Machine and Steel Supply | Mold Projects, Faster Sourcing, Better Coordination

This move can ensure H13 and other mold steels 24 hours within enter warehouse, reduce 15% communication cost, realize extreme speed purchasing and high efficiency coordination.

Mold Projects

Purchasing Speed

A set export Europe's car door panel mold weighs up to 12 tons, drawing on marked P20 forging requires 72 hours within cut milled finished transported into factory area. Consumer electronics factory left to whole set mold's development period early by hard live live pressed to 21 days.

Large steel material's purchasing time window fully hit fully calculate only has 48 hours. Purchaser skillfully cuts into supplier's inventory background, queries Sweden ASSAB 8407 special steel's local spot goods. A piece length width 600 millimeters, thickness 150 millimeters' 1.2343 electro-slag remelting steel, towards Europe original factory order goods wants fully wait on 4 weeks.

Pearl River Delta's large mold factory outside surrounded a whole circle special steel agents' warehouses. Night 8 o'clock confirmed well material list, warehouse inside's band saw machine through the night energized saw cuts steel plate. Steel material edge's saw cutting error strictly stuck at positive negative 2 millimeters within, second day early morning 6 o'clock, carrying 5 tons half-finished product's 12 meters flatbed big truck punctually stops at factory area gate mouth.

Factory inside white board on's purchasing countdown board written clear clear Chu Chu:

· LKM standard mold base: place order after 5th day transport arrive

· Yudo valve pin type hot runner: customized cycle 18 days

· Beryllium copper heat dissipation insert: send out 2 days within rough processing deliver goods

· Standard ejector sleeve ejector pin: spot goods warehouse 4 hours within load truck send away

Drawing on even if only change one root line, prepared well spot goods' parts immediately become scrap iron. Hot runner system's nozzle spacing on design drawing moved 0.5 millimeters, originally arranged well heating coils all must throw away re-wind wire. Purchaser flips out three cooperating processing factories' WeChat groups, fire speed takes deep hole drill processing work send out, water path hole diameter 8 millimeters, must drill to 450 millimeters deep.

Outsourcing processing takes originally line up do's work dismantled into quite a few strips respective running's processing lines. Factory inside own home's three-axis CNC machine tool exactly with 3000 revolutions' speed milling front mold core's appearance face, 20 kilometers outside's outsourcing factory exactly on boring machine hitting slider's slant guide pillar hole. Hole position coordinate tolerance requires 0.02 millimeters, delivery period dead dead stuck at 48 hours after.

Truck just unloaded carrying rough milling cutter marks' half-finished product steel block, inspector holding portable hardness tester just pressed on went. Facing surface hit five points take average value, instrument screen on jumped out's Rockwell hardness stopped at HRC 52. As long as hardness lower than drawing written's HRC 50 lower limit, whole piece value three ten-thousands bucks money's S136 stainless steel on spot pasted on red strip returned.

Main material once returned, delivery period will by pitiless towards back delayed whole whole one week. Mold late deliver one day, plastic outer shell factory that machine 1200 tons' Haitian injection machine just must stop machine empty run 24 hours, one day white white lose exceeds 2 ten-thousands yuan. Old purchaser forcedly requires material merchant send goods before send come spectrometer's material analysis bill, carbon element content must accurately pressed at 0.38% to 0.42% between.

Follow goods come over's inspection documents thick like a book:

· Steel material original factory material certificate attached heat number

· Ultrasonic internal flaw detection level two qualified bill

· 1020℃ vacuum quenching's temperature curve graph

· Three coordinate equipment hit out's outline dimension bill

One root diameter 4 millimeters' SKD61 ejector sleeve stuffed into mold core hole position time stuck lived. Purchaser midnight two o'clock from bed on climbs up dials through hardware city boss's phone. Early morning four o'clock, flash delivery little brother carrying three roots different tolerance grade's spare parts rushed into factory area security room.

Long-term reliable's supplier list all is rely on deep night rescue emergency and real gold white silver smashed out's. Factory inside's ERP background hangs hundreds hardware stores' annual accurate delivery rate report cards. All year round supply miniature guide pillars' A factory, 1500 sheets orders' on schedule delivery rate does to 98.5%. Provide rough processing cutter blades' B factory, material return rate all year round dead dead pressed at 0.2% below.

Desperately rob time's behind all is taking profit exchange progress. One set send to Mexico's smart phone double color mold, in order to catch up brand side's new product release conference, weighs up to 800 kilograms' metal mold whole plate gives up sea shipping. SF Airlines chartered flight's extra fast freight fee per kilogram 75 yuan, fly over Pacific Ocean's single trip logistics bill nearly six ten-thousands bucks money.

Micrometer Level Machine Processing

Weighs up to two tons' H13 special steel block by traveling crane hoisted onto Makino five-axis processing center's work table. Hydraulic fixture dead dead bites live steel block edge, spindle changes onto diameter 50 millimeters' flying cutter disc starts rough milling. Full sky splashing's metal chips temperature high reaches 600℃, cutting fluid with per minute 40 liters' flow rate sprays drops temperature. Originally flat's steel block surface in four hours within by milled away nearly 80 kilograms waste material.

Allowance left to 0.5 millimeters time, cutter library automatically changes onto fine processing cutter tools. Workshop top's air conditioner out wind mouth takes room temperature locked at 22℃ positive negative 1℃. Several tons heavy's machine tool base is use marble resin composite material casted's, factory building outside drives past one vehicle heavy load truck, machine tool spindle's tiny vibration also can by base absorbed away 95% above.

