Tool life is an important concept to understand when it comes to understanding how metal-forming tools and processes can impact the longevity of the tooling involved. Tool life estimation involves making predictions about how long a tool will last in a given process, taking into account factors such as metal forming processes, the wear of the tools, and other relevant data. With proper tool life estimation, manufacturers can easily identify potential problems or changes that may be needed to extend the life span of their tooling and ensure optimal performance.
But the exact life span of a forming tool is not something that can be determined by a numerical figure, as there are various factors that can influence how long it lasts and how much quantity it is able to draw out from a particular die. Factors such as the material used for the tool, the type of die being used, and other environmental factors all contribute to an unpredictable Die & Tool life span. Although it is impossible to accurately predict the lifespan of a forming tool, it is possible to extend its life by taking the necessary steps. Becoming familiar with key factors that decrease the longevity of forming tools can help you make informed decisions in order to maximize Die lifespan. The details of these factors are explained below.
It is important to keep in mind that when forming high-strength and/or thick materials, as well as abrasive materials such as aluminum, the expected tooling life will be significantly shorter than normal. This is due to the added wear and tear on the tooling that occurs when forming these types of materials.
As materials become tougher and harder to cut, the amount of force required to form them increases exponentially. This constant force and pressure lead to faster wear-and-tear of the dies and tools used, as well as higher side loads and top loads, which can ultimately cause cracking if not monitored properly.
The thickness of the metal is an important factor when considering tool life; heavier-gauge metals require more force to cut, shape, and form, resulting in a shorter lifespan for the tooling and equipment used in the process. This is why it is essential to consider all aspects of the material being used, including its thickness, when factoring in tool life and performance.
The life expectancy of a die is directly dependent on the level of accuracy with which it is pressed. Even if the die is made from the highest quality materials and crafted with extreme precision if it is put into a press that does not meet its exacting standards, its lifespan will be drastically reduced, leading to inefficiency and unnecessary costs incurred.
In order to ensure that a tool will last for a long time, it is important to consider several factors such as ram parallelism, the amount of vibration, frame rigidity, and press speed. All of these can have an impact on the life of a tool and if any of these factors are not maintained to a high standard then the life expectancy of the tool can be significantly reduced.
Properly calibrating and setting up the die is essential for extending its life expectancy. Its location, offloading amount, shut height accuracy, and other setup parameters all play a key role in the longevity of the die’s performance. If these are not set up correctly, it can significantly reduce its useful life and lead to costly repairs or replacements down the road.
Therefore, it is essential that the die must be securely clamped on the press machine with all necessary support below it. Additionally, the die must be positioned and leveled carefully to ensure that pressure is evenly distributed throughout the metal forming and cutting processes. Without proper pressure distribution, there is a risk of damage to the die.
The exact type, amount, and application of the stamping lubricant used are integral in controlling the longevity of a tool and ensuring its long-term performance. Without any lubricant or using an inadequate quality of lubricant can significantly increase the risk of friction and heat build-up, which in turn can result in premature tool steel failure, requiring more frequent resurfacing and sharpening.
Misapplication of lubricants can lead to disastrous metal Forming errors such as catastrophic splitting and cracking of the material. This can have serious repercussions on product quality and lead to costly rework and repairs, ultimately leading to financial losses. It is therefore important to ensure the proper use of lubricants in order to prevent such errors from occurring.
The techniques used to grind, polish, and clean the die have a huge impact on the longevity of the tooling. The proper method needs to be employed in order to maximize tooling life and minimize costs. Grinding, polishing, and cleaning should be done carefully and consistently with the utmost precision in order to make sure that the die is ready for use with maximum effectiveness.
It is paramount to properly maintain and polish your dies on a regular basis in order to ensure longevity and maximize output. Additionally, it is important to promptly replace any damaged components within the die in order to eliminate potential issues that could arise and affect other parts of the operation.
So, these are Some key factors that contribute to die wear & tear, and ultimately reduce the lifespan of a die tool. By understanding these factors, you can take steps to mitigate their effects and ensure that the die tool life is maximized. Finally, it is most important to take care of metal-forming tools in order to increase their lifespan. Proper maintenance and proper storage are key factors in ensuring that these tools last as long as possible. Regular inspections should also be done to ensure that any worn or damaged parts are repaired or replaced quickly and efficiently.
