The industry of metal forming and production of circulation parts has always been one of the main pillars of the automotive, home appliances, electronics and construction equipment industries. In the east of the country, especially Khorasan-Razavi province, the metropolis of Mashhad is known as one of the powerful industrial hubs of Iran. The ever-increasing need of production units for precise and high-quality metal parts has caused the familiarity with the stages of making metal molds and pressing in Mashhad to become doubly important. Making metal parts is a complex engineering process that starts from the initial idea and drawing and ends with precise machining, thermal hardening and final production by industrial presses.
Meanwhile, choosing an experienced and specialized industrial group like Azin Sanat workshop can guarantee the accuracy, speed, durability of the mold and ultimately reduce the finished price of the product. Azin Sanat Workshop, with years of brilliant experience in the field of molding and pressing services, has been able to cover the industrial needs of Khorasan province and other parts of the country with the highest quality standards. In this specialized article, we will examine step by step and comprehensively the design process and the stages of making metal molds and pressing in Mashhad and review the role of modern technologies in this industry.
Industrial importance of metal mold making and pressing in Mashhad
Precision in making a metal mold means that the output piece is produced without the slightest dimensional deviation, additional pleats or external defects. The smallest error in mold geometric tolerances can cause damage to press machines or widespread breakdowns in assembly lines. Therefore, by investing in modern equipment and employing expert technicians, Azin Sanat workshop has improved the standards of metal mold making and pressing in Mashhad and offers products that are fully compliant with technical drawings.
Types of metal molds in manufacturing industries
Before going into the details of the metal mold making and pressing process in Mashhad, it is very important to know the types of metal molds commonly used in the sheet metal forming industry. These templates are selected based on the circulation of the work, the complexity of the geometry of the part and the type of material.
Mandrel and matrix cutting molds are used to separate the part from the raw sheet, punching and pleating. Blades and mandrels in this type of mold must have the highest wear resistance.
Bending molds are used to create different angles, simple bends, V and U-shaped forms in metal sheets, and they require very high accuracy in determining the material's spring return.
Deep drawing molds are designed for forming hollow parts such as filter shells, tanks, body parts and sinks, which require precise thickness control and special lubrication.
Progressive or stage molds are considered to be the most advanced types of molds in which the metal sheet is continuously inserted and a cutting, drilling, form or bending operation is performed at each station so that the complete piece is removed at the final station. Azin Sanat workshop has a special expertise in making progressive molds, which multiplies the speed of the pressing production line.
Compound molds are another type of molds that perform several operations at the same time in a press course and are considered an economical choice for high-volume precision parts.
The steps of making a metal mold in the workshop of Azin Sanat
Designing and making a high-quality metal mold has completely interconnected steps and requires metallurgical knowledge and precise machining. In the workshop of Azin Sanat, the steps of metal mold making and pressing in Mashhad are carried out based on modern industrial standards in the following order:
The first step: receiving the map, prototyping and analyzing the customer's needs
The first step in the implementation of the metal mold making and pressing project in Mashhad is the detailed analysis of the part sample or its engineering plan. At this stage, the engineering team of Azin Sanat workshop carefully evaluates the type of sheet material, thickness, material, hardness, circulation desired by the customer and dimensional tolerances in order to choose the most economical and accurate molding method.
Second stage: engineering design with specialized CAD software and form analysis
Basic design is the main foundation of mold quality. Using advanced software such as SolidWorks, CATIA and modeling analysis software such as AutoForm, the engineers of Azin Sanat workshop simulate all parts of the mandrel, matrix, cover, springs, guides and press course. In this section, things such as the cutting angle, the amount of slack or clearance between the mandrel and the matrix, and how to arrange the part on the strip layout (Strip Layout) are calculated to reduce material waste.
The third step: selection and preparation of the steel material of the mold
The strength and longevity of the metal mold is directly related to the quality of the tool steel used in it. For the main cutting and wearing parts, resistant alloy steels such as SPK (1.2080), SPK-R (1.2436), Mo40 and VCN are generally used. In the workshop of Azin Sanat, the best quality steel blocks with ID are used, and before machining, the health of the material is checked.
Fourth stage: basic machining and CNC milling
After cutting the steel blocks, the parts enter the stage of rough machining and CNC milling. In this section, the initial dimensions of shoes, holding plates, mandrel seat and matrix are machined with speed and precision to provide the necessary base for finishing operations.
The fifth stage: heat treatment and hardening (Heat Treatment)
During pressing, mandrels and matrices are under severe shock and wear pressures. Therefore, after initial machining, these components enter standard hardening furnaces to obtain a suitable hardness, usually between 56 and 62 Rockwell C (HRC), depending on the type of steel and the application of the part. Adhering to accurate temperature cycles prevents steel from warping or cracking.
The sixth stage: final machining, spark, wirecut and magnetite
After hard work, due to the high hardness of the material, the final shaping is done with ultra-precise methods. The cutting edges and delicate forms of the matrix are cut by modern CNC (Wire Cut) wire cutting machines with micron precision. Also, the mold plates get a completely smooth and parallel surface by the magnetic stone machine, and complex holes are formed through spark machining (EDM).
The seven-stage certified material is used and the health of the material is checked before machining.
