Solutions
CASE1：Combining polishing and coating processes to reduce overall cost
Issues/challenges
What improvements can we make to die components in order to boost the durability and performance of dies and molds while at the same time reducing costs?
Solution
Conventional hard chrome plating of die components was replaced by a combination of polishing and TiN coating, delivering improved resistance to wear and corrosion.
The service life of components increased from 3,000 shots to 1,000,000 shots (a 333 x improvement)! We used our experience and technical expertise to tailor machining processes to the new coating for maximum performance at the lowest overall cost.
CASE2：Integrating cutting, quenching, polishing and finishing processes to
reduce turnaround times and boost quality standards
Issues/challenges
Cutting, quenching, polishing and finishing processes were previously outsourced to different contractors.
This involved extensive coordination between processes and inevitably leads to variation in quality standards.
Solution
We introduced an integrated combination of cutting, quenching, polishing and finishing processes.
This reduced the need for coordination between processes on the client side and compressed the turnaround time by around one week.
It also allowed us to guarantee consistent quality standards across all processes, resulting in higher quality products overall.
CASE3：Modifying machining processes to boost accuracy and reduce lead times
Issues/challenges
Conventional machining processes were not always able to accommodate irregular forms.We want to modify the processes to prevent occasional damage and/or deformation of irregular forms.
Solution
The conventional process for irregular shapes involves electrical discharge die milling followed by polishing and finishing. We modified the sequence of processes to start with grinding (creating the basic form), then cutting in a high-speed machining center followed by polishing and finishing.
We also introduced diamond-kneaded rubber abrasive grains in the polishing process to prevent damage to irregular shapes.
This improved the accuracy of finished components without compromising the shape.
Turnaround times can be further reduced by operating machining centers overnight.
In addition to making metal dies and molds to micron-level accuracy, we also supply a range of precision parts and components to the auto, medical and airline industries, via our seamlessly integrated production system encompassing all stages from material procurement through to product delivery.
Rhine Seiko supplies cold forging dies, resin molding dies and powder casting dies as well as press and deep-draw die components. Our specialty is metal die and mold components made from hardened materials with micron-level surface smoothness and machining tolerances.
Rhine Seiko supplies the medical, auto and aircraft industries with precision parts and components as well as micron-level tools, jigs and gauges produced via our seamlessly integrated production system encompassing all stages from procurement through to product delivery.