Appearance face's fine processing takes spindle rotate speed pulled to 30000 revolutions/minute. Diameter only has 2 millimeters' ball head tungsten steel milling cutter on steel material surface carries out high frequency cutting. Every time walk cutter's spacing set as 0.02 millimeters, cut down come's steel chips fine like powder. Continuously running 36 hours, car front headlight lamp shade's complex 3D curved surface by one cutter one cutter carved shapes.

Have some deep narrow's concave grooves, rotating's milling cutter fundamentally stretches not in go. Operator takes half-finished product steel block moved to Sodick slow walk wire line cutting machine on. One root diameter 0.15 millimeters' yellow copper wire threads into metal bottom's pre-drilled hole inside. Two ends apply high frequency pulse voltage, yellow copper wire distance steel block 0.01 millimeters time produces several thousands degrees high temperature electric arc, takes hardness HRC52's steel material live live melts.

Line cutting machine table inside soaking deionized pure water, flushes away melted's metal micro particles. One roll weight 5 kilograms' yellow copper wire can on machine on continuously discharge cut 70 hours. In order to prevent fine wire at discharge time produce tiny shake, water flow's spray pressure by constantly fixed at 15 kilograms. Processed out come's slider fit gap stuck at 0.005 millimeters within, two pieces steel inserted at together pull draw time even carries vacuum suction force.

Slow walk wire cuts not through blind holes, worker pushes come mirror face electric spark machine (EDM). Fitter first on beside's CNC on uses purple copper mills out a with target concave groove shape exactly identical's copper block. Purple copper installed on spark machine spindle on, immersed in special used's insulating spark oil inside towards down discharges. Copper block and steel block whole journey separated empty not touch, completely rely on electric spark takes steel material little by little etched shapes.

Below lists out these three kinds main force equipment's processing parameter indicators:

Discharge gap by controlled at harsh's 0.01 millimeters. Purple copper electrode loss rate beforehand written into processing program, hit a deep 20 millimeters' narrow groove needs rough, medium, fine three sizes descending's copper blocks take turns discharge. Just is process a mobile phone charger outer shell mold's four right angles clear angles, spark machine just wants continuously discharge etch 12 hours.

Machine do finished work, parts all by sent into constant temperature measuring room. Three coordinate measuring machine (CMM)'s ruby probe lightly touches steel block surface. Issues out "di"'s one sound, screen on instantly generates a spatial coordinate data. Probe with 0.1 micrometers' movement resolution on steel block on collects several hundreds points, automatically compares computer inside's original 3D drawing.

Data report on as long as has one dimension out of tolerance 0.01 millimeters, parts on spot returned redo. Those processing cutter tools left down's tiny connect cutter marks three coordinate feels not out come, entirely rely on possess ten-plus years working age's polishing master hand work process. Master wearing inch mirror, pinching dipped 3000 grit diamond grinding paste's bamboo stick, under strong light lamp facing 0.2 square millimeters' area lightly grinds.

Below is grinding polishing procedure's used materials and consume time list:

· 400 number red sandpaper: remove surface processing cutter marks, single piece consumes time 2 hours

· 800 number to 1500 number water sandpaper: horizontal vertical cross grinding, single piece consumes time 4 hours

· 3 micrometers diamond paste pairs wool felt: initial step polishes out mirror face reflection, single piece consumes time 3 hours

· 1 micrometer diamond paste pairs absorbent cotton: reaches SPI A1 grade high bright mirror face, single piece consumes time 5 hours

Scheduling & Working Procedure

Project manager knocks keyboard, takes a set car bumper mold's 3D drawing drags into MES software. Screen on's Gantt chart instantly pulls out 500 plus strips horizontal progress bars. This set mold by 320 independent metal parts assembled and becomes, leave factory delivery period by dead dead stuck at 25 days after.

Workshop wall on's 60 inches electronic signboard real time rolling every machine tool's load data. 15 machines CNC processing centers' scheduling table by dismantled to according to minutes calculate. Front mold core steel block needs on 3 number machine tool lies on whole whole 120 hours do rough milling, every day three shifts rotating's workers only at hand over shift time stop machine 15 minutes.

"Slider and slanted top must advance 3 days enter spark machine, ten million cannot with main mold core snatch equipment's processing time."

Working procedure flow turning just like building wooden blocks, if bottom's workpiece not do finished, top's parts all must on shelf on line up eat ash. In order to prevent parts at different working sections get lost, every piece cut well's metal blank on all use laser hit a 2D code.

Operator uses tablet computer scans a bit 2D code, screen immediately pops out this piece steel plate's "birth certificate" and follow-up journey:

· June 1st 08:00: bottom face grinding machine, thickness see light leave 0.5 millimeters allowance

· June 2nd 14:00: deep hole drilling machine, hit through 16 roots diameter 10 millimeters' cooling water paths

· June 4th 09:00: send out vacuum heat treatment, quenching add hard to HRC 50

· June 6th 10:00: five-axis CNC, curved surface fine processing punctually opens machine

Weighs up to 500 kilograms' steel block loaded onto truck, transported to 20 kilometers outside's professional heat treatment factory. Parts in 1020℃'s vacuum furnace inside whole whole baked 24 hours, again pass into high pressure nitrogen gas rapidly cooling. Steel block out furnace after deformation amount even if exceeds 0.5 millimeters, earlier stage's CNC processing fee all hit water skips.

Steel block at outside quenches, factory inside's electrode processing area one second all not idle. 40 purple copper electrode blocks exactly lying in high speed fine carving machine inside milling. Copper material soft, spindle rotate speed directly pulls to 24000 rev/min, copper chips like snow flakes same fly out come. These 40 electrodes want at steel block return factory before entirely measured finished dimension, error all pressed at ±0.01 millimeters within.

