WJ-800 Quote Guide | Heavy Cuts, Mold Bases, RFQ Checklis

WJ-800 quotation needs to clarify heavy cut depth ≥2mm, mold base size ±0.02mm tolerance, in RFQ needs to provide 3D drawing, material grade (like H13), heat treatment hardness 48-52HRC, and attach processing cycle (usually 15-25 days) and unit price composition details to ensure cost controllable.

Heavy Cuts

Cutting Parameters

Machine spindle per minute rotates 600 circles, cuts into hardness measured value HRC 32 of P20 mold steel. Worker gives 160 mm wide milling cutter head installs 10 pieces carbide inserts, lets metal teeth bite into steel material 12 mm deep. Metal being violently torn sound covers over next door three 80-ton punch presses' roar.

Control panel's 85% load red light flashes crazily, this 37 kilowatt power behemoth is currently consuming 80 amperes of current. Insert hits steel block's that zero point several seconds inside, must hard carry 4500 Newtons of instant impact force.

Thick heavy steel material like planing wood shavings same rolls up falls off, per minute being stripped metal volume reaches 1800 cubic centimeters. One 0.5 cubic meter iron scrap cart fills full 120 kilograms emitting blue-purple colored waste iron scrap only needs 45 minutes. Take one 2 tons heavy 4140 steel block cut off 600 kilograms allowance, machine must continuously run 5.5 hours.

Intense friction lets metal teeth wear extremely fast, purchase price ￥135 insert at 150 meters per minute speed scrapes steel plate. 25 minutes inside, insert cutting edge will wear away 0.3 mm, becomes unable again used waste product.

· 160 mm cutter head on is fixed 10 pieces inserts

· Every one piece square insert owns 4 usable corners

· Operator every interval 25 minutes must press stop machine tool flip insert face

· 8 hours of one shift will consume away 200 pieces waste old inserts

· Single machine every day just buying inserts then will spend away ￥27,000

Scraping metal generated friction heat lets contact point temperature soar to 850°C. Machine tool pipes with 70 bar high pressure spray out 12% concentration water-based cooling liquid, suppress almost burned through dark red iron scrap.

Ice cold water column hits upon bright red metal stirs up large piece white mist, cold hot alternating lets insert surface explode open 0.05 mm deep tiny cracks. Spindle inside bearings under 90°C high temperature rotate enough 3000 hours, rotation error will from 0.005 mm enlarge to 0.015 mm.

Factory opens out ￥450 one hour processing fee to fill machine wear. Machine spindle uses 18000 Newtons pull force dead dead drag hold heavy reaching 15 kilograms tool holder, prevent it in intense vibration fly out hurt people.

· Push tool move metal lead screw thick reaches 63 mm

· Two hydraulic oil cylinders at two sides support hold 3 tons heavy cutting machine head

· Padded at most bottom bed body used HT300 high strength cast iron

· Machine empty run fastest speed is limited at 15 meters per minute

· Find accurate position error is controlled at ±0.02 mm within

Heavy reaching 18 tons base presses holds position, motor hard pushes insert every time forward gnaw 0.8 mm. Cut finished steel material surface touch up like rough sandpaper, above fully distributed 3.5 mm wide one circle circle tool marks.

Worker will at surface extra leave 1.5 mm thickness, wait 72 hours after again do fine grinding. Violent cutting lets steel plate down 4 mm deep places all situate in tight state, must at empty ground put 48 hours let it itself relax. Ahead of time take go fine finish, one piece 1500 mm long steel plate pass 3 days will irreversibly warp up 0.08 mm.

Move 1.4 tons heavy tight metal block, must use 5-ton level jib crane. Hook on hung yellow nylon tie band can bear 20 tons pull force not break. Just cut open metal face not coated on 0.2 mm thick anti-rust oil, in humidity 65% workshop put 2 hours then will grow out yellow spots.

Rust water will toward steel material inside corrode 0.05 mm, must dispatch two workers take grinding machine do 2 hours then can fix well. Bill inside use wooden box plus vacuum paper pack anti-rust fee according to per square meter ￥15 separately calculated. Modify several lines computer processing code, can let millions order total price float 15%.

· Insert less cut 2 mm deep, machine work time extra out 35%

· Cutter head rotation speed raise fast 10%, insert use life shorten 40%

· Cooling water mixed too thin lower than 8%, steel block rusts returns extra 12%

· Machine push speed doubles, inside transmission lead screw life less half

Machine Occupancy Time & Cost

One 15 tons heavy gantry milling machine occupies 60 square meters workshop ground. Start this head industrial behemoth, meter according to per hour ￥450 rate jumps. Milling cutter still not touched below P20 steel block, two workers must first spend 45 minutes, operate 10-ton level bridge crane take 3 tons heavy blank move to work table on.

Fix steel block needs use to 8 pieces M24 high strength T-type bolts. Worker holds one meter long pneumatic wrench, gives every piece bolt apply 600 N·m tightening torque. One Renishaw probe from spindle inside stretches out, spends 12 minutes at rough surface taps 16 coordinate points, lets machine remember steel block's initial position.

