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Through years of work experience, many clients and friends have asked me how to extend the service life of a ring die. I am writing this post based on my experience with clients to introduce some factors for extending the life of a ring die. Focusing on two critical factors can help you achieve this: selecting a high-quality ring die and proper maintenance.
1) What Makes a High-Quality Ring Die?
Raw Materials
First of all, the raw materials are crucial. X46Cr13 is the preferred material code. However, the same X46Cr13 code can have different levels of steel quality based on the supplier’s forging ability and process. Raw material is the main cost for die manufacturers, so when choosing a die supplier, ensure the company is reliable.
Heat Treatment
Secondly, we need to talk about heat treatment. The vacuum heat treatment process is essential for ring die production. This process is complicated and requires a manufacturer with significant experience. Normally, the proper hardness for a die is HRC50-55, depending on the performance requirements of various pellets. Some small producers lack experience and don’t have vacuum heat furnaces, outsourcing the heat treatment to third parties. This can make it difficult to control the timing and results, and it may not ensure uniform hardness throughout the component.
Die Hole Design and Production
Thirdly, the die hole design is crucial. Sometimes, even when the raw material and hardness are not problematic, the lifespan may still not be ideal. This can be due to improper hole design that doesn’t suit the pellet ingredients. The ring die hole design, including the hole pattern, compression ratio, counterbore degree, and depth, should be customized specifically for the material you are using. Sharing your ring die usage experience with your supplier can help you find a suitable one
2) Proper Operation and Maintenance
Gap Adjustment
Adjust the gap between the roller and the ring die to the correct working position.
Many modern pellet mills have automatic roller adjustment systems, which help address this issue.
Regular Inspection
Conduct regular inspections to identify early signs of wear or damage,including wear on other parts such as clamps, flanges, and transmission keys. These components’ wear can also affect the ring die’s lifespan;Maintain the ring die by keeping it clean and well-lubricated.
Chamfering
Finally, chamfering an old die is an essential maintenance process that extends its service life. During a visit to a leading feed producer in April, I was impressed by their extremely clean and tidy production workshop and their professional ring die operation and maintenance skills. They have their own chamfering machine, and the operation manager mentioned that their ring dies are chamfered every 3,000 tons, which extends the lifespan of the die and ensures continuous high-quality pellet production.
The topic of how to extend the life of ring dies has many details that still need to be explored. Due to the limited length of this article, I can only briefly introduce it based on my work experience. I hope this is helpful to you and that more people will join the discussion. If you have further questions or need more guidance, feel free to communicate.