Parts complete set rate not reaches 95%, fitter assembly group uniformly refuses receive material onto table.

Drawing on miss one diameter 3 millimeters' positioning pin, several tons heavy's mold just closes not on seam. Material shelf on placed hundreds transparent tidy boxes, BOM table inside's parts every scan code enter warehouse one, system inside's progress bar just towards front walks 1%. Wait progress bar walks to 100%, 3 experiences old way's fitters just holding drawing start do work.

Slider in guide rail inside back and forth pull draw time if issues astringent, master just wants to pad on thickness only has 0.02 millimeters' yellow copper shim do fine tuning. 48 hours not interrupted's whole night close mold, assembly table on's red lead powder used away small half can. Traveling crane hoisting upper mold core up up down down fifty plus times, until close mold face's contact area reaches 90% above.

Water path test procedure arranged at try mold before's last 4 hours. Worker takes pressure pump connected on mold water throat on, towards inside hits into 10 kilograms pressure's anti-rust water. Keep pressure test continues 30 minutes, water pressure gauge on's pointer even 0.1's scale all cannot drop. Once internal waterproof rubber ring by cutting iron chips pierced broken leaks water, several thousands bucks' high temperature plastic raw materials all must scrap.

One vehicle 3 tons heavy's electric forklift takes assembled well's mold pushes into try mold area. Injection machine material barrel inside's ABS plastic particles already by heated to 240℃. Mold connects on water pipe and oil cylinder, accompanying one sound muffled's close mold huge ring, 120 megapascals' high pressure will melted's plastic injects cavity body. First mold hit out come's sample plate carrying remaining temperature drops on conveyor belt on, 25 days' day night scheduling exchanged came this piece real object.

Faster Sourcing

Purchasing Network

East China and South China areas built have 22 store large steel materials' warehouses. Warehouse inside's computer bills every pass 15 minutes will automatically refresh one time in out goods record. Screen on displays out specific's store position, Kunshan warehouse's C area shelf on placing 350 tons Baosteel leave factory's 1.2738 plastic mold steel. Dongguan warehouse inside has 120 tons Fushun Special Steel produced's Cr12MoV cold work mold steel.

Look for truck's work handed to a call car software to handle. Platform inside registered 4100 vehicles large flatbed big trucks. Departure place, receive goods factory's address input into system, radius 30 kilometers within idle truck's driver mobile phone will ring up come. Transport 15 tons heavy's S136 anti-rust mirror face mold steel, must dispatch one vehicle 13 meters long's semi-trailer big truck go pull. Driver snatch order's time almost is 45 seconds.

· 13 meters semi-trailer at most can pull 33 tons goods

· 9.6 meters high fence truck runs one trip transports 18 tons

· 4.2 meters small light truck responsible deliver 5 tons within's small pieces

· Specially made air cushion truck used to pull fear bump's precision machine parts

Leave factory before give steel plate do ultrasonic inspection's PDF report, sent to inspect goods personnel's mobile phone on. Thickness exceeds 200 millimeters' steel plate, must pass National Standard GB/T 2970-2016 stipulated's level two flaw detection test. Screen on drew out detection instrument swept past steel material internal's wave line graph.

Steel material inside has a diameter exceeds 3 millimeters' empty hole, computer system will light red lamp report police. Inspected qualified's steel plate will by big truck pulled into specially used to cut material's big factory building. 6 machines large CNC band saw machine tools receive to computer sent come's dimension drawing, start drop material cut. Machine cut's speed fixed at per minute 25 millimeters, saw blade used's is contain cobalt's high speed steel.

Cut broken a piece long 800 millimeters, wide 600 millimeters' P20 big steel block, machine must not stoply ring on 2.5 hours. Cut left down's edge corner material by strictly controlled at single side 5 millimeters inside. Cut down come's big iron block by forklift picked up, sent to CNC gantry milling machine's operation table on. Cutting cutter disc one minute turns 800 circles, every time enter cutter scrapes away 0.2 millimeters' iron skin.

· CNC band saw machine one day can cut 150 tons material

· Flame gun used to cut 300 millimeters above's big thick plates

· Water knife specially cuts encounter high temperature easily deform's alloy

· Plasma cutting machine used to process 20 millimeters' thin plates

Cutting fluid like water tap same, according to per minute 15 liters' water amount poured on steel block on, give friction produce 700 degrees high temperature's cutter tool drop temperature. Four faces milled flat flat neat neat, surface's roughness reaches Ra 3.2 micrometers' fine degree. Big small dimension's error by controlled at positive negative 0.1 millimeters' interval inside. Machine tool stops down come, worker towards half-finished product on pastes a sheet carrying bar code's paper.

Holding scan code gun di a bit, screen on jumps out come this piece steel's electronic household register book, inside writing steelmaking heat number, chemical composition table, hardness test value. Contain carbon amount 0.38%, contain chromium amount 5.0%'s H13 hot work mold steel, household register book on will use red words write on want at 520 degrees' furnace inside roast two times. A sheet written full 4 pages paper's processing record, follows this piece iron lump handed to next worker's hand inside.

· Spectrometer responsible check verify 16 kinds chemical elements

· Rockwell hardness tester used to on steel material surface press pit measure hardness

· Metallographic microscope takes metal particles enlarge see texture

· Three coordinate instrument uses probe check length width height dimensions have not have skewed

Loaded full Sweden ASSAB 8407 mold steel's big container ship, from Gothenburg port pull anchor set sail. Ship on sea on wants to float 35 days, ship on's satellite locator every interval 12 hours give land send one time located's sea area longitude latitude position. Long reaching 12 pages' customs declaration documents, advance 7 days use electronic file format sent to Shanghai Yangshan Port's customs.