57 minutes preparation work burned away ￥427 machine occupancy fee, not cut down even if one gram heavy iron scrap. Quotation document on preparation time multiplied 1.5 coefficient, used to fill workers in owning 20 machine tools factory building inside line up wait for crane's empty consumption period.

37 kilowatt spindle motor electrifies runs, electric meter numbers crazy roll. Extreme rough machining one hour consumes electricity 45 degrees, single machine tool every month electricity bill breaks through ￥28,000. Machine divides early late two shifts 22 hours continuously rotate, stop machine time is compressed into workers eat meal and hand over shift's 30 minutes inside.

Per minute produces 1800 cubic centimeters metal fragments, forces out one not small logistics expense. 4 meters long chain plate type chip conveyor crawler non-stop takes 3 tons boiling hot waste iron dumps into collection box. Pull away this box waste material needs pay to truck driver ￥200 freight, offsets away ￥1,800 per ton waste steel recycling money in extremely small one part.

Become blunt inserts drag slow scraped steel material's progress. Spindle from 600 revolutions brakes stops steady spends away 4 seconds, skilled worker twists open 10 pieces torx screws changes finish all carbide inserts uses away 8 minutes. One shift changes 6 times tools, swallows 48 minutes machine running billing time length.

One copy length width 1500 mm, height 500 mm mold base steel block quotation, uncovers routine processing and violent remove allowance at account face on gap.

Fierce scraping burned away 4 times tool budget, purchase ￥3200 inserts in sparks inside transform into waste iron. Machine less rotated 20 hours, takes final remove allowance bill forcefully cuts away near ￥2000.

Factory spends ￥3,200,000 buys in this brand new gantry machine tool, expects in 5 years return capital. Finance department takes purchase machine money spread flat to 30,000 hours expected running life inside, every start machine one hour then toward account book on record in ￥106 fixed depreciation fee.

Intense vibration tears pulling machine tool's every one mechanical joint. Rotate full 3000 hours after, replace one set NSK high precision spindle bearing needs spend ￥45,000 buy parts. Machine stops work major repair 3 days, current month's revenue report on will empty out ￥32,400 income gap.

Base's water storage tank inside holds 800 liters synthetic cutting fluid. 850°C high temperature evaporation and iron scrap takes away's water content, lets water tank every day decrease 15 liters liquid. Toward inside supplement 12% concentration chemical factory raw material, every month's material list on extra out ￥1,500.

Serve huge equipment needs monthly salary ￥12,000 senior technician. CAM engineer writes code avoid ￥15,000 cutter head crashing onto fixed fixture, 4 hours programming work according to ￥150 hourly wage recorded into early stage cost.

Size is 500 megabytes CNC program file inside writes full 2.5 million lines G code. Equipped with 16 core processor computer workstation needs spend 45 minutes run 3D simulation, check tool has not toward steel plate inside extra plunge into fatal 20 mm.

One place code written wrong triggers spindle striking pin scrap, maintenance bill on numbers reach high to ￥120,000. Quotation template's last one line leaves 5% risk reserve fund, handle workshop inside extremely small probability machine collision accident.

Transformer room pulls out dedicated 100 kilovolt-ampere line, carry hold giant motor start instant 120 amperes current impact. Power supply bureau every month collects ￥3,000 capacity fee, maintains whole strip industrial level cable's power supply qualification.

Tool Consumables Estimate

Diameter 160 mm cutter head on, tightly fastens 10 pieces yellow shiny carbide inserts. By tungsten carbide powder at 1500℃ high temperature under sintered into small squares, hardness reaches HRA 92. Spindle taking them with per minute 600 revolutions speed smashes into P20 mold steel. Every piece cutting edge gnaws into steel plate 1.2 mm deep, bears extremely big cutting resistance.

Metals mutually crazy friction, cutting area's temperature in 3 seconds inside from room temperature soars past 800℃. Insert surface's CVD coating only has 15 microns thick, inside contains aluminum oxide and titanium carbonitride. High temperature lets coating slowly peel off, exposes out fragile tungsten carbide matrix.

One piece heavy 18 grams square insert, at 150 meters/min linear speed under scrapes steel billet, effective survival time is accurately calculated as 25 minutes.

Sandvik R390 series heavy cutting insert, purchase order on purchase price is ￥135 one piece. 10 pieces install full one cutter head needs ￥1350. Short short 25 minutes, with steel material contact cutting edge relief angle will wear out one 0.3 mm wide wear band.

Worker steps down machine tool foot pedal, uses T15 torx wrench twist loose 10 pieces covered full oil stain M4 screws. Takes every piece getting hot insert rotates 90 degrees, changes one brand new cutting corner newly tightens. Change one face cutting edge spends 8 minutes, this period time inside 37 kilowatt machine tool hangs machine stops rotating, electric meter and billing meter still are walking.