Fourth stage: basic machining and CNC milling
After cutting the steel blocks, the parts enter the stage of rough machining and CNC milling. In this section, the initial dimensions of shoes, holding plates, mandrel seat and matrix are machined with speed and precision to provide the necessary base for finishing operations.
The fifth stage: heat treatment and hardening (Heat Treatment)
During pressing, mandrels and matrices are under severe shock and wear pressures. Therefore, after initial machining, these components enter standard hardening furnaces to obtain a suitable hardness, usually between 56 and 62 Rockwell C (HRC), depending on the type of steel and the application of the part. Adhering to accurate temperature cycles prevents steel from warping or cracking.
The sixth stage: final machining, spark, wirecut and magnetite
After hard work, due to the high hardness of the material, the final shaping is done with ultra-precise methods. The cutting edges and delicate forms of the matrix are cut by modern CNC (Wire Cut) wire cutting machines with micron precision. Also, the mold plates get a completely smooth and parallel surface by the magnetic stone machine, and complex holes are formed through spark machining (EDM).
The seventh stage: assembly, adaptation and initial testing of the metal mold
At this stage, all the parts including mandrels, matrix, mandrel holder, guide rods and ball bushings are assembled together with the skill of master workers of Azin Sanat workshop. They also increase the slackness.
Hydraulic presses that have the ability to apply uniform and adjustable pressure tonnage throughout the movement course. These presses are the most suitable choice for deep drawing operations, heavy forming and production of high thickness parts.
Hand and light impact presses are also used for workshop work, one-offs and special settings. By combining these equipments, Azin Sanat workshop has provided a complete chain of metal mold making and pressing services in Mashhad to craftsmen.
Key points in increasing the lifespan of mandrel and matrix molds
Depreciation of mold is one of the main concerns of factory managers. In order to maintain the quality of the piece and prevent repeated manufacturing costs, it is necessary to observe several technical principles: regular lubrication of mandrels and matrices with special oils for tension and form prevents surface welding and premature erosion. Accurate control and adjustment of the clearance between the mandrel and the matrix according to the material and thickness of the sheet prevents unbalanced pressure on the cutting edges.
Using modern resistant coatings such as TiN or hard chrome coatings on the surfaces involved in the mold increases the wear resistance several times. Checking the health of bushings and guide rods periodically prevents vibration and step error during continuous press operation. Azin Sanat workshop, in addition to design and construction services, also provides repair, restoration, re-grinding and specialized maintenance services for all types of metal molds in Mashhad with full warranty.
Why is Azin Sanat workshop the best choice for making metal molds and pressing in Mashhad?
Finding a committed and equipped center that can manage zero to one hundred ideas from design to mass production is the key to the success of industrial projects. Azin Sanat workshop has established itself as one of the pioneers of the metal mold making and pressing industry in Mashhad by relying on the following competitive advantages:
- Experienced engineering team and proficient in global standards of advanced industrial mold design.
- Equipped with advanced CNC milling machines, precise wirecut and high tonnage presses.
- Using first grade alloy steels with valid analysis certificate to guarantee long life. Razavi.
- Providing mold performance guarantee and technical support services, troubleshooting and providing spare parts in the shortest possible time.
- Possibility of producing parts with continuous and automatic pressing method to significantly reduce the costs of respected employers.
Application of production parts with metal molds and pressing in different industries
The wide range of metal mold making and pressing processes in Mashhad covers various sectors of economy and industry. Car body parts, washers, fasteners and support bases in the car industry are obtained from this method. The metal panels of refrigerators, washing machines, gas stoves and cooler bases in the field of household appliances are made with the help of stretch and bend molds.
Also in the construction industry, the production of structural joints, facade bases, Kenaf style profiles, pipe fasteners and door and window fittings is done by pressing. In the power industry and power plant equipment, parts such as terminals, switchboard frames, brackets, and heatsinks all rely on precision molding services. Azin Sanat workshop has extensive cooperation experience with active companies in all these fields and has a successful track record of producing sensitive industrial parts.
Cost optimization in mold making and pressing services
In order to achieve the highest economic efficiency in the implementation of metal mold making and pressing in Mashhad, an expert look at cost management should be taken. Choosing a logical circulation, optimizing the placement of metal sheets to prevent the production of scrap waste, using multi-cavity or progressive molds if the circulation is high, and accuracy in intelligent tolerance are some of the factors that adjust the final cost.
Technical consultants at Azin Sanat workshop before the start of each project hold specialized consultation meetings with employers and suggest the best engineering path so that the project budget is spent in the most economical way possible without quality loss.
conclusion
The process of making metal molds and pressing in Mashhad is a completely specialized, multi-stage process that requires the integration of metallurgical knowledge, engineering software, precise CNC machining and practical workshop experience. Any negligence in design, material selection or machining can lead to financial damages and production time loss.
Azin Sanat workshop with years of continuous experience, using modern mandrel and matrix molding equipment, progressive, stretching and equipped pressing lines in Mashhad, is the most reliable choice for the owners of industries, factories and entrepreneurs across the country. If you are looking to improve the quality of metal parts, reduce circulation costs and make solid molds with the highest industrial standards, Azin Sanat workshop will be a reliable companion in all stages of your production. You can contact the specialists of Azin Sanat workshop in Mashhad to receive expert advice, check the plans and inquire about the costs of making metal molds and pressing services.