professionals and sales experts, an informative website, or comprehensive product catalogs, the information should be there.

Moeller is committed to making our product and service information accessible so you feel comfortable and capable of finding the solutions you need. We have an extensive list of catalogs, a robust website with product information, and a blog with industry-related topics. Plus, our customers are always welcome to give us a call or shoot us an email with any questions.

4. They Use State-of-the-Art, Up-to-Date Systems, and Technology

For high-quality die building, you need high-quality die components. And for high-quality die components, you need technologically advanced machining equipment. Look for a manufacturer that has up-to-date systems so that the job is completed according to your high standards. You may even look at whether or not they’re certified by various industry standards organizations.

Moeller is committed to ongoing innovation. Our equipment is the most technologically advanced in the industry, and we’re continuously looking for better solutions to increase product quality and customer satisfaction. Our Wixom headquarters is also ISO 9001:2015 certified.

5. They Have a Few Patented Products and Services

This isn’t a need-to-have, but it’s definitely a nice-to-have. Some die component manufacturers have been in the industry long enough to notice inefficiencies in standard products and services. Then, they go on to develop their own solution that alleviates those inefficiencies. It’s a trait that shows thought leadership, innovation, and going the extra mile to provide solutions for industry-wide issues.

At Moeller, we’re passionate about being an industry leader for new, innovative products. We’ve created various patented solutions that have resulted in streamlined operations and significant cost savings for our customers. Some examples include:

• MPTCrib
• Moeller Exclusive Surface Treatments
• True-Fit Retainers
• True-Set Retainers
• True-Strip Mechanical Strippers
• DuraPunch Punches

6. They Communicate Clearly About Lead and Delivery Times

Lead times are an important factor in keeping your inventory stocked with what you need when you need it. Your manufacturer shouldn’t keep this information hidden, but rather provide clear expectations for what you can rely on.

Unfortunately, machining and supply chain processes aren’t foolproof. Things pop up, and delays can happen. Because of this, no manufacturer can promise fast lead times or 100% on-time delivery rates — but there are some that can offer you a higher level of customer service, so you’re always updated.

At Moeller, we strive to deliver that high level of service to every customer. Our lines of communication are always honest, clear, and considerate. Our hope is to provide certainty and clarity, even in uncertain and unpredictable times.

7. They Take Time to Build a Relationship With You

Customer service is one thing. Relationship building is another much better thing. Find a manufacturer you feel like you can build a relationship with, not just one you can purchase from. They should be open to emails, calls, and meetings to answer your questions, provide advice on parts, etc. They’re your go-to.

This is something we’ve prioritized at Moeller. We don’t want to be your supplier; we want to be your partner. For us, that means always welcoming questions, workshopping ideas, providing feedback, or helping with whatever tooling tasks you need. Our salesforce is eager to meet with you and cater our services to your needs.

How to Find a Custom Die Component Manufacturer You Can Trust

You can find custom die component manufacturers all over the world. But where exactly can you start your search to find one that works well for you? Here are some ideas:

• Trade shows — come see Moeller at FABTECH on November 8-10, 2022!
• Precision Metalforming Association — Moeller is a Gold member!
• References from colleagues, partners, and other industry experts
• Industry publications like Precision Manufacturing Journal, MetalForming Magazine, etc.

For Excellent Products & Even Better Service, Trust Moeller.

Innovation, service, quality. At Moeller Precision Tool, those are our main focuses. We’re always looking for ways to help our customers meet their goals — whether that means making improvements to our current products or developing new ones. It’s what makes us passionate about our jobs, and it’s what makes our customers happy to work with us.

If you need a standard or custom die component manufacturer that you can trust, you’re in the right place. Contact our team to learn more about how you can partner with us.

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