· Single quadrilateral insert owns 4 usable cutting corners

· Every flip one time gains 25 minutes effective processing cutting

· 100 minutes after whole piece 18 grams carbide completely scrapped

· Cut away 2 tons steel material allowance usually consumes 5 boxes (50 pieces) inserts

· Consumables warehouse every month for single heavy cut equipment spends ￥65,000 tool fee

Machine tool nozzle shoots out 70 bar pressure water-soluble cooling liquid, pours at 800℃ cutting edge on. Heat expands cold shrinks lets insert surface appear network-shaped fine cracks. Cold water not aimed correct, insert in 10 minutes inside will suffer heat uneven on the spot shatter.

Except consume amount extremely big inserts, loading them cutter head body also is wearing. One Φ160 mm cutter head body selling price ￥8,500. Experienced 500 hours heavy pressure vibration, insert groove's positioning accuracy from 0.01 mm deforms into 0.03 mm. Installed on new inserts high low uneven, workshop must dig money buy new cutter head.

Quotation inside consumables item, takes ￥8,500 cutter head depreciation fee according to 500 hours allocate, every hour records in ￥17 hidden expense.

Steel billet inside hides hardness reaching HRC 45 hard spots, insert hits on will instantly explode crack. Fragmented carbide embeds into cut seam, forcefully pushed cutter head takes remaining 9 pieces good inserts together crash break. Operator presses down emergency stop button, one time crash tool accident scrapped inserts and cutter head, account face amount reaches ￥9,850.

· Scrapped carbide inserts are unified collected in blue plastic bucket inside

· Waste old tungsten steel recycling price according to weight calculates, per kilogram ￥160

· Save enough 100 kilograms waste inserts can exchange back ￥16,000 cash

· Waste material money only enough offset workshop 7 days tool purchase expense

· Finance every month beginning verifies 15 pieces total limit exceeds 200 thousand tool invoices

Give mold base drill lifting holes use Φ24 mm U drill. Drill bit center passes water cool, with 120 mm/min feed downward plunges into 50 mm deep steel material. Drill bit top end's two pieces WCMX inserts bear hundreds Newtons torque, every drill 80 holes must throw into waste material bucket. Change two pieces U drill inserts spends away ￥110.

Write code programmer uses Mastercam software simulates tool path. Takes enter tool angle from 90 degrees vertical down cut change to 3 degrees spiral down cut, insert received impact force reduces 30%. Spend 2 hours modify 50 thousand lines code, saves down ￥2,700 tool depreciation fee.

Physical wear all turns into financial report on numbers, tool consume amount occupies to rough processing quotation amount's 35% above.

Warehouse shelf on all year round prepares 300 boxes each model rough processing inserts. Occupy land not to 2 square meters yellow plastic boxes, press hold factory ￥405,000 liquid funds. Supplier delivery period late 3 days, stop work wait inserts machine tool every day loses ￥10,800 production capacity.

Change on new cutter head, worker takes it puts into ZOLLER tool presetter inside. Infrared probe aims at rotating tool tip, at screen on reads out 160.02 mm real diameter. Bring with 0.02 mm error data passes into machine tool control system, this test tool equipment spent workshop ￥180,000.

Mold Bases

Grade & Deformation Tolerance

800-ton machine closes mold, two pieces big steel plates must hard resist nearly 8000 kilonewtons squeezing. 150 mm thick ordinary S50C medium carbon steel put inside, middle no support place immediately will be pressed out 0.15 mm pit. Meet upon make thick wall plastic parts, mold inside high temperature melted material toward outside braces, internal pressure soars to 180 megapascals.

S50C yield strength at 340 megapascals up down, take come make several hundred mm small boxes no problem. Start work one meter long home appliance shell, must at steel plate middle dig out one big deep pit. Rough processing once finish, steel material internal residual strength force randomly runs, put one night diagonal line runs off 0.2 mm above.

Change on drawing specified 1.2311 pre-hardened steel, smelting iron furnace inside added 1.4% to 1.6% chromium and 0.15% to 0.25% molybdenum. Leave factory before whole piece steel material enters furnace bake, pull to machine processing workshop hardness steady at Brinell 280 to 320. Worker opening 6000 revolutions machine tool cuts, iron scrap making curls fly out, cut face roughness does to Ra 1.6.

Contain carbon amount dead dead stuck in 0.35% to 0.45% range, machine tool on tool head can extra use good several days. Drill through dozens ejector pin holes, tool tip at bottom not easy crash break. Walk 2500 mm/minute big fly cutter cut, several hundred kilograms steel plate do finish, four corners deformation amount not to 0.02 mm.

· S50C steel material tensile strength big past 580 N/mm².

· 1.2311 inside sulfur content not to 0.03%, cut open not crack.

· 1.2738 big material pass ultrasonic flaw detection, take SEP 1921 D/d level report.

· SUJ2 guide pillar contain carbon amount dead guards in 0.95% to 1.05% range.

Plastic mixed in 30% glass fiber, injection molding machine barrel temperature burns to approaching 300 degrees. 1.2311 every day experiences hundreds of thousands times heat expands cold shrinks, surface starts crack out fine seams. Immediately change on contains 1% nickel 1.2738 steel. 400 mm thick giant steel block, from outside cut to most center, hardness tester hit out drop not to HRC 2.

Assembly workshop toward steel plate inside twists M20 high strength screws. Hardness reached HRC 30 to 34 1.2738 steel, hard eats 300 N·m torque. Below screw threads slightest bit not slip, hole edge flat flat neat neat doesn't have any depression.