Container arrived at dock, shore bridge big crane takes it lift up put to container truck's carriage bottom board on. Truck drives onto highway, run 120 kilometers roughly wants to spend 2.5 hours. Vehicle drives into machine processing workshop's unload goods area, one machine can hoist up 5 tons heavy object's traveling crane drives over come, takes surface smeared original factory anti-rust oil's steel material hoist up, steadily put at 3D shelf's B area 3 layer.

Beside stopping one machine build cost up to millions' CNC processing center, mechanical arm stops at mid air anytime prepare do work. Worker takes material block pushes onto work table, closes on protection door presses down green's start key. Tungsten steel material's milling cutter starts high speed rotate, opened a continuous 24 hours not stopping's milling grinding work job. Splash all around's iron chips fall into bottom's chip discharge machine inside, by auger slowly pushed towards outside's waste material box.

Warehouse corner inside piled 20 tons just transported arrive's Japan Daido NAK80 plastic mold steel, waiting next batch order's summon. Every month has exceeds 1500 tons' various types mold steel, through this strip line from four faces eight directions gather to here. Warehouse keeper hand inside holding tablet computer, one by one check verify shelf on's number tags. Shelf highest layer away from ground 8 meters, top on placing several pieces weighs up to 3 tons' forged round steel.

Every day morning 8 o'clock punctually has one vehicle red's express delivery truck stops at factory area big gate mouth. Truck on unloaded down come's is from Guangdong sent over come's 300 sets HASCO standard's mold ejector pins. Spare parts inspector takes out a handful micrometer, stuck on ejector pin's cylinder body on read take numerical value. Diameter tolerance exceeded 0.005 millimeters, whole batch 60 roots ejector pins will by original road returned to Dongguan's production factory.

Eliminate Communication Time Difference

Morning 9 o'clock, Germany customer sends come a copy 500 megabytes' mold drawing. Past business personnel wants to take file download save, transfer to engineering department, again copy send to purchasing department. One continuous string forwarding consumes whole whole two days. Now 3D file with .STEP format dragged into parsing software, 3 minutes within extract out all 218 parts' material list.

Customer at drawing corner remarked one sentence English "Need high wear resistance". Ordinary purchaser holding original words go ask steel material wholesaler buy what material, one come one return send emails wants to delay 48 hours. Technical personnel looked one eye 3D model, that is a inject contains 30% glass fiber's car bumper mold cavity.

Background called took past's processing parameter records. Targeting 30% glass fiber brought come's serious wear, purchasing list on automatically fills on "Sweden ASSAB Stavax ESR anti-acid corrosion mirror face steel". Remark column follows on a string parameters: hardness requires reach HRC 50-52, polishing grade wants to reach SPI A2 grade standard.

Give supplier sent over go's no longer is one sentence vague's asking words, but is a sheet filled full data's table. Steel factory salesperson opens computer, not need hit phone check verify any dimension details, following table just can give out per kilogram 85 bucks money's accurate quote.

Order contract inside's technical attachments fully have 15 pages thick, inside densely packed written full various items physical chemical indicators. Thick thick's attachments through encrypted channel sent to thousand miles outside's heat treatment workshop director hand inside.

Heat treatment's fire condition control extremely easily issues mistake. Drawing on specifies Cr12MoV cold work steel wants to undergo 1030 degrees quenching. Computer takes a strip raise temperature curve sent to vacuum furnace's control panel on. Furnace temperature with per minute 15 degrees' speed towards up climbs ascends, arrived 850 degrees automatically keep temperature 90 minutes.

Furnace inside's probe every interval 10 seconds collects one time temperature change situation. Numerical values become broken line graph, synchronously displayed at purchasing personnel mobile phone's APP inside. Sitting at office building inside drink tea's people, can see 500 kilometers outside's vacuum furnace inside, two tons heavy's mold steel exactly experiencing how many degrees' burn roasting.

· 3D model parsed out's 25 items geometric tolerance data

· Material composition table inside contained's 12 kinds rare alloy proportion

· Heat treatment craft bill required's 4 segments step style raise temperature time length

· Ultrasonic flaw detector recorded's 6 sheets internal defect cut face graphs

Before workshop master see not understand long string's foreign language drawing, takes surface roughness Ra 1.6 treated as Ra 3.2 go grind. Rework wants to extra consume two hundred work hours. Now's electronic drawing on, every one processing face all by marked on different colors. Blue color face represents leave out 0.5 millimeters allowance, red color face expresses want onto slow walk wire line cutting machine tool.

Steel material loaded onto big truck that one moment, weighbridge bill on's weight numbers "15430 kilograms" just passed into finance reconcile account library. Who also not need holding calculator, go multiply steel material's length width height and 7.85's density to estimate weight. Goods payment according to actual weigh heavy generated a sheet pay money application bill.

Every day afternoon 4 o'clock, software will take that day encounter dimension question's parts summarize into a sheet table. Table on has 5 parts' length width proportion exceeded conventional steel plate's rolling width.

Designer receives pop window prompt, clicks green's "agree" button. Big drawing by one divided into two, became two copies drop material detail bills, respectively sent to two machines CNC flame cutting machines. Cutting gun sprays out 2000 degrees' high temperature flame, along newly drawn well's track cut open 150 millimeters thick's steel plate.

