Writer： admin Time：2019-09-18 03:47:21 Browse：299℃
Customer background
A high-end hardware tool manufacturing enterprise in Vietnam, belonging to a well-known German industrial group, focuses on the research and production of manual tools such as pliers and saws. The customer's products are exported to high-end markets in Europe and America, with strict requirements for tool surface hardness (≥ 60HRC), dimensional accuracy, and environmental standards. The traditional salt bath quenching process has pain points such as large thermal deformation, high energy consumption, and difficulty in uniformly hardening complex cutting edges, and urgently needs innovative technologies to enhance competitiveness
Customer Demand
1. High precision surface hardening: The jaw biting surface, saw blade and other parts need to achieve a controllable hardening layer of 0.2-0.8mm, with a hardness fluctuation of ≤ 2HRC, to avoid the risk of brittle fracture of the blade edge
2. Complex shape adaptability: Irregular tools such as curved saw blades and multi tooth jaws require fully automatic and precise quenching, while traditional induction hardening is difficult to achieve due to coil design limitations
Our Solution
1. Generate dynamic scanning paths based on tool 3D models, with adjustable spot shapes (circular/rectangular/linear), suitable for complex geometric features such as serrations and grooves, and a quenching coverage rate of ≥ 95%
2. By adjusting the power segmentation (800-2800W) and optimizing the scanning speed (200-1500mm/min), the surface hardness reaches HRC58-62, and the hardness gradient of the transition layer is gentle (decreasing by ≤ 3HRC every 0.1mm), avoiding micro cracks caused by stress concentration
Project results
1. Breakthrough in performance: The wear resistance of the clamp bite surface has been increased by three times, the continuous cutting life of the saw blade has been increased from 800 times to 2500 times, and the customer's product has passed T Ü V Rheinland's 1 million fatigue test certification
2. Cost optimization: The cost of single quenching has decreased by 35%, saving over 80000 US dollars in annual heat treatment expenses, and the equipment investment payback period is less than 10 months
3. Sustainability improvement: Reduce quenching oil consumption by 8 tons and carbon dioxide emissions by 120 tons annually
Customer reviews
This equipment has completely changed our production mode. The uniformity of serrated quenching has reached ± 0.5HRC, and the product return rate has decreased from 1.2% to 0.15%, helping us to leap to the technical benchmark in the global supply chain evaluation of our German parent company. ”——Hamilton， production director