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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.

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PDF - Z-TUFF PM CASE STUDY BLANKING PUNCH

Z-Tuff PM® Case Study Blanking

TOOL TYPE

Blanking

WORK MATERIAL

HSLA (900 Mpa) .113" thickness

PROBLEM IDENTIFICATION

Chipping and Breakage 

SOLUTION

Z-Tuff PM at Rc 58-60

RESULTS

Z-Tuff PM ran 17,500 strokeswith no chipping resulting in lower downtime, higher productivity and reduced tooling costs. Previous material results were D2 (700 strokes), K340 (2,150 strokes), Vanadis 4E (2,340 strokes), Z-Wear PM (3,000 strokes) and Caldie (4,500 strokes).

Z-Tuff PM resulted in reduced downtime and increased productivity with reduced tooling costs.

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PDF - Z-TUFF PM CASE STUDY BLANKING

Z-Tuff PM® Case Study Connector Tooling

TOOL TYPE

Connector Tooling

WORK MATERIAL

1008 Cold Rolled Steel 0.26" thickness

PROBLEM IDENTIFICATION

Breakage and chipping on small tabs located on the inside edge of the connector part. D2 at Rc 58-60 ran an average of 30,000 parts. CPM 3V ran an average of 60,000 parts at Rc 57-59.

SOLUTION

Z-Tuff PM at Rc 60-62

RESULTS

Z-Tuff PM has run in excess of 150,000 parts and continues to produce parts at this time. Downtime on the press has been reduced by 70%.

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PDF - Z-TUFF PM CASE STUDY CONNECTOR TOOLING

Z-Tuff PM® Case Study Fineblanking Punch

TOOL TYPE

Fineblanking Punch

WORK MATERIAL

304SS at 12 mm thickness

PROBLEM IDENTIFICATION

Complete punch failure. All previous grades (D2, M4 PM and CPM 3V) failure by catastrophic breakage.

SOLUTION

Z-Tuff PM at Rc 60-62

RESULTS

Z-Tuff PM ran a total of 18,000 parts to complete the current requirements. Tool was put into storage awaiting next production requirement. Previously, the highest production from D2, 3V or M4 was 8,000 parts before the punch broke.

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PDF - Z-TUFF PM CASE STUDY FINEBLANKING PUNCH

Z-Tuff PM® Case Study Trim Die

TOOL TYPE

Trim Die

WORK MATERIAL

HSLA (620 Mpa)

PROBLEM IDENTIFICATION

All previous tooling materials broke in application. The maximum production with other materials was 2,000 - 3,000 parts. Breakage was experienced with A2, D2, S7, Caldie, DC53 and Vanadis 4E.

SOLUTION

Z-Tuff PM at Rc 56-58.

RESULTS

Z-Tuff PM has provided 10X improvement running nearly 30,000 parts and even survived 2 double hits without breaking. Production improvements are impressive.

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PDF - Z-TUFF PM CASE STUDY TRIM DIE

Z-Tuff PM® Case Study Embossing Punch

TOOL TYPE

Embossing Punch

WORK MATERIAL

Dual Phase HSLA (980Mpa)

PROBLEM IDENTIFICATION

D2 punches failed prematurely because of exceessive wear and chipping resulting in the need to produce 831 punches/ year and excessive downtime on the press.

SOLUTION

Z-Tuff PM with TiCN PVD Coating at Rc 60

RESULTS

Reduction from 831 punches per year to 330 Z-Tuff PM punches for an annual savings of $251,000.  Additional increases in production resulted from higher uptime on the press. Z-Tuff PM was the perfect substrate for the TiCN coating based upon excellent impact resistance at Rc 60 in combination with good compressive strength.

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PDF - Z-TUFF PM CASE STUDY EMBOSSING 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.

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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

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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.

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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!