One meter long, 800 mm wide super big size steel plate, up down two big faces parallelism error must compress at 0.02 mm within. Worker takes 0.03 mm feeler gauge if inserts into seam inside, close mold instant two pieces plates crooked crash at together, inside parts immediately bear good several tons partial load squeeze.

Side face datum corner used to align, perpendicularity standard writes 0.01/300 mm. Machine tool touch number finds coordinate origin, off one root hair thread all not okay. Slightly deviate out thousandth of several mm, downward dig out 150 mm deep inner frame after, side wall inclination can take inside mold core dead dead stuck.

· Front back face diagonal length error at ±0.05 mm within.

· Four guide pillar holes position deviation less than 0.01 mm.

· Fixation use lock mold holes distance difference at ±0.015 mm within.

· Drill 100 mm deep ejector pin holes, tilt not to 0.02 mm.

Middle dug empty place size fixed at 800 mm plus 0.005 to 0.015 mm allowance. Single side leaves out 5 to 10 microns gap. Fitter master taking purple copper stick knocks, takes inner core tight thread joined seam smashes into frame inside.

Frame bottom flat plane hits dial measures nine points, high low drop not exceeds 0.01 mm. Below sticks not to solid place, high pressure plastic once injected come in, inner core bottom follows goes soft downward sinks.

Pipes inside flow 120 degrees heat conducting oil, whole piece steel plate receives heat expands. One meter long steel plate naturally stretches long 1.1 mm. Four pieces diameter 60 mm guide pillars if gap left small, meet high temperature immediately dead dead stuck in hole inside move cannot.

Guide sleeve inner circle compared guide pillar outer circle big 0.015 to 0.025 mm. Coated full molybdenum disulfide high temperature grease, dozen microns seam inside fills full oil film. Moving plate uses per second 800 mm speed fiercely rushes closes, machine friction resistance drops to extremely low.

Parameters & Annealing

WJ-800 spindle hangs diameter 63 mm corn milling cutter, rotation speed fixed at 850 rev/minute. Insert cuts into S50C steel plate, eat tool depth reaches 2.5 mm, per minute cuts down 500 cubic centimeters iron scrap. Splashing out iron scrap touches machine tool protective cover, temperature exceeds 400 degrees, surface floating deep blue color.

Several hundred kilograms steel material flat lies at table face on, is by three bench vises dead dead locked. Cutting fluid with per minute 40 liters flow fiercely sprays, suppresses not tool and steel material intense friction generated heat. Steel plate surface temperature locally breaks through 200 degrees, originally neatly arranged metal crystal lattice is forcefully torn deformed.

One piece heavy reaching 800 kilograms P20 pre-hardened steel, digs empty inside opens out deep frame, weight sharply reduces to 550 kilograms. Dug away 250 kilograms metal took away original bearing force balance.

Worker takes just down machine tool template throws at normal temperature workshop air dry. First two days take micrometer measure, diagonal length pattern wire not move. Arrive at fourth day morning again hit dial, four corners warp up 0.08 mm, originally flat bottom face became tiny pot bottom shape.

Not put into heat treatment furnace walk one trip annealing program, later stage hundreds of thousands processing fee all hits water float. Workshop uses overhead crane takes big steel plate hoists into pit type resistance furnace. Furnace door once closes, heating pipe electrifies, temperature with per hour 80 degrees speed slowly upward climbs.

Temperature dial climbs to 550 degrees, heating speed slows down. Furnace inside thermocouple probe dead stares every corner's temperature difference, up down float controlled at ±5 degrees within. Thickness 200 mm template, insulation time set as 4 hours. Let heat completely fully penetrate into steel plate most center.

Furnace inside high temperature lets twisted metal crystal lattice newly arrange, tight strength force slowly relaxes. Insulation time once arrives, absolutely cannot immediately pull open furnace door drop temperature. Cold air once flushes, steel plate surface quickly shrinks, inside still expanding, just eliminated stress immediately newly grows out.

Control panel on writes well cooling curve, drop temperature speed dead dead suppressed at per hour 30 degrees. Furnace hearth inside fan slowly circulates, takes away weak heat. All the way endure until furnace temperature drops to 200 degrees below, worker then dares pull open thick heavy furnace door. Overhead crane takes bearing residual temperature steel plate hoists out, throws into sand pit continues natural cool.

Different material annealing parameters completely not one routine. Temperature given low, stress removes not clean; temperature given high, originally HRC 32 hardness drops to HRC 28 below, material becomes soft, on machine hit high pressure on the spot sinks.

Oxide layer thickness roughly 0.1 to 0.2 mm, hardness extremely high. Take ordinary white steel tool up go scrape, tool tip touches one time on the spot crashes drop. Must on CBN cubic boron nitride insert, rotation speed drops to 400 rev/minute, hard eats away that layer hard skin.

Bottom face newly goes on grinding machine, 80 mesh aluminum oxide grinding wheel with 2800 rev/minute speed sweeps past. Every time enter tool amount only 0.005 mm. Sparks following cutting fluid direction fiercely spray, walks complete three round trips, surface's black color completely fades go, exposes out silvery white metal luster.

