| | Welded Reclamation of Forge Dies
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Forge Dies #1 (United Kingdom)
An axle beam manufacturer in the UK were purchasing up to 80 sets of die blocks a year, each set consisted of 4 blocks, 2 moulds and 2 finishing. A shut height restriction meant that re-sinking could not be used to reclaim the blocks.
A programme was devised to reclaim the blocks by the forgeweld layer welding process, and as a result the number of new blocks purchased fell from 80 to 16 per annum, resulting in an annual cost saving of more than £650,000.
A breakdown of the cost differences are shown in the table below: |
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|
Item |
New Die Block (Pair) |
Layer-Weld Reclamation (pair)
|
|
Block Value (£) |
8,000 |
4,051 |
|
Machining Pattern Cost (£) |
5,000 |
5,000 |
|
Blocking Cost (£) |
1,200 |
|
|
Total Value (£) |
14,200 |
9,051 |
|
Saving (%) |
|
36.3 |
|
|
|
|
|
Campaign Life (pieces forged) |
4,000 |
6,000+ |
|
Increase in Life (%) |
|
50 | |
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Forge Dies #2 (United Kingdom)
The table below shows the differences in costs reported by a crankshaft manufacturer in the UK: |
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|
Item |
Original
(Set of 4) |
Layer-Welded (Set of 4)
|
|
Block Cost (£) |
10,000 |
7,800 |
|
|
|
|
|
Blocking Cost (£) |
6,000 |
|
|
Machining Pattern Cost (£) |
12,000 |
12,000 |
|
Total Value (£) |
28,000 |
19,800 |
|
Cost Saving (£) |
|
29 |
|
|
|
|
|
Campaign Life (pieces forged) |
4,000 |
8,000 – 12,000 |
|
Increase in Life (%) |
|
100+ | |
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