Technology is constantly evolving and so you should look into an alternative to the traditional coating options.
The fabrication of punches, forming instruments as well as dies and other tools is often described as a process that uses brute force. This allows a piece to be cut, pierced, shaped, or any other form. They are commonly referred to as "chipless" methods of machining. Today's tool/die buyers and tool/die machinists need to be more aware of the characteristics of the raw steel that forms the blank. They must be aware of the interplay between the whole system, including the design of the making raw materials for the tool, processing and heating and coating properties, the properties of the material that is machinable, cycle times requirements, allowed machine downtime, the process of heating and processing for tooling.
Punches and Dies: Coating Advantages
Based on the needs of your project, ACS can offer a variety of PVD coatings that add value and reduce the total cost of punches, dies, as well as the tools for forming. The combination of low friction coefficients and high film hardness gives the desired properties of:
reduced friction of sliding
increased abrasive wear resistance
reduced punch & die retraction forces
Increased surface hardness and toughness
Tablet punches increase pill tablet release
reduced galling, less wear on adhesive and material wear
Eliminating material reaction due to chemical inertness
Each of these upgrades have to be achieved while preserving the crucial dimensions and tolerances that punches dies, and other forming tools require when they are in use; thus, the utility of using PVD as an option to provide useful surfaces.
SPREAD YOUR LIFEESPAN OF DIIES PUNCHES, FORMING TOOLS
If coated with PVD thin-film coatings dies, punches, and the forming tools will last for a longer lifespan. The Platit Arc deposition systems provide full control over deposition temperatures between 160oC and 490oC. These temperatures are well suited for many of the water, oil, or air hardening steels such as S1, S7 A2 W1, D3, W2, O1 & O2, M1 and M2 T1, M4420SS and different alloys, and powdered metals which are employed in the manufacturing of die components and other forming tools, plus materials such as tungsten carbide.
PVD VS CVD COATING
PVD is preferable to CVD in coatings for punches, dies, and forming tools because of the lower temperatures that PVD employs during processing to protect the heat treated hardness and austenitizing temperatures of the forming tool substrate materials.
TIGHTER TOLERANCE
Since PVD can provide coating thicknesses that range from 1 to 5 um range (0.00004" between 0.00004" and 0.00020") Parts can be machined to a final dimensions prior to coating, permitting the resulting clearances required in close tolerance punch and die applications.
INCREASE WEAR RESISTANCE
The term "wear" is used to describe the impact of corrosion or abrasion on contact with other materials, tools, grit, and/or equipment. "Toughness" is defined as a tool or die or tool's resistance to cracking, breaking or chipping when used. Every material used in the making of a punch is unique in its properties for wear and durability. They are available in the following varieties:
Wear resistance is low, but High toughness
BALANCED wear resistance and toughness
HIGH wear resistance with LOW durability
The specific application for forming will determine which material to choose. Therefore, wear resistance will be impacted by the hardness of the tool, plus any additional coating applied.