Originally a scene want to wrangle three days three nights' change drawing storm, in few down mouse clicks middle quietly without sound ground calmed down. Night 8 o'clock, workshop operator from computer inside calls out milling program. Cutter tool library inside's D12R6 flying cutter already according to list installed to spindle on. Spindle with 8000 revolutions' speed cuts into metal block, splash out golden yellow color's iron chips.

Digitized Inventory

Factory building top's four high definition cameras face occupying land 5000 square meters' 3D warehouse. Every piece enter warehouse's special steel material surface pasting a sheet carrying chip's flexible anti-metal tag. Warehouse keeper hand inside holding handheld terminal walks past aisle, screen on jumps out 85 material codes. A piece thickness 350 millimeters' P20 pre-hardened steel placed at C area shelf's third layer.

Crane takes this piece weighs up to 4.2 tons' steel block moves onto CNC processing center. Computer inside's this piece material status from "in warehouse" became "processing in". Machine tool spindle according to per minute 1200 revolutions' speed cuts, iron chips hua-la-la ground drop into bottom's collect cart inside. Machine tool every consumes one millimeter's steel material, background account book on's weight follows towards down subtracts.

Traditional's inventory count lets three workers holding paper pen climb up climb down count three days. Mouse clicks a bit, few seconds calculate out warehouse inside left 2850 tons material.

Workshop's computer screen can see own home's warehouse, can stare live 600 kilometers outside's steel factory spot goods warehouse. Data interface every interval 5 minutes grabs takes one time Fushun Special Steel Wuxi warehouse's flow water bills. Page on displays there just entered warehouse 50 tons diameter 80 millimeters' Cr12MoV round steel. Purchaser uses mouse takes among 15 tons' quota scratched into own home's prepare material pool.

Buy material must wait material fast used light then go hit phone ask, often run into steel factory stop furnace check repair. System background now drew a strip safety warning line. NAK80 plastic mold steel's remaining amount drops to 12 tons' time, red color's alarm strip frame will on desktop on pop out come. Computer generates a sheet containing 25 specifications dimensions' replenish goods bill sends to supplier.

· 15 millimeters thickness's A3 carbon steel plate inventory remaining amount 280 sheets

· Shelf B area storing 6 sets scrapped wait for dismantle's old molds

· Temperature humidity sensor displays indoor relative humidity 68%

· Anti-rust oil smear record reminds has 15 pieces material need maintain

Steel material fears damp, surface polished to like mirror same's S136 anti-corrosion steel see water easily grow rust. Warehouse corner pillar on hung's temperature humidity meter connects alarm. Run into South's plum rain days, air humidity exceeds 70%, ceiling on's 4 machines big power industrial dehumidifiers pass electricity run. Condensation water follows white's PVC pipes flows into sewer.

A piece heavy 800 kilograms' H13 hot work mold steel in corner inside lay 180 days not moved ever. Computer takes it marked into yellow color's sluggish material. Schedule production software in next come's new orders inside, takes this piece old material arranges into cut drop material's program inside. Two ten-thousands plus bucks money's capital re-flows turns up come.

Machine cut down come's waste iron chips hang on digital account book on. Every day night weigh heavy settle account, 3 tons pure copper broken chips can exchange back fast 20 ten-thousands' cash money.

Forklift driver every day's driving route recorded in vehicle mounted's tablet computer inside. Receive order after screen on's 3D map draws out a strip green's navigation line. Guides him bypass exactly repairing's 2 number aisle, spend two minutes half clock drives to E area shelf front. He wants to accurately pick out that root length 2.5 meters, printed white leave factory heat number's tungsten steel rod material.

Warehouse's light follows walk. Forklift drives to which area, that area top on's LED factory mine lamp lights up. Night no people's time, whole 5000 square meters' warehouse only reserves aisle two heads' few lamps ground lamps. Electric meter's degrees one day save down come 150 plus degrees. One month calculate down come less pay big thousands bucks' electricity fee.

· Vehicle mounted tablet electricity amount lower than 20% remind return charge

· Scan code gun one day average scans 600 times material tags

· Electronic weighbridge induction error controlled at positive negative 0.5 kilograms

· Waste material recycle truck box bottom installed has wireless weigh heavy module

Morning checked out two pieces thickness out of tolerance 0.3 millimeters' mold plates. Quality inspector takes mobile phone shot photos passed to system inside, warehouse jumps out a red's return goods task. Afternoon 2 o'clock, heavy goods logistics' truck stops at platform edge. Driver takes out palm big's printer, hits out two sheets waybills pastes on packed well's wooden pallet on.

Better Coordination

Material Characteristics

Bought back a batch Sweden S136 stainless steel, quality check bill writing chromium occupies 13.6%. Workshop do work's master even stares tight heat number behind's impurity data. As long as sulfur element passed 0.03%, polished out come just will pop out a pile like needle eye same's white spots.

Factory inside processes P20 plastic mold steel, leave factory tag on writing hardness 30 to 32HRC. Same one piece steel plate, outer layer and inside's hardness difference can have 2HRC. Machine tool master do work before habit measures a measure deepest place has how hard, again go adjust machine's rotate speed.

Scrape to inside soft's place, machine rotate speed opens to per minute 1200 revolutions, cutter towards front pushes' speed fixed at 400 millimeters. Run into outside hard's skin, rotate speed must press to 800 revolutions below. Not drop down come, a handful 450 bucks' hard alloy milling cutter even 20 minutes all support not to just collapses mouth.