On coordinate measuring machine hits points test, originally 0.08 mm deformation amount is by grinding machine completely wiped flat. Flatness reading shows as 0.008 mm. Stress totally releases complete, machine continuously hits one month high pressure, steel plate slightest bit will not again happen any spontaneous twist.

Side face datum corner newly calibrates, roughness Ra 0.8 datum face flashes flashes shines. Machine tool probe with 50 mm/minute speed touches side wall, system automatically compensates 0.002 mm machine tool error. Change on diameter 12 mm alloy drill bit, opens internal cool system, high pressure oil from drill tip sprays out.

Drill water route holes is a extremely test discharging scrap job. 800 mm long gun drill, rotation speed 1200 rev/minute, according to per revolution 0.03 mm feed toward inside drills. 6 megapascals high pressure cutting fluid takes iron scrap forcefully flushes out hole outside. Slightly has block up, drill bit at hole bottom instantly twists breaks, must spend money invite electrical discharge master salvage broken wire.

To avoid open inside ejector pin holes, water route center leaves hole wall only mere 8 mm. Gun drill happens 0.01 mm deflection, 800 mm deep hole bottom deviates out near 1 mm, on the spot hits through side's ejector pin hole. Machine tool guide rail straightness error must control at 0.005 mm within.

Parameter Setting and machine tool performance dead dead bind. Meet upon hardness reaches HRC 40 hard material, cutting speed cut in half at waist, drops to 60 meters/minute. Feed amount compresses to 0.1 mm per tooth, take selling price 120 bucks one piece coating insert hard gnaw, one shift down just insert consume two boxes.

RFQ Quotation Cost

One piece long 1200 mm, wide 1000 mm, thick 150 mm B plate, calculate on processing allowance, volume approaches 0.2 cubic meters. Multiplies 7.85 steel density, simply simply this piece plate heavy reaches 1.5 tons.

S50C medium carbon steel factory price at per kilogram 11 bucks up down. 1.5 tons buy return, raw material fee spends away 16500 yuan. Drawing changes uses Germany Böhler 1.2738 pre-hardened steel, unit price turns into per kilogram 35 yuan. One truck material pulls into factory area, just buy iron must pay 52000 plus bucks.

“Quotes 12 bucks one kilogram 718H, sends go do spectrum analysis, nickel content even 0.3% all not arrives.”

Drawing sends to LKM buy standard mold base, CI type 7090 series quotation document on writes 48000 yuan, delivery period 15 days. Bump into car dashboard that kind irregular part, needs tear into five pieces plates assemble, find small factory customize non-standard mold embryo. Fee rises to 75000 yuan, wait material wastes on whole whole 35 days.

WJ-800 machine tool start machine fee according to hour calculates. Power 22 kilowatt spindle taking 63 mm big fly cutter rough mills open frame, one hour charges 150 yuan. Digs out one 800 multiply 600, deep 100 mm cavity, machine tool continuously runs 24 hours, report on extra out 3600 bucks machine time fee.

Vacuum furnace annealing according to weight charges fee, one kilogram charges 3.5 yuan. 1.5 tons plate throws into furnace bakes 48 hours, bill adds on 5250 bucks. Saves down this pen money not bakes, on machine fine processing size runs off 0.05 mm, whole piece plate as waste iron according to per kilogram 2 bucks processes.

Outsource processing project bill is by one item one item fragmentary fees piled out:

· Surface Grinder Start Machine Fee: One meter wide guide rail grinder one day rent 2500 yuan.

· Slow Wire Cutting Fee: Cut 4 high precision guide pillar holes charges 500 yuan.

· Deep Hole Drill Discharge Scrap Fee: Cooling pipe route every drills in one meter values 80 yuan.

· Heat Treatment Annealing Fee: Vacuum furnace according to weight calculates fee one kilogram 3.5 yuan.

· CMM Inspection Fee: Issue bring CMA stamp inspection report asks price 1200 yuan.

Takes parallelism from 0.02 mm compresses to 0.005 mm, worker takes plate moves up constant temperature workshop Swiss high precision grinder. Grinding wheel every time only goes down 0.002 mm, processing time flips three times, machine time fee straightly approaches 8000 yuan.

Guide pillar guide sleeve hardware parts price difference extremely big. Uses domestic ordinary SUJ2 bearing steel makes guide pillar, one root 50 bucks. Drawing specifies uses Japan Punch high frequency quench part, one root quote prices marks to 280 yuan. Four guide pillars match on oil-free self-lubricating guide sleeve, small parts dry drop near 2000 bucks.

“Drawing marked plus minus two threads (0.02mm), sends goods come one measure differed ten threads (0.1mm), returns back return work logistics fee single trip just needs 800 bucks.”

B plate takes ultrasonic probe all covers sweeps one time, according to square centimeter charges fee, issues one copy complies with SEP 1921 D/d level inspection report asks price 1800 yuan. Steel material inside hides one 2 mm sand hole not measured out, hundreds of thousands mold core installs on one presses, scrapped loss all by mold embryo factory compensates.

