Cold Forging Die Insert

Name: Cold Forging Die Insert | High-strength tooling insert – Frigate
Price: 249.00 USD
Availability: InStock

Cold Forging Die Insert must tolerate compressive loads often exceeding 2200 MPa without yielding or fracture. Achieving this requires high-tempered tool steels like H13 or CPM 3V, with core hardness stabilized through vacuum hardening and sub-zero treatments. Insert geometry is optimized to distribute axial and radial loads uniformly, minimizing localized overstress zones during repeated high-tonnage strokes.

Material Specification

Vanadis 4E, AISI D2, DC53, Tungsten Carbide (for high-volume production)

Hardness (HRC)

60-64 HRC (Tool Steel), 80-85 HRA (Tungsten Carbide)

Surface Finish (Ra/RMS)

Cavity Surface – 0.1-0.3 µm, Side Walls – 0.4-0.8 µm, Mounting Surfaces – 0.8-1.6 µm

Dimensional Tolerances

Cavity Profile – ±0.005 mm, Critical Dimensions – ±0.01 mm, Overall Height – ±0.02 mm

Cavity Profile Geometry

As per 3D CAD Model (STEP/IGES) with ±0.005 mm profile tolerance

Product Description

Cold Forging Die Insert must maintain sub-micron dimensional stability over millions of strokes. Thermal fatigue, wear abrasion, and microstructural distortion are mitigated through controlled heat treatment, post-machining nitriding, and CMM-based final inspection. Deviation in critical geometries such as land, cavity, and relief zones remains within ±2–3 µm even under sustained die pressures and elevated temperatures.

Draft Angles and Radii

Draft – 0.5°-1.5° (per side), Transition Radii – 0.2-0.5 mm (min)

Mounting/Retention Features

Interference Fit – 0.02-0.05 mm, Bolting – M8-M16 (Class 12.9), Shoulder Height – ±0.01 mm

Ejector Pin Hole Locations

Position Tolerance – ±0.01 mm, Diameter – +0.005/+0.01 mm, Flatness – 0.01 mm/m

Coating/Surface Treatment

TiAlN or DLC Coating (2-4 µm), Nitriding (0.1-0.2 mm depth)

Certification Standard

ISO 9001, NADCA #207-2003, DIN EN ISO 4957 (Tool Steel), IATF 16949 (Automotive)

Technical Advantages

Cold Forging Die Insert requires precise interface tolerances to maintain concentric alignment within the die assembly. Fitment geometry is machined with sub-micron accuracy to match holder pockets, reducing relative motion and preventing vibration-induced microfractures. Coefficient of thermal expansion is matched between insert and die block material to prevent dimensional shift during thermal cycling.

Cold Forging Die Insert must resist adhesive wear when used on high-friction materials like stainless steel, Inconel, or dual-phase steels. Surface coatings such as CrN, AlTiN, or DLC, applied via arc-PVD or magnetron sputtering, reduce interfacial shear forces. Coating hardness exceeding 2500 HV and friction coefficients below 0.2 are essential for consistent galling resistance.

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Industry Applications

Fastener Manufacturing

Used to forge high-strength bolts, screws, and rivets with consistent head geometry and shank concentricity in multi-station forming machines.

Aerospace Structural Hardware

Cold Forging Die Insert shapes titanium and nickel-based alloy pins, lugs, and brackets with controlled grain flow and minimal machining.

Bearing Races and Hubs

Enables high-volume forming of inner and outer bearing races with uniform hardness distribution and precise radial wall thickness control.

Two-Wheeler Engine Parts

Forms components like rocker arms and cam lobes requiring tight dimensional repeatability and superior surface finish for sliding contact zones.

Electrical Connector Pins

Cold Forging Die Insert manufactures non-ferrous pins with micron-level diameter control, essential for interference fit and conductivity in connector housings.

Hydraulic Fitting Bodies

Supports forging of complex-shaped coupling and adaptor bodies with uniform wall thickness and defect-free internal flow paths for pressurized systems.

Fracture Resistance in Complex Stress Fields

Cold Forging Die Insert is subject to multi-axial stress states with high stress concentration near corner transitions and punch shoulders. FEM-based topology analysis is used to design insert profiles with optimized fillet radii and chamfered load-bearing zones. Materials selected exhibit high fracture toughness (K_IC > 25 MPa√m) to avoid crack initiation under cyclic mechanical impact.

Cold Forging Die Insert experiences rapid thermal cycling that can lead to surface cracking and spalling. Isotropic heat treatment and retained austenite control are critical to preventing thermal fatigue. Tool steel microstructure is refined to eliminate carbide segregation, ensuring resistance to grain boundary crack propagation during continuous high-frequency forging operations.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does Frigate ensure dimensional consistency in Cold Forging Die Inserts during mass production?

Frigate uses CNC machining combined with wire EDM to control die insert dimensions within ±2–3 microns. Every insert is inspected using coordinate measuring machines (CMM) to verify profile accuracy. Thermal distortion is minimized through precision heat treatment and cryogenic stabilization. This process ensures that inserts remain consistent across multiple production batches.

What methods does Frigate use to extend the wear life of Cold Forging Die Inserts?

Frigate applies advanced surface treatments like TiCN or AlCrN coatings using PVD techniques for enhanced hardness and low friction. Inserts are also cryogenically treated to improve wear resistance and reduce microstructural stress. Edge conditioning and radius optimization prevent early cracking at high-stress zones. These measures collectively extend die life in high-load forging cycles.

How does Frigate control microcrack formation in Cold Forging Die Inserts under repeated impact?

Frigate selects tool steels with high fracture toughness and controlled carbide distribution to reduce crack initiation. FEM simulation is used to refine insert geometry and eliminate stress concentration points. Inserts are tempered multiple times to improve thermal stability and fatigue resistance. These practices reduce failure under cyclic mechanical and thermal loads.

What design factors does Frigate consider to improve alignment in multi-stage forging using Cold Forging Die Inserts?

Frigate machines locating features with sub-micron tolerances to ensure concentricity between insert and die block. Each insert is designed with alignment keys or tapered seats for repeatable positioning. Insert profiles are modeled to maintain geometric consistency under axial and radial forces. This ensures accurate part formation in progressive forging operations.

How does Frigate match Cold Forging Die Insert material to specific workpiece alloys?

Frigate analyzes the forming load, flow stress, and thermal conductivity of the workpiece alloy before insert material selection. For abrasive materials, high-vanadium tool steels are used; for ductile metals, impact-resistant grades are preferred. Material trials and wear mapping are performed to validate compatibility. This process ensures optimal die performance for each application.

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LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

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