Steelmaking time towards inside adds a little little material, machine tool's setting just must all change:

· Carbon extra 0.05%, cutter cuts down go's resistance big 15%

· Adds 0.2%'s vanadium, cutter tool breaks fast one fold

· Molybdenum occupies to 1.5%, must change on resist heat's high aluminum coating cutter

· Nickel exceeds 1%, iron chips easily stick in cutter groove inside

· Sulfur high out 0.01%, cut out come's face not that smooth slippery

Like NAK80 this kind hardened steel, inside mixed 3%'s nickel and 1%'s copper. Pass electric spark machine tool time, surface will burn out a layer roughly 15 micrometers thick's white hard skin. Takes current fixed at 5 amperes, pulse width pinched at 45 microseconds.

White skin on all is naked eye see not see's small cracks, surface stretched tight tight, tension has 800 megapascals. Master takes 200 number's rough oil stone little by little rubs away it, at least do 3 hours. Make mold base loves use 718H steel, a piece moves not moves exceeds 5 tons. Dig away 30%'s iron chips after, steel block inside hidden's that strand strength just towards outside releases.

One root 2 meters long's steel material, two heads will towards up warp a 0.8 to 1.2 millimeters. Take this deform's fault treat well, must take cut one half's iron lump stuff into high temperature furnace. 600 degrees high temperature inside stew 4 hours, according to every hour drop 20 degrees' speed slowly cool down come. Furnace inside's temperature drops to 200 degrees take out come, put back machine tool fine carve fine sculpt.

Get steel material test's bill, workshop re-arranges do work's progress:

· Ultrasonic swept out has 2 millimeters' empty hole, whole piece material return goods

· Impurity measured out come arrived 1.5 grade, original fixed's mirror face polishing stop away

· Crystal grain rough fine reaches not 7 grade, burn red quench water crack open's probability has 10%

· Composition uneven reaches 2 grade, take drill bit hit hole's speed put slow 30%

Make die casting's mold very spends H13 hot work steel, inside's chromium roughly has 5%. Towards inside pour's aluminum water scalding very, temperature at 680 degrees to 720 degrees between. Mold inside every minute wants to ice fire two layers heaven ground toss one round. By rolling hot's aluminum water flushes 15000 times, H13 steel surface cracks open 0.2 millimeters deep's lines.

Buy steel material require factory inside use electro-slag remelting's technique re-smelt one pass. Impurities less, oxygen content even one million part of fifteen all not reach. Tossed out come's steel block, compared to ordinary furnace out come's tough strength big 40%. Made into's parts carry down 50000 times impact, originally half month repair one round, now support three months no matter.

Holding M333 plastic steel's bill look, carbon's proportion is 0.28%. Worker takes handheld measure light instrument towards not processed's steel block beside sweeps a bit. Screen immediately jumps out data, chromium's composition has 16%, take this steel go press has corrosive's PVC plastic exactly good.

One kilogram sells 120 bucks' ASP23 high speed steel hardness high, take come make stamping. Molten steel uses fog gas spraying cool down come, inside's hard dregs not reach 3 micrometers big. Placed on grinding machine on, installs 120 grit rough fine's special grinding wheel, cutter towards down one presses, every time only can cut away 0.005 millimeters.

Grinding wheel pastes on go turn, edge speed controlled at one second run 30 meters, ground out's place not will instantly scald pass 200 degrees. Cutter presses ruthless, one cutter cuts 0.02 millimeters, steel face pulls out 0.1 millimeters deep's net shape fine seams. Old master takes DC53 cold work steel throws into 520 degrees' high temperature furnace continuously burns two times.

Every time at furnace stew two hours, steel inside structure changed, hard bang bang's. Internal one change, whole piece steel swells roughly 0.05%. A originally 300 millimeters long's slider, burn finished take out come measure, hard live live grew 0.15 millimeters. Machine tool on cut time advance takes extra out's meat calculate well.

Use slow walk wire machine tool cut very thick's DC53 boards, thread 0.25 millimeters thick's yellow copper wire, put wire's speed adjust one second walk 8 meters. Flushing's water, resistivity stable at 50000 ohms, break wire's trouble not reach thousand part of one. Steel plate inside's strength not release finished, cut middle will deform, takes yellow copper wire stuck broken.

Machine dial one look, cut open's seam close together 0.03 millimeters. Hurry stop machine, take wood hammer along steel plate four circumferences knock one circle, let that strand strength scatter away. Cavity cut finished send polishing group, master towards up smears point carrying 3 micrometers particles' grinding paste.

Thumb tops a piece small wool felt, uses out almost 2 kilograms strength, on top draws "8" character. Not stop hand rubs 40 minutes, surface touches up like mirror, roughness even Ra0.05 all not reach. Stamp 0.8 millimeters thick stainless steel plate, take VIKING steel surface plates layer thin titanium, thickness only 4 micrometers.

A layer thin film covers on go, surface hardness soars to 2500HV, cutter mouth durable degree flips three times. Change PD613 this kind material, dry rub time friction force compared to ordinary's less 15%. Workshop takes it cuts into 50 millimeters times 50 millimeters square block serves as guide pillar, left's gap only 0.015 millimeters. Up down run 5 ten-thousands trips, surface touches hot 20 degrees.

Allowance Control

A piece 500 times 500 times 80 millimeters' S136 pre-hardened plate send into vacuum furnace before, master takes caliper measured a bit thickness. Drawing requires thickness is 80 millimeters, now blank actual measure is 81.2 millimeters. Single side leave out 0.6 millimeters' meat, specially deals with 1030 degrees high temperature quenching time's deformation.

Steel block burns red hot again rapidly cool down come, internal's austenite transforms into martensite, volume will swell big. Almost every 100 millimeters' length, just will towards outside stretch long 0.08 to 0.1 millimeters. Milling machine does rough work pasting drawing dimensions cut, out furnace after parts dimensions just out of bounds stuff not into frame inside.

