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PT Industry Background and Machining Challenges:
In the die casting mold manufacturing industry, hardened steel is widely used due to its excellent wear resistance and dimensional stability. Typical products include injection molds, hot chamber molds, and cold chamber molds. The general processing flow involves: rough machining of pre-hardened steel, heat treatment to achieve hardness levels of 45–65 HRC, followed by finish machining such as milling, drilling, and reaming.
Hardened steel presents a series of machining challenges. The high hardness of the material significantly increases tool wear, especially during high-speed milling. Surface finish requirements are strict, with Ra values often below 0.8 µm, necessitating precise tool geometry and stability. Additionally, the formation of long chips and vibration during cutting can lead to tool chipping, reduced productivity, and increased maintenance costs.
Technical Requirements for End Mills in This Industry:
When selecting end mills for die casting mold machining of hardened steel, the following key performance criteria are essential:
- High chip evacuation capability: Prevents chip recutting and improves tool life.
- Superior surface finish: Achieves fine tolerances and smooth surfaces with minimal tool wear.
- Low vibration: Ensures high stability during high-speed machining, reducing chatter and improving tool durability.
- High wear resistance: Essential for extended tool life in hardened materials.
- Effective chip control: Maintains consistent cutting conditions and reduces tool load.
- Thermal stability: Withstands high temperatures generated during cutting to prevent performance degradation.
- Impact resistance: Resists chipping and cracking in interrupted cutting or roughing operations.
SDF’s Product Solution:
SDF has developed a series of solid carbide end mills specifically for hardened steel machining in die casting mold applications. These tools are engineered to address the challenges described above through advanced design, coating technology, and material selection.
- Structural Design: Optimized flute geometry with variable helix and pitch to reduce vibration and improve chip formation.
- Coating Technology: Multi-layer nanocomposite coating system that enhances wear resistance and heat dissipation.
- Material Selection: High-performance carbide grades with fine grain structure for improved toughness and cutting edge retention.
Compared to other industry-leading tools, SDF end mills demonstrate superior performance in key parameters. The following table illustrates the comparison in terms of key performance indicators and tool life under identical cutting conditions:
| Performance Parameter | SDF End Mill | Competitor End Mill |
|---|---|---|
| Maximum Cutting Speed (m/min) | 400 | 350 |
| Surface Finish (Ra) | ≤ 0.4 µm | ≤ 0.6 µm |
| Chip Formation | Short, broken chips | Occasionally long chips |
| Vibration Level | Very low | Moderate |
| Tool Life (hours) | 120 | 90 |
| Edge Retention After 100 Hours | Excellent | Acceptable |
Typical Customer Application Case:
A European automotive die casting mold manufacturer was experiencing frequent tool breakage and poor surface finish when machining hardened H13 steel molds at high speeds. Their previous solution required tool change every 30 hours, which caused significant downtime and affected production efficiency.
The SDF technical team conducted a detailed analysis of the customer’s cutting parameters and machine setup. Based on the application, we recommended a custom variant of SDF solid carbide end mill with a 5-flute design and a high-precision corner radius for finish milling. After a series of on-site trials, the tool was integrated into the production line.
Following implementation, the customer observed a significant improvement in machining performance. The tool life was extended, and the surface finish met the required specifications consistently. The following table summarizes the performance improvements achieved with SDF end mills:
| Performance Metric | Before SDF | After SDF | Improvement |
|---|---|---|---|
| Tool Life (hours) | 30 | 80 | 167% increase |
| Cutting Speed (m/min) | 250 | 380 | 52% increase |
| Surface Finish (Ra) | 0.8 µm | 0.3 µm | 62.5% improvement |
| Tool Change Frequency | Every 30 hours | Every 80 hours | 70% reduction |
| Production Efficiency (parts/hour) | 20 | 30 | 50% increase |
| Defect Rate | 5% | 1.2% | 76% reduction |
Conclusion and Brand Value Summary:
SDF solid carbide end mills have demonstrated a strong technological advantage in the die casting mold industry. With our advanced flute design, nanocomposite coatings, and high-performance carbide materials, SDF tools deliver reliable performance in high-hardness applications, significantly improving productivity and reducing downtime.
As a Chinese-manufactured solution, SDF offers a high cost-performance ratio that is increasingly challenging to ignore. Our tools not only meet but often exceed the expectations previously reserved for international competitors, positioning SDF as a viable and competitive alternative in the global tool market.
Looking ahead, the trend in die casting mold machining is toward higher efficiency, better surface quality, and longer tool life. SDF is committed to innovation and close collaboration with customers to lead in this evolving market. By continuously improving our product design and application support, we are well-positioned to become a long-term partner in the precision machining of hardened steel for die casting molds.