MATERIALS AND MANUFACTURE OF FORGING DIES

MATERIAL OF DIE BLOCKS

The hot forging dies operates in under very severe conditions since the forging is characterized
by high interface pressure coupled with high temperatures therefore the tool and die materials are
selected and manufactured with the greatest care. The material used for making dies must be heat
resistant posses adequate strength of low wear rate and lend them well for machining by cutting
tool. A compromise between hardness and ductility must be struck since the dies are exposed to
thermal shock.
Die blocks used for the production of forging the dies are manufacture from high grade special
tool steel. These steels are made by the open hearth process either basic or acid or by electric
furnace. The ingots are worked under large forging pressure, varying from 30-40 MN capacity,
to achieve the utmost grain refinement and resistance to shock. After this, the die blocks are
normalized and usually heat treated in the final stage by quenching and tempered to the required
hardness. The double heat treatment insures a maximum resistant to wear.
Heat treatment of die blocks is carried out either before or after complete machining of dies. The
most common practice is to purchase the blocks as hardened and tempered forgings and to
machine the impressions into the forged blanks as received. Hardness of the die blocks vary from
269-477 BHN, the most common range being 341-375 BHN. At hardness higher than 302 BHN,
these steel are difficult to machine and machining is done only at sacrifice in cutting speed and
tool life.
DIE MANUFACTURE
Below, we discuss the various methods (conventional and latest) for cutting impressions in die
block.
MECHINAL MACHINING PROCSSES
They are the most commonly used methods for manufacturing die. The processes include
turning, machining on planner, milling and grinding. Turning is used for rough and finish
machining of rotary working surface, whereas for rectangular and square die blocks, these
operations are done on a planner. Grinding is mainly used for finishing the surfaces. The
impressions are cut in the die block by highly skilled men who used the milling machine
specifically designed for sinking dies. Cutters of various types are used in accordance with the
shape of each section of the impression.
In copy milling, the following variations in the process are available:
1. Manual copy milling, where the feed of the spindle controlled by the hand.

2. Semi automatic copy milling, where the feed in the longitudinal and lateral axes is
automated but the vertical movement is controlled manually.
3. Automatic copy milling, where the movement of the cutting tool is controlled automatically by
the movement of a sensor of the surface of a 3D pattern. This method can produce intricate
surfaces economically on both small n large dies.

DRAWING OF DIES
DIE MATERIAL
ROUGH CUTTING
FINISH CUTTING
POLISHING
ACCOMPLISHIED DIE