1. Pre-tooling
Raw material is cut to overall profile considering machining allowances. This operation is carried out generally by sawing and flame cutting.
2. Surface Grinding
After pre-tooling cleaning all the sides and maintaining right angles, this block is further smooth machined on grinding machine.
3. Conventional Machining
According to drawing and process sheet the raw material is rough machined to the geometric features and size of the part by providing sufficient allowance for finishing. Conventional machining is generally carried out by Lathe, Milling and Shaping machines.
4. CNC Machining
Features such as Pockets, Profiles, which requires close tolerances are machined in this stage.
5. Stage Inspection
After each operation stage inspection is carried out to check the required profiles are having geometric accuracy or not.
6. Bench Work
Drilling, Tapping is done using drilling machines. Finishing, corner radius, cavity profiles are done at this stage.
7. Heat treatment
The cavity block is now quenched and tempered to required hardness of 46 to 48 HRC.
8. Sparking and Wire cutting
Features which cannot be machined by conventional machine are done by this process.
9. FinishingThis is the last stage in manufacturing done by Grinding, Polishing or Lapping as required.
10. Final Inspection (CMM)
Co-ordinate measuring machine is used to check complex profiles which require close tolerance. Detail of CMM and tolerances used for manufacture tool components are detailed.
