#Product Trends
MICO Generators from eldec
Full hardness and short processes for the tool and mold making industry
Tool and mold making professionals routinely face many challenges unique to their industry. In order to ensure the stability of the tools produced, very hard grades of steel are required, however, specialists must also be able to precisely shape this material for use in creating demanding components for things such as car body manufacturing. In other words, quality in the toolmaking process has an enormous impact on quality in automobile manufacturing. It is clear that under these conditions the final surface hardness of the tools is essential, and additional hardening of the cutting edges is usually necessary. The production planners at Werkzeugbau Laichingen, in Ulm, Germany, have been relying on technology from eldec: Their cutting edges are hardened by mobile and robust MICO generators. This flexible technology significantly decreases and simplifies the production process.
Experts often describe toolmaking as a link between development and production with a considerable impact on the industrial value added. This is why the industry is considered a trendsetter for the continued development of production technologies ¬and is always in search of new solutions to improve workflows and quality. Cutting-edge hardening is no exception. This process hardens the features of the tool that later have to bear the greatest load in the punching or embossing machine. The stability of the cutting edge is decisive in determining the length of the tool life.
Benefits of Induction Hardening
Toolmakers generally use edge-layer hardening where the outermost layer of the cutting edge is heated to about 800 or 900 degrees Celsius (1,472-1,652 degrees Fahrenheit), depending on the material. The "quenching", where the real transformation takes place, then happens by natural cooling in the ambient air. As a result, the surface of the edge is harder and more resilient to wear (toolmaking typically requires a hardness of between 54 and 56 HRC), while the core of the material retains its toughness. Various methods are available to achieve these results. Toolmakers primarily use either flame hardening, the very expensive laser hardening or, alternatively, induction hardening. Why is that? "For starters, all these methods have flexible applications. Even large, bulky components with complex geometries can be produced manually or automatically when using lasers", explains Stefan Tzschupke, Head of Business Development Generators at eldec. "However, induction hardening offers significant advantages in terms of processing quality and time, as well as safety and cost. Our technology is becoming increasingly important for a growing number of toolmakers." A quick look at the characteristics of the eldec procedure confirms this assessment. The cutting edge is heated by induction. This way, the tool reaches the required temperature much quicker, because the heat is delivered directly to the volume underneath the surface. With flame or laser hardening, only the surface itself is heated at first. eldec energy sources also make it possible to precisely control power, current, or temperature, enabling users to respond optimally to special requirements as well as the ambient conditions of the process. As a result, the hardening pattern is very uniform. "Another benefit is that the process generates no toxic or explosive gases that might contaminate the workplace", adds Tzschupke. "Finally, its good energy efficiency makes our technology much more environmentally friendly than flame hardening."
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