Thank you for your help in improving our tool life. We have been looking for a way to improve tool life for our flattening and bending operation.

Our current dies made of D2 showed dramatic wear (which does not help accuracy) and usually did not last more then 5,000 pieces. This caused us to make a lot of adjustments during the production run and, of course, frequent die replacements.

The process takes place on an 800 ton knuckle joint press. The parts are front end suppression brackets made of 3/4" diameter SAE1541 material. The parts are flattened to 1/2" thickness and also receive a 30 degree bend over a 1" length.

Your representative suggested that we utilize DC-53 material for improved die life. International Mold Steel sent us a sample piece of material. We made the die in our tool room and the toolmakers commented that "this really machined well". Your representative told us that it should machine 30% to 40% better than other steels - we agree that it does.

We then had the part heat treated, ground and polished. We tried the die and did not get any improvement. We talked to your representative and asked how the die was heat treated. We soon discovered that the heat treat instructions were not followed as recommended.  We reworked the die, send it back for heat treatment and this time made sure that the heat treat instructions were properly followed.

Of course, everyone was now curious and skeptical. The die was placed back in the press and we processed 10,000 pieces (all good) before the die failed.

With this result, we are replacing our dies with DC-53 material. It costs $.50 to $0.60 more per pound, but is machines better and a $300.00 to $500.00 tool lasts twice as long and improved quality. We will certainly explore the use of this material in other applications.

Thank you for your firms help.

Joseph P. Klink

President, Custom Metal Products
A Division of The Rockford Co.
1827  Broadway, Rockford, ILLINOIS 61104