Incline degree 5 degrees wear block, one set four pieces adopts S136 material vacuum quenches to HRC 52. Assembly worker takes red lead powder coats at on top slowly fits mold, one fit just is two days. These four pieces small iron lumps connect labor belt material adds into quotation document, amount rose 4500 yuan.

A plate exposed at air inside easy rusts, drawing demands do chemical immersion nickel treatment. Electroplating factory takes plate hoists into potion pool soaks 6 hours, plates on one layer 0.015 mm anti-rust layer, according to per kilogram 1.5 yuan charges fee, 1.5 tons plate again increases 2250 bucks cost.

One whole set mold embryo assembles finishes heavy reaches 3.5 tons, freight bill amount very big. Finds one 13.5 meters flatbed truck runs long distance, from Dongguan pulls to Kunshan, freight opens price 6000 yuan. Factory building inside not installs 10-ton level overhead crane, unloads goods spends 800 bucks invites outside car crane.

Old oil stick quotation clerk at total price inside buries in 5% loss fee. Drills water route hole breaks one root several hundred bucks drill bit, finds electrical discharge master salvage spends 1500 bucks. Opens frame time operator inputs wrong code extra digs 0.1 mm, pulls go do laser burn weld patch meat, two hours consumes away 600 yuan.

RFQ Checklist

Material & Metallurgy

Smelting steel furnace inside temperature high reaches 1650 degrees, waste iron at strong current under melts into steel water. Machine takes steel water draws vacuum, inside hydrogen gas is squeezed to two millionths below. Worker at big steel bucket inside adds silicon calcium wire, like stir fry vegetables adds salt same takes extra oxygen and sulfur exhausts clean.

Puts at microscope under looks, steel material inside impurities more little more good. Long strip shape sulfide and oxide controlled at 1.5 level within, round shape impurities cannot exceed 1.0 level. Sulfur composition exactly stuck at 0.003% to 0.008% between, cutting time iron scrap easy breaks, polishing face also can maintain brightness.

Steel water slowly becomes hard all relies cold water flushes drops temperature. Machine pulls steel strip one minute walks 0.8 meters, per ton steel must spray 120 liters water. Water sprays little cold slow, carbon and chromium gather into one lump, whole piece steel has places hard has places soft.

Heavy water press takes heats to 1200 degrees steel block repeatedly hammers strikes, volume compresses to original one third. Rough internal structure is pressed extremely tight solid, fineness reaches 7 level above. Worker holding ultrasonic instrument at cold down surface slides checks.

Instrument screen on appears exceeds 2 mm size pit hole reflection then not counts qualified. Worker pressing atlas one by one verifies, millet grain big cracks also all picks out. Long 3 meters wide 1.5 meters material block is by big crane sent into big fire furnace.

· Carbon composition: 0.35% to 0.45%

· Chromium composition: 1.80% to 2.10%

· Molybdenum composition: 0.15% to 0.25%

· Nickel composition: 0.90% to 1.20%

Fire furnace temperature rises to 880 degrees, continuously burns 12 hours takes composition completely melts even. Blower machine uses per second 15 meters big wind fiercely blows drops temperature. Steel plate at cold hot alternating under becomes hard, takes hardness tester knocks, number jumps to HRC 52.

Furnace again adjusts to 580 degrees warm fire bakes 8 hours. Too hard steel easy brittle, high temperature can take internal stress scatter away. Worker at surface grinds out 50 mm square, press head consecutively pokes five times, measured out hardness steady stops at HRC 39.5.

Processing workshop air conditioner all year round opens at 22 degrees. Machine rotation speed adjusts to per minute 800 revolutions, 63 mm big cutter head on installing 5 pieces sharp alloy tools. Tool tip downward plunges into 3 mm, one minute forward gnaws 1200 mm, planed out iron flowers all are deep blue color.

· Drill bit tip angle: 135 degrees to 140 degrees

· Cold water concentration: 10% to 12%

· Cutting speed: per minute 15 to 20 meters

· Per revolution feed: 0.15 to 0.20 mm

Machine load meter jumps to 65%. Steel plate inside hiding hard particles like sandpaper same grinding insert. Cutting temperature reaches 800 degrees, coating very quickly drops skin. Every digs away 200 cubic centimeters iron, insert wear 0.15 mm.

Worker stops machine uses 3.5 N·m strength takes inserts all changes drop. Become blunt tool mouth hard rubs steel plate, surface will be pressed out one layer 0.5 mm thick hard skin. Next step drills screw holes drill bit once touches this layer skin then easy click breaks drop.

Water nozzle uses 30 kilograms pressure toward cut seam inside fiercely sprays cooling liquid. Filter net takes compared 20 microns big iron foam skims out. Water flow takes 500 degrees getting hot iron flowers flushes away, prevents steel plate heat expands cold shrinks warps up 0.05 mm edge, big magnet electric switch one pull down.

Small probe touches edge walks one circle, dial pointer shakes not to 0.02 mm. Machine changes to per minute 3000 revolutions speed, takes 20 mm thick milling cutter trims edge, takes last 0.1 mm skin scrapes clean, air gun blows flies fine sand same iron scrap.

