ProductsProducts

Case Studies

Z-Tuff PM® Case Study Blanking Punch

TOOL TYPE

Blanking punch

WORK MATERIAL

.113" thick High Strength Low Alloy (HSLA)

PROBLEM IDENTIFICATION

D2 (Rc 60–62) was chipping at the corners after 700 hits resulting in unscheduled downtime, lower production and higher tooling costs. Most narrow point on the part is .143", so a difficult die design. Additional materials were investigated with these results:

  • K340 (Rc 58-60) 2,150 parts
  • Vanadis (Rc 58-60) 2,340 parts
  • Z-Wear PM (Rc 60-62) 3,000 parts
  • Caldie (Rc 58-60) 4,500 parts
     

SOLUTION

Z-Tuff PM

RESULTS

Zapp’s Z-Tuff PM (Rc 58-60) successfully ran 17,500 parts before requiring resharpening. Production levels improved dramatically and tooling costs were reduced.

DOWNLOAD

PDF - Z-TUFF PM CASE STUDY BLANKING PUNCH

Z-WEAR PM® CASE STUDY COMPRESSION RING

TOOL TYPE

Compression ring

WORK MATERIAL

Balata Golf Balls

ORIGINAL TOOLING MATERIAL

A-6 Tool Steel (Vega®)

PROBLEM IDENTIFICATION

The D2 slotting punch experienced chipping which resulted in unscheduled down time.

SOLUTION

Z-Wear PM® heat treated to RC 60-62

RESULTS

The equipment used in the production of golf balls has compression rings on either side of the machine. They had been using A-6 tool steel but the compression rings had performed inconsistently because of premature breakage. Z-Wear PM® trials resulted in tool life that equals the very best of the A-6 with no instances of premature failure.

DOWNLOAD

PDF - Z-WEAR PM CASE STUDY COMPRESSION RING

Z-WEAR PM® CASE STUDY THREAD ROLLING DIE

TOOL TYPE

Thread Rolling Die

WORK MATERIAL

Rebar at 2 1/8" diameter

ORIGINAL TOOLING MATERIAL

D2 at RC 59

PROBLEM IDENTIFICATION

The D2 thread roll dies experienced premature wear. Efforts to harden the D2 beyond Rc 59 resulted in catastrophic failure with the dies splitting from the OD  to the ID.

RESULTS

D2 thread roll dies were used to thread 120 to 150 feet (1440-1800 lbs) of 2-1/8" dia rebar before wearing out. Attempts to increase the wear performance by hardening to above Rc 60 resulted in the dies splitting. The customer substituted Z-Wear PM® at Rc 62 and saw tool life improve to 1113 ft (13,350 lbs) before wearing out, an improvement of 750% to 900% compared to the D2.

SOLUTION

Z-Wear PM® heat treated to RC 62

DOWNLOAD

PDF - Z-WEAR PM® CASE STUDY THREAD ROLLING DIE

Z-WEAR PM® CASE STUDY SLOTTING PUNCH

TOOL TYPE

Slotting Punch

WORK MATERIAL

301 Stainless Strip at .030" thick

ORIGINAL TOOLING MATERIAL

D2 at RC 60-62

PROBLEM IDENTIFICATION

The D2 slotting punch experienced chipping which resulted in unscheduled down time.

SOLUTION

Z-Wear PM® heat treated to RC 60-62

RESULTS

The Z-Wear PM® Slotting Punch extended tool life approximately 250% compare to the D2. Some wear was noted but no chipping or breakage. Tooling is performing with much better consistency and downtime has been reduced.

DOWNLOAD

PDF - Z-WEAR PM® CASE STUDY SLOTTING PUNCH

Z-WEAR PM® CASE STUDY COINING PUNCH APPLICATION

TOOL TYPE

Coin Punch

WORK MATERIAL

430 SS .031 thick

ORIGINAL TOOLING MATERIAL

AISI M2

PROBLEM IDENTIFICATION

AISI M2 chipped, cracked and/or fractured in this application. Customer attempted to improve performance by adjusting Rockwell C hardness with no improvements. Problem resulted in excess tooling costs, unscheduled down time and expedited freight charges.

SOLUTION

Z-Wear PM®

RESULTS

The Z-Wear PM® Coin punch extended tool life by 500% on average compared to AISI M2. The improved toughness of Z-Wear PM® eliminated chipping and breakage allowing the punch to wear. Downtime has decreased dramatically and shipments are on schedule!

DOWNLOAD

PDF - Z-WEAR PM® CASE STUDY COINING PUNCH APPLICATION

ZDM Blanks

ZDM Blanks Data Sheet

Same day shipment on most orders!

New Products For Technology Innovations.

Technological Innovations from Zapp Tooling Alloys

Zapp’s ZDM Blanks offer the convenience of a precision ground, pre-hardened PM block ready for the EDM process. Eliminate the wait for costly grinding and heat treating. Zapp has high performance Z-Series PM Blanks ready to EDM.
Quality PM Steels and Quality Heat Treatment.

Tolerances | Hardness

Tolerances Hardness
Std Width 5.000" +.010"/.040 Z-Wear PM Rc 58/60 Excellent Toughness
Std Length 7.500" +.010"/.040" Z-M4 PM Rc 60/62 Best Combined Wear & Toughness
Std Thickness Below +.010"/.020" Z-A11 PM Rc 60/62 Excellent Wear Resistance

Standard Thickness

Z-M4 PM Z-A11 PM Z-Wear PM
0.500" 0.500" 0.500"
0.750" 0.750" 0.750"
1.000" 1.000" 1.000"
1.250" 1.250" 1.250"
1.500" 1.500" 1.500"
1.750" 1.750" 2.000"
2.000" 2.000" 2.540"
2.500" 2.500" 3.040"
3.000" 3.000" 3.500"
3.500" 3.500" 4.000"
4.000" 4.000"