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РусскийTool manufacturing is a complex and multi-faceted process, which begins with drawing up of an inquiry by the potential customer for manufacturing of necessary tooling. The more accurately the information is provided (drawing, terms of reference, mathematical model), the faster our professionals can form a proposal with the indication of the cost and terms of production, as well as the specific characters (if they are) which affect an execution of an order. In some cases, it is possible to provide options for the execution of tooling (operations in a die, mold cavities, material of working parts, material of products, etc.)
Professionals of engineering department design molds and dies based on terms of reference of a customer using modeling CAD-programs. Drawings and specifications are produced based on 3D model of a product and a tooling. Along with it, production engineers of die stamping plot and production shop of plastic products develop product on manufacturability and give to a designer recommendation on the development of tooling.
After the approval of design documents, the project is transferred to production engineers for the development of the tooling manufacturing technology, they write up the way of operations, material sheet for work pieces, the need for electrodes, burning, etc.
If the customer is satisfied with the offered terms and conditions, a contract for the design and manufacture of the tooling is concluded (or the manufacturing according to the customer's design documentation). After contract execution and getting an advance payment, designers proceed to create the project, which is subjected to necessary agreement with the customer, if necessary changes and adjustments are made, the part is processed and brought to foundry.
In the course of working of design documentation out, technological process of tooling manufacturing as well as technological programs of machining tool art are determined, the tool of the second-order is designed (special-purpose tool, devices, electrodes). Then design-technology documentation is transferred to the tool shop.
The next stage is a full cycle of tooling manufacturing (molds, dies) in the tool shop of the factory. The workshop consists of several production sites: Manufacturing of molds and dies is carried out at our production sites, which are provided with turning, drilling, grinding and milling, electro erosive, coordinate-grinding equipment of domestic and imported production.
Sites by field of work
- Department of machining of parts of molds and dies.
Machining is carried out with the use of turning, drilling, milling and other machines.
- The site of the coordinate boring.
The work on boring of base plates and field shapers is carried out.
- The site of CNC milling machines and coordinate grinding.
The elements of the electrodes of the shaping parts of the molds and dies are processed by processing programs and grinding of holes to the specified coordinates.
- The site of electro erosive machines.
Cutting with wire and processing of field shapers of the molds and dies by the method of burning graphite and copper electrodes.
- The site of specialized and optical grinding.
Grinding of profiles of field shapers and electrodes is carried out.
- The site of assembly of molds and dies.
All kinds of operations, related to finishing, assembling of molds and dies are carried.
Besides the operations listed above, at the plant there is necessary equipment for applying embossing to the shaping surfaces of mold elements, and also laser mark.
Field shapers of tooling are made both from domestic (40Х13, 4Х5МФС, 9ХС, У8А, У10А, ХВГ, Х12 and etc.), and imported steels (Bohler, SCHMOLZ+BICKENBACH AG).
There are also auxiliary services at the shop: repair, maintenance of equipment, tool sharpening.
After the manufacture, testing of tooling is carried with the participation of production engineer, who takes the project, measurement report is made, and the finished product is checked for compliance with the agreed drawings. If small deviations are found out, the tooling is reworked to get the final product. Representatives of the customer are invited to the tests, and in the case business trip is impossible, end products along with the measurement sheets are sent to the customer for approval, it is also possible to send the photo and video report (in agreement with the customer). After the approval of the end samples, the acceptance of tooling (mold, die) is carried, the documents, confirming the compliance of the produced product with the drawings and terms of references are signed. After that, the tooling is packed and loaded onto the customer’s transport (or is shipped by corporate carrier).