· Flatness requirement: 1 meter inside deviation not exceeds 0.015 mm

· Round hole error: at most 0.005 mm

· Diagonal line difference: less than 0.02 mm

· Screw hole position: 100 mm inside differs 0.05 mm

Purple copper block one second discharges several hundred times electricity, 45 amperes spark crackles sounds. Steel plate surface is by several thousand degrees high temperature burned into bubbles, bubbles explode open after leaves 0.1 mm wide fine small pit holes.

Scalded melted iron water at oil inside one cold again sticks back surface forms into white bright skin. Bright skin only 0.02 mm thick, hardness soars to 60 degrees inside all are fine small cracks. Old master holding 320 mesh grinding stone dipping kerosene rubbed 4 hours takes skin wipes clean.

Wool wheel smears full 3 microns thickness diamond paste, one minute rotates ten thousand circles at mold pit inside grinds. Steel material early stage eliminates impurities, polishing face sees not bring tail pit spots. Instrument probe sweeps past roughness stops at 0.05.

Crane hook hangs holds four M30 specifications iron rings. 1.8 tons steel plate hangs at mid air toward boring machine direction moves. Air conditioner room inside laser instrument turns on machine, prepares gives drill hole do positioning correction, every time moves 0.001 mm.

Drawings & Geometry

Computer screen on hangs one 80 megabytes STEP format file. Design personnel clicks opens 3D model, mouse scroll wheel zooms in inspects WJ-800 mold base four corners. Edge corner places marks C2 chamfer, edge forcefully slices away 2 mm incline face, carries iron block time iron skin no longer cuts breaks worker's gloves.

Conversion software takes 3D stereo drawing slices into flat plane, exports out one copy DWG format 2D engineering drawing. Drawing border frame marks A0 size, length 1189 mm, width 841 mm, prints out lays at table on like one piece single bed sheet. Right lower corner title block writes scale 1 to 1, version number fixed at Rev.03.

Engineer holding red pen at drawing edge draws circles. Datum face A sets at mold base bottom part, side's triangle symbol brings Ra 0.8 number.

Datum face B chosen at long side, datum face C stuck at short side. Three faces mutually perpendicular puzzle into XYZ absolute coordinate system. Ruby probe touches one time bottom face, scrapes one time long side, again clicks one time short side, machine tool operation desk screen on coordinate numbers all return zero into 0.000.

Drawing middle draws one thin long square frame, inside filled parallelism symbol and 0.015 number. Two pieces thickness 45 mm templates stacked at together, seam inside stuffs not in 0.015 mm thick thin steel sheet. Several pieces big screws lock tight, template fitting face's light transmission rate is zero.

Guide pillar holes size stuck gets very dead, four round circles side marks diameter 32 mm, brings H7 tolerance band. Upper deviation limited at +0.025 mm, lower limit is 0. Boring tool stretches into hole inside rotates dozens circles, scrapes away last 0.01 mm iron skin, inner diameter micrometer measures one circle stops at 32.012 mm.

Four round holes center distance respectively is 450 mm and 350 mm. Cross line intersection point drags out one position degree square frame, inside writes 0.02. Machine tool walks to predetermined coordinate downward plunges tool, drilled out hole heart deviates originally drawn well cross silk not to 0.01 mm. Inserts on steel pillar up down mold base one closes, hears not iron grinds iron interference sound.

Water route holes solid lines and dashed lines at drawing on crisscross. Side face drills in cooling water holes diameter only 10 mm, depth fully has 380 mm. Thin long gun drill at steel plate deep place easy runs off, drafter at hole end specially marks 1.5 mm drift limit.

Seal block water route hole mouth draws PT 1/8 taper pipe thread. This circle thread brings 1 to 16 taper degree, worker takes tap only attacks in 10 mm deep. Wraps on three circles raw material tape twists tight yellow copper joint, passes in 8 kilograms pressure cooling water, passes half hour not oozes out one drop water bead.

Ejector pin holes densely packed arranges 120. 2.5 mm fine holes from back face straight hits through to front face. Prevents steel pin receives heat stuck dead, hole cavity front section only 15 mm straight body section leaves +0.01 mm allowance, back half section all uses big drill bit expands into 3 mm escape empty channel.

Mold concave pit surroundings draws toward outside inclined incline degree. Outer side wall inclines 1.5 degrees, inner side undercuts part enlarges incline amount reaches 3 degrees. Injection molding machine takes 200 degrees plastic melts hits into pit inside, cools shrinks after follows incline degree one pushes slides out, surface leaves not down white pull hurt marks.

Drawing left upper corner lists one copy material list table. Table writes clear needs 8 pieces M16 inner hexagon screws, screw tooth length 35 mm, strength marks 12.9 level. Assembly worker holding brings scale torsion wrench, according to 150 N·m torque takes one circle screws all presses dead.

Lifting installs uses screw holes arranged at mold base surroundings. Outer circle marks M24, works uses thread depth must hit enough 36 mm. Several circles screw teeth must bear 1.5 tons vertical pull force, crane hangs on four pieces refined steel shackles, takes 3 tons heavy iron lump steady steady hoists leave ground face.

