03 — Die / Mold System
Precision Powder Metallurgy (PM) Sintered Filter Elements Components Compaction Die Mold Engineering
This die mold system is used for compacting metal powders into high-precision porous sintered filter elements and components of various shapes, including cylindrical, tubular, cup, disc, and customized geometries.
Use Case
It supports the production of stainless steel, bronze, nickel, and specialty alloy filters for automotive, hydraulic, pneumatic, chemical processing, and industrial filtration applications, while ensuring controlled porosity, permeability, and dimensional accuracy prior to sintering.
Technical Specifications (Tooling)
Tool Type
- Single-action or double-action PM compaction die set.
- Floating die tooling system for improved density distribution.
- Core rod and mandrel-supported tooling for hollow filter components.
- Mechanical, hydraulic, or CNC powder compaction press compatible tooling.
- Single-level and multi-level compaction die configurations.
Tool Materials
- Die inserts manufactured from Tungsten Carbide (WC-Co) for superior wear resistance.
- Upper and lower punches made from PM High-Speed Steel (PM-HSS) or hardened tool steel.
- Core rods and mandrels fabricated from carbide or hardened alloy steel.
- Die holders and backing plates produced from hardened D2, H13, or equivalent tool steel.
- Guide pillars and bushings manufactured from precision hardened bearing steel.
Tool Construction
- Modular die set design with replaceable wear components.
- Precision-ground punch and die interfaces.
- Carbide-lined die cavity for extended service life.
- Interchangeable core rods for different filter dimensions and configurations.
- Heavy-duty support structure designed for high compaction pressures.
- Suitable for automated powder feeding, compaction, and ejection operations.
Multi-Level Tooling
- Multi-level punch arrangements for stepped and complex component profiles.
- Independent upper and lower punch motion control.
- Capability to form varying heights, wall thicknesses, and geometric features in a single press cycle.
- Supports components with shoulders, flanges, grooves, and multi-diameter sections.
- Enables improved density control across complex filter geometries.
Alignment Accuracy
- Punch-to-die alignment accuracy: ±0.005 mm or better.
- Die concentricity: ≤ 0.01 mm.
- Core rod positioning accuracy: ±0.01 mm.
- Guide system repeatability: ±0.003 mm.
- Ensures uniform density distribution and minimizes tooling wear.
Surface Finish
- Die cavity surface finish: Ra 0.1–0.2 µm.
- Punch working surface finish: Ra 0.05–0.1 µm.
- Core rod and mandrel surfaces polished to mirror finish.
- Low-friction surfaces improve powder flow and reduce ejection forces.
- Supports excellent dimensional consistency and surface quality of green compacts.
Lubrication
- Compatible with internal powder lubricants used in PM processing.
- Optional automatic die-wall lubrication system.
- Micro-spray lubrication for high-volume production.
- Anti-wear coatings available including TiN, TiCN, CrN, and DLC.
- Reduces friction, galling, and wear during compaction and ejection.
Tool Life
- Carbide die inserts: 500,000 to 2,000,000+ compaction cycles.
- PM-HSS punches: 200,000 to 1,000,000 cycles.
- Core rods and mandrels: 300,000 to 1,500,000 cycles.
- Guide pillars and bushings: More than 1,000,000 cycles.
- Tool life depends on powder abrasiveness, compaction pressure, component geometry, lubrication, and maintenance practices.