Make one root long 300 millimeters, diameter 6 millimeters' ejector pin, choose use SKD61 hot work steel. Length diameter ratio reaches 50 to 1, quenching time absolutely will bend into a bow. Lathe turns outer circle time, diameter must leave out 0.4 millimeters' thick skin guard against it bend.

Burn finished take dial indicator one hit, middle position bent 0.15 millimeters. Take it framed on straightener machine on press flat, again send to centerless grinder on walk three cutters. Relying on that 0.4 millimeters' allowance, exactly takes bend deform's part grind flat, final dimension bites dead at 5.995 millimeters.

Electric spark machine tool hits spark discharge, rough hit and fine hit left's gaps completely not same. Rough male purple copper electrode compared to actual dimension single side small 0.2 millimeters, current opens to 8 amperes towards down burns. Spark gap big, burn finished surface like rough sandpaper, leave out 0.05 millimeters give fine hit.

Change on fine hit's purple copper electrode, current drops to 1.5 amperes. Slow fire endured 4 hours, takes that 0.05 millimeters' pockmark skin peel away. Master still wants to dig out 0.01 millimeters' meat, give later procedure polishing go grind that layer see not see's white bright layer.

CNC milling machine digs a deep 50 millimeters' square pit, cutter walks to bottom cannot one cutter cut flat. Bottom face Z axis habit leaves 0.15 millimeters' meat, side face XY axis leaves 0.2 millimeters. Turn corner's place, diameter 10 millimeters' flying cutter cuts past, leaves down radius 5 millimeters' circular arc meat lump.

Change on diameter 4 millimeters' flat bottom cutter go clear angle. Rotate speed pulls to per minute 4000 revolutions, every time only eats 0.05 millimeters deep's iron chips. Side face that 0.2 millimeters' allowance, must use fine milling cutter divide four times pasting edge walk, walk one circle measure one time.

Line cutting cuts a piece thick 40 millimeters' Cr12MoV mold plate, one cutter cuts accurate manage not to. First cutter rough cut, single side leave out 0.1 millimeters, cut finished steel plate's internal stress will take gap squeeze skewed. Second cutter following edge walks, takes allowance eats to only left 0.02 millimeters.

Third cutter fine repair, yellow copper wire carrying's current very weak, slowly takes final's 0.02 millimeters scrapes flat. Three cutters walk finished, dimension error pressed at 0.003 millimeters within. Cut out come's hole, exactly can take one root diameter 20 millimeters' guide pillar tightly strictly ground stuff in go.

Deep hole drill machine tool hits a strip long 500 millimeters' cooling water path, uses diameter 10 millimeters' gun drill. Drill bit towards inside walks, every deep enters 100 millimeters, skew amount roughly has 0.1 millimeters. Water hole distance beside's product cavity only has 8 millimeters' distance.

Must take water path's hole diameter shrink small to 8 millimeters hit bottom hole, give skew leave out 2 millimeters' safe meat thickness. Drill bit passes to bottom hit skewed 0.5 millimeters, not pierce through cavity. Take 10 millimeters' extra long milling cutter enter go expand hole, takes that point skewed's meat repair straight.

Plane grinding machine grinds a piece long 300 millimeters' bottom plate, grinding wheel dry grinds temperature will rise to 80 degrees. Steel plate receive heat expands, grew 0.05 millimeters. Operator rely on experience at drawing dimensions on extra leaves 0.02 millimeters' meat not towards down grinds.

Steel plate from magnetic disc take down come, put at normal temperature under air dry two hours. Temperature drops back 25 degrees, steel plate one shrinks, that 0.02 millimeters' meat itself just dissipates down went, take micrometer measure exactly steps at tolerance band middle.

Different shapes' steel materials onto machine tool, leave more leave less has old master's a set habit:

· Length width exceeds 400 millimeters' big flat plates, four sides at least each leave 2 millimeters allowance deal with warp

· Depth exceeds 80 millimeters' deep blind holes, bottom extra leave 0.3 millimeters prevent chip discharge not smooth pierce cutter

· Carrying 15 degrees slant angle's inserts, slant face single side extra leave 0.15 millimeters give final's step match leave back road

· Want to plate 2 micrometers titanium layer's punches, processing dimensions advance make small 0.002 millimeters free out plate layer space

Vacuum quenching craft under, common mold steel single side needs reserved's processing allowance data as follows:

Take DC53 make a molding slider, vernier caliper measures out blank height 80 millimeters. Look one eye table inside's numerical values, up down two heads altogether extra left 0.4 millimeters' meat. Enter furnace burns to 1020 degrees, out furnace after dimensions swell up to 80.12 millimeters.

Throw onto grinding machine, magnetic disc sucks live bottom face. 100 grit's aluminum oxide grinding wheel pastes on go, every time enter cutter 0.01 millimeters. Up down each grinds away almost 0.06 millimeters, slider exactly can stuff into mold base's slide groove.

Drawing temporarily changes dimensions, or earlier stage milling machine extra ate one cutter, rely on argon arc welding towards up piles meat. Welding wire melts in go's place, hardness soars to 55HRC above. Welding seam surroundings high out 0.2 millimeters' ups and downs, uses tungsten steel milling cutter little by little towards down gnaws.

Gnaw flat after takes micrometer measures, distance drawing that root line still short 0.02 millimeters. This point like hair wire same fine's allowance, only can rely on fitter pinching diamond file, pure hand work one down one down files away, until assembly completely tightly seamlessly matches.

