Background
A sheet metal components manufacturer aimed to extend the life of its D2-grade profile die and punch used in a hydraulic press blanking operation on cold-rolled carbon steel. With no coating on the tool, wear and burr formation became prominent after around 10,000 parts.
Cryogenic Solution
The die and punch were subjected to a deep-cryogenic treatment cycle designed specifically for cold-work tool steels. The process included a -185 °C soak, controlled warming, and post-tempering to refine carbide distribution and reduce internal stresses.
Quantified Results
| Metric | Pre-Cryogenic | Post-Cryogenic | Improvement |
|---|---|---|---|
| Components per tool set | 10,000 | 25,400 | +150 % |
| Tool-life multiplier | 1.00× | 2.54× | – |
Additional Benefits
- Significant reduction in blanking burr, resulting in cleaner edges and fewer secondary operations.
- Blanking clearance maintained over longer tool life, indicating consistent dimensional accuracy.
- Slower wear progression enabled more predictable maintenance schedules.
- Improved tool reliability led to reduced unplanned downtime.
Takeaway
The cryogenic treatment extended tool life by 150 %, delivering over 2.5× more output per tool set without coatings or redesign. Reduced burrs and consistent clearance offered further process efficiencies, validating cryogenics as a simple, cost-effective upgrade in high-volume blanking operations.