Assembly drawing inside cross section section view line diagonally slashes past whole screen. Sliced open seam exposes out three roots reset springs pit positions. Spring outer diameter 40 mm, compression amount sets at total length 30%. Drawing on marks clear hole bottom must use flat bottom drill mills flat, spring crooked receives force presses several thousand times definitely breaks.

Heat Treatment & Surface Quality

Furnace hearth big door slowly closes on, five tons heavy WJ-800 steel block is pushed into vacuum furnace. Exhaust pump runs 45 minutes, dial on air pressure drops to 0.1 pascals. Heating pipe electrifies gets red, furnace hearth temperature with per hour 80 degrees speed slowly upward climbs.

Temperature stops at 550 degrees not moves. Steel block at inside hard stiffens 4 hours. Rough milling cutter just dug away half iron meat, steel block inside holds back one strand twisted force.

Open furnace door absolutely cannot hurry, must follow furnace covers to 200 degrees below.

Drop temperature speed fixed dead at per hour 30 degrees. Large axial flow fan takes purity 99.9% nitrogen gas blows into furnace inside takes away heat. Early opens door sees cold wind, long wide 800 mm steel plate four corners can immediately warp up 0.2 mm. Workshop old worker takes infrared thermometer aims at steel plate, screen jumps to 180 degrees then signals crane hangs hook.

Rockwell hardness tester press head changed to diamond cone. 150 kilograms strength presses at steel plate surface, dial pointer shakes after stops at HRC 41. Quality inspector every interval 100 mm hits one point, one consecutive at flat plane on hit ten points, number up down difference not exceeds 0.5 degrees.

Diameter 400 mm grinding wheel clips 60 mesh aluminum oxide particles. Grinding wheel with per minute 1400 revolutions speed rubs past steel plate, sparks at workshop inside sprays out two meters far. Machine tool work table back forth moves, every time only scrapes away 0.02 mm thick skin layer.

· Grinding wheel spindle feed amount setting: 0.01 mm/time

· Grinding fluid nozzle pressure meter reading: 0.5 megapascals

· Water tank filter cloth net hole density: 15 microns

Probe style roughness tester sticks ground marks slides past 5 mm. Machine body small screen jumps out Ra 0.4 number. Finger belly touches on like touches glass, fingernail cover scrapes not out little bit sound.

Worker takes steel part hoists into deep pit type furnace, pipe inside passes in ammonia gas. 520 degrees environment inside ammonia gas decomposes out active nitrogen atoms. Billions nitrogen atoms little bit little bit toward steel skin inside drill.

Nitriding process whole whole lasts 48 hours, gas flow meter dial fixes at per minute 15 liters.

Skin layer only 0.15 mm thick. Worker takes Vickers hardness tester toward skin on one presses, leaves down one small small rhombus concave pit. Screen reading jumps to HV 850, compared original internal hardness flipped one double more.

Escape empty part not uses that fine delicate, processing drawing on draws Ra 6.3 symbol. CNC milling machine leaves down one circle circle fine dense fish scale marks. Tool marks between spacing has 0.8 mm.

Polishing master sits at desk lamp below, head on wears 3 times magnifying glass. Hand inside holding ultrasonic polishing machine, top end fine wood strip dips 800 mesh silicon carbide paste. Wood strip per second vibrates 20 thousand times, follows fine fine tool marks back forth rubs whole whole 3 hours.

· First pass grinding process: uses 400 mesh fine oil stone pushes flat transverse tool marks

· Second pass transition process: changes 800 mesh grinding paste finds flat metal face

· Third pass finish up process: smears 3000 mesh natural diamond paste all around lifts bright

Roughness tester again up field, profile maximum height Rz reading shows as 0.6 microns. Mold deep pit inside clearly reflects out head top fluorescent lamp tube outline. Injection molding machine plastic liquid hits into bright face pit inside, demolds out plastic parts at light under can serve as reflector uses.

Sandblasting workshop worker wears on thick canvas clothes. Spray gun pressure meter dials to 0.6 megapascals. 120 mesh fine broken glass micro beads like rainstorm same fiercely smashes at steel plate outer surroundings side face. Spray nozzle distance steel plate surface 150 mm, one second horizontally sweeps 50 mm wide area.

Bright shiny bottom all gets smashed out even matte face. Microscope under surface becomes countless depth 0.01 mm tiny pock pits. Toward surface on sprays two passes anti-rust paint, paint film dries thoroughly takes crosshatch knife uses force slashes pulls tears, fingernail how picks all drops not down one piece paint skin.

Flaw detection worker carrying one bucket penetrant walks over comes. First at metal surface sprays full red color liquid, holding stopwatch waits on 15 minutes. Red water beads follows compared hair thread still fine microscopic seams toward inside drill. Rag dipping dedicated cleaning agent takes surface red water all wipes gets clean clean.

White color developer powder closely follows sprays on one layer. 3 minutes pass go, white powder inside not oozes out one strand one hair red line. Deep 0.05 mm heat treatment tiny crack also will be by developer powder sucked out obvious red mark.