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

Z-WEAR PM® CASE STUDY FINEBLANKING PUNCH

TOOL TYPE

Fineblanking Punch

WORK MATERIAL

20MnCr5+H (550MPa) 7mm thickness

PROBLEM IDENTIFICATION

Premature failure due to chipping and edge cracks. Previous material was D2 at Rc 60-62 with life cycle of 5,000 – 8,000 parts.

SOLUTION

Z-Wear PM at Rc 60-62

RESULTS

Z-Wear PM ran 20,000 – 25,000 parts with no chipping and normal wear. Productivity improved by 3-4 times because of the increased tool life.

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PDF - Z-WEAR PM® CASE STUDY FINEBLANKING PUNCH

Z-WEAR PM® CASE STUDY BLANKING FORMING

TOOL TYPE

Blanking/ Forming

WORK MATERIAL

409 SS at .060″ thickness

PROBLEM IDENTIFICATION

D2 at Rc 60 was chipping after producing 7,000 parts.

SOLUTION

Z-Wear PM at Rc 60-62

RESULTS

Z-Wear PM lasted for 52,900 parts before the first regrind. The maximum performance for D2 previously was 8,200 parts. Production improved over 6 times.

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PDF - Z-WEAR PM CASE STUDY BLANKING FORMING

Z-WEAR PM® CASE STUDY PROFILE INSERT COIN PROTECTOR

TOOL TYPE

Profile Insert with Coin Protector

WORK MATERIAL

1040 Cold Rolled Steel .134″ thickness

PROBLEM IDENTIFICATION

The coin protectors continually broke inserts when using PM A11 at Rc 60-62. The life cycle of the inserts was between 5,000 and 10,000 hits before breaking causing excessive downtime.

SOLUTION

Z-Wear PM at Rc 62-64

RESULTS

The Z-Wear PM insert ran a total of 24,000 hits with no breakage. The insert experienced normal wear, was resharpened and put back into production. Z-Wear PM has the right combination of toughness, wear resistance and compressive strenght to handle this application resulting in an average of 300% productivity improvement.

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PDF - Z-WEAR PM CASE STUDY PROFILE INSERT COIN PROTECTOR

Z-MAX PM® CASE STUDY MOUNTING CUP FORMING TOOL

TOOL TYPE

Forming Tool in Progressive Die for Aerosol Mounting Cup

WORK MATERIAL

Epoxy Coated Tin Plate .018″ (.46mm) thickness

PROBLEM IDENTIFICATION

Forming tool was performing well with Z-A11 PM (10V) material. Failure mode was always wear with the best production of 50,000 parts before resharpening. Although the customer was satisfied with tooling Performance, they wanted to try for further tooling improvements.

SOLUTION

Z-Max PM at Rc 67-69

RESULTS

Z-Max PM produced in excess of 300,000 parts before resharpening. In a high production environment, Z-Max PM outperformed previous materials by 6 times with significant reduction in downtime.

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PDF - Z-MAX PM CASE STUDY MOUNTING CUP FORMING TOOL

Z-MAX PM® CASE STUDY TWIN EXTRUSION BARREL LINERS

TOOL TYPE

Twin Extrusion Barrel Liners

WORK MATERIAL

Recycled Materials (Plastic and Steel Mixture)

PROBLEM IDENTIFICATION

Liners were not Lasting as long as the customer would like resulting in excessive downtime. Heavy wear lines (grooves) up to .375″ deep were common. Stress cracks would develop catching the slurry and causing build-ups that would shut down the Extrusion process.

SOLUTION

Z-Max PM at Rc 62-64

RESULTS

Z-Max PM liners have been in production now for 2- 1/2 years producing over 25 Million Ibs. With no signs of wear or cracks. Previous liner materials, D2 and CPM 10V, produced 4 million and 8 million Ibs. Respectively before needing replacement. Production improvement is over 3 times that of 10V and the liners are still running! User will next try Z-Max PM at a slightly higher hardness (Rc 64-66) for even higher production rates.

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PDF - Z-MAX PM CASE STUDY TWIN EXTRUSION BARREL LINERS

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"