Route & Delivery

Guangdong Dongguan's mold factory rushes a set car bumper mold, 32 tons' 718H steel material from Jiangsu Kunshan's steel factory pulls over come. Two places mutually separate 1400 kilometers, total length runs high speed must 18 hours. Truck driver Tuesday night 8 o'clock punctually sets out, catches at Wednesday afternoon 2 o'clock before takes goods sends to workshop gate mouth.

Factory inside that machine travel 3 meters' gantry milling machine one day's machine depreciation fee plus labor is 4500 bucks. Machine tool master Wednesday afternoon 3 o'clock wants to punctually takes steel block hoists onto work table. Truck late arrives one hour, machine tool empty running wasted's electricity fee and delay work fee just white white burns away 200 bucks money.

Kunshan warehouse pack time, 12 pieces dimensions each different's steel plates by loaded onto one vehicle 13.5 meters long's semi-trailer high fence truck. 6 tons heavy's base plate presses at carriage exact middle's axle position. Two sides each pad on thickness 50 millimeters' pine wood blocks, take bear weight 10 tons' tight rope device strangles out three paths anti-slip binding bands.

Dispatch truck bill instruction: carriage must cover double layer waterproof tarpaulin, passes through Jiangxi Ganzhou road section encounters thunderstorm, speed drops to 60 kilometers, strictly prohibit steel material gets wet in rain grow rust.

Truck runs on G45 Daqing-Guangzhou highway on, vehicle mounted GPS every interval 3 minutes towards send goods warehouse's computer pass one time positioning data. Computer calculated accurately along the way's 3 toll stations and 2 provincial border checkpoints, reserved 1.5 hours' traffic jam time. Dongguan factory inside's receive goods personnel staring at screen sees small truck icon cross over Guangdong province border.

Wednesday afternoon 1 o'clock 40 minutes, trailer backs into workshop's unload goods area. Factory inside two machines load weight 10 tons' traveling cranes early just stop at mid air waiting. Lifting worker takes diameter 20 millimeters' steel wire rope threads through steel block on's lifting ring hole. Unloads down whole vehicle 32 tons' material exactly spent 45 minutes.

Make mobile phone shell mold's tiny inserts change use S136 pre-hardened steel. Altogether only wants 200 kilograms' material, divided into 80 different dimensions' small square blocks. Big truck pulls not cost-effective, steel factory cut well after loads into 4 standard wooden boxes, called Debon Logistics' extra fast auto transport.

Less-than-truckload logistics carpooling goes, arrange goods' path completely two kinds:

· Passes through 3 transit hubs, every time load unload goods consumes time roughly 2.5 hours

· Wooden box outer side pastes on 3 fragile labels, inside stuffs full thickness 20 millimeters' pearl cotton

· Scan code gun scans a bit, data 0.5 seconds within passes to processing group leader mobile phone inside

· Terminal end dispatch deliver change into 4.2 meters light truck, thread streets walk alleys hide away limit travel road sections

Driver driving one vehicle load weight 1.5 tons' pickup truck, afternoon 4 o'clock avoids evening peak's ring city fast road. Walks bottom road saves down 20 bucks money pass road fee, extra stepped 15 feet brakes, 50 minutes after takes material sends to heat treatment workshop.

Heat treatment factory's vacuum furnace night 8 o'clock punctually opens furnace. Afternoon sent over go's material has 3 hours' line up buffer period. One furnace can load 400 kilograms' material, furnace chief takes those 80 inserts and other two factories' H13 steel pieces at together burns.

Out furnace countdown remind: Friday morning 6 o'clock 30 minutes, 2 number vacuum furnace drops temperature to 150 degrees. Please arrange vehicles at 7 o'clock 20 minutes stop docking pick goods platform.

Morning 8 o'clock takes back quenched well fire's material, hardness reached 52HRC. Taking advantage of steel block surface still carrying 40 degrees around's remaining temperature, smooth hand pushes into constant temperature 22 degrees' fine processing workshop. Line cutting master takes drawing data knocks into computer, machine immediately takes over starts do.

A set large injection mold, accessories come from whole country each place. Dongguan's standard mold base, Huangshi's extruded H13 mold core, Wuxi's non-standard customized ejector pin. Purchaser pulled a scheduling table, 3 suppliers' send goods time stagger 2 to 3 days.

Batched arrive goods' time axis by dead dead stuck live:

· Monday morning 9 o'clock, 5 tons heavy's mold base first arrives, fitter spends 1 day time grinds burrs

· Wednesday afternoon 2 o'clock, cut well water path's H13 mold core enters warehouse, assembles measure tolerance test fit

· Friday morning 10 o'clock, 300 roots customized ejector pins finally send reach, immediately insert into ejector pin plate

Huangshi that side's truck on high speed on blew tire, delayed 6 hours. Purchaser watching logistics track stops at service area not move, immediately give Wuxi's ejector pin factory hit phone. Let ejector pin factory late half day send goods, do not let wooden boxes pile at Dongguan workshop aisle inside occupy place.

Workshop's aisle only has 2.5 meters wide. Mold base first occupied assembly table's one big half position. Mold core late point arrives, fitter master just first go takes cooling water pipe's copper joints screw well. 6 hours' time difference by hand inside other's works filled full, no people at milling machine beside dry wait.

Mold assembled finished weighs up to 8 tons, find professional's flatbed trailer truck transport give downstream's injection factory. Injection machine has three storeys building that high, factory building big gate limit height 4.5 meters. Trailer truck master takes tire air release away a point, vehicle body shorted 3 centimeters, pasting door frame takes mold sends into factory building.