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Applications

The hardest prehardened tool steel in the world, Toolox® can be used in nearly endless applications.

With its combination of superior toughness and hardness, as well as its excellent machinability, dimensional stability, high cleanliness, fatigue resistence and guaranteed properties, you’ll surely find a good use for it. In molds and dies that produce all types of products, from TV frames, engine covers and car safety parts to high-performance machine components, you'll find Toolox® bringing benefits to its users every day.

The following examples show the benefits of Toolox® at work in selected applications.

Plastic injection mold

Plastic injection mold

Function: Top for covering cables, in PA nylon with 15% glass fiber

Solution: Toolox® 44

Manufacturing: This is a two-part mold with direct injection. The forming parts of the mold are in Toolox® 44. The test mold was done with a standard hardness of 45 HRC. Later, before production, the mold received ionic nitriding to 61‑62 HRC.

Result: Approximately 10,000 pieces were made monthly until a total of 50,000 pieces were produced, after which production stopped. The mold was still fully functional.

For more information, contact your local Approved Toolox® Dealer or SSAB Tech Support at techsupport@ssab.com.



Cold-forming die for heat exchange plateCold-forming die for heat exchange plate

Function: Stainless steel die for pressing pieces used in heat exchangers

Solution: Toolox® 44

Manufacturing: Previous solution was W.Nr 1.2344, bought in soft-annealed condition. After the die was manufactured, the steel was quenched to approximately 50 HRC. The final die was made using a modular system consisting of many parts.

Result: The die was milled out from one Toolox® 44 plate, representing major cost and time improvements compared with the previous solution. Approximately 600,000 pieces were produced with perfect results.

For more information, contact your local Approved Toolox® Dealer or SSAB Tech Support at techsupport@ssab.com.



Cold working

Cold working – progressive dies for producing refrigerator parts

Function: Bottom plate for a refrigerator compressor

Solution: Toolox® 44

Manufacturing: Previous steel was W.Nr. 1.2363 hardened to 60 HRC. Toolox® 44 was chosen to save time, avoid the difficulties in heat treating long parts and make final adjustments easier. Manufacturing of the dies went well, saving more than 3 days in die-making. The usual post-heat-treatment adjustments, needed with the previous material solution, were eliminated.
Result: The die was inspected after 150,000 pieces were produced. No visible wear could be detected. Control measurements of the die proved satisfactory. More than 1.5 million pieces have been produced in the same die.

For more information, contact your local Approved Toolox® Dealer or SSAB Tech Support at techsupport@ssab.com.



Tool holder

Tool holder

Function: Tool holders for specialized turning tooling, in various diameters starting at 17 mm (0.669″)

Solution: Toolox® 44

Result: Previous material showed cracks on thin sections (4140 44‑46 HRC). Using Toolox® 44 resulted in a long holder life (3 times), no heat treatment, less wear on the tip connection holes, and fewer vibrations, which improved the work piece surface.

For more information, contact your local Approved Toolox® Dealer or SSAB Tech Support at techsupport@ssab.com.


Car shredder axle

Car shredder axle

Function: Axle around which the hammers rotate. Diameters: 101 mm, 121 mm, 125 mm (3.98”, 4.76”, 4.92”).

Solution: Toolox® 44

Result: The previous material, 42CrMo4 HT, showed problems with deformation after heat treatment. Besides making manufacture easier and faster, Toolox® 44 also showed significant improvements in an average service life increase of 30%. The customer introduced Toolox® as the standard for the application.

For more information, contact your local Approved Toolox® Dealer or SSAB Tech Support at techsupport@ssab.com.



Plastic mold

Plastic mold

Function: Fixture for an electrical box used in electrical installations, in PA 6 nylon. No filler material.

Solution: Toolox® 44 (replaced Stavax (AISI 420 mod.))

Manufacturing: Manufacturing worked well; the only problem was threading. Using machine taps, the chips were difficult to remove from the holes. The problem was solved by changing to taps having straight threads pushing the chips forward.

Result: The mold was used for an annual production of up to 50,000 pieces, totaling approximately 200,000 pieces, which was fully satisfactory. Toolox® 44 was also used for the inserts in several other molds. Toolox® 44 brought major time savings in mold production since it eliminated the need to heat treat and adjust the mold.

For more information, contact your local Approved Toolox® Dealer or SSAB Tech Support at techsupport@ssab.com.




Brass die casting

Brass die casting

Function: Mold for die casting brass components

Solution: Toolox® 44

Manufacturing: Previous steel solution QRO 90 heat treated to around 48 HRC. Technically a well working but expensive solution. A better surface on Toolox® 44 was achieved after polishing than with the previous steel (QRO 90 heat treated to roughly 48 HRC), which the customer valued greatly. Machining of the mold went well.

Result: Toolox® 44 was used in a parallel test to QRO 90, in the mold and in the cores. In the cores, Toolox® 44 wore out faster than QRO 90. The mold itself was run to the full series of 45,000 pieces. Almost no difference was noted between the Toolox® 44 and the QRO 90 molds. (QRO 90 had slightly better surfaces.) The customer decided to introduce Toolox® 44 as the standard for the application and to initiate testing with larger molds.

For more information, contact your local Approved Toolox® Dealer or SSAB Tech Support at techsupport@ssab.com.




Aluminium die casting

Aluminium die casting

Function: Piston for a Piaggio Vespa scooter

Solution: Toolox® 44

Manufacturing: Previous solution was W.Nr 1.2343, ESR quality heat treated to 46‑48 HRC. Technically, the solution worked well for the customer. 
The piston comes in 10 different sizes. Therefore, a series of 10 molds were manufactured using 130 mm (5.12”) thick Toolox® 44 blanks. Usually, a mold like this is manufactured in four weeks.

Result: The Toolox® mold went successfully into production. Using Toolox® 44, one week’s manufacturing time was saved because heat treatment was eliminated. No surface engineering was done.

For more information, contact your local Approved Toolox® Dealer or SSAB Tech Support at techsupport@ssab.com.



Tool for manufacturing automotive B-pillar

Tool for manufacturing automotive B-pillar

Function: Tool used to manufacture B pillars for a German car manufacturer

Solution: Toolox® 33

Manufacturing: A new tool was required because of new crash test requirements. Forged Toolox® 33 in 300 x 600 x 3000 mm was used. The previous steel, W.Nr. 1.2379, was replaced due to delivery time. The lead time for die manufacturing was reduced by two weeks since heat treatment could be avoided.
Milling went well with a fine surface and a very small shape deviation, 0.01 mm on a length of 1700 mm. Only cemented carbide tools were used.

Result: The mold went into service in early 2005 and has been running without any known problems ever since. The average daily production of these components is 80 pillars. The mold is designed to manufacture a total of 80,000 components.

For more detailed information, please contact our distributor Gebrüder Recknagel Präzisionstahl GmbH Germany or Tech Support at techsupport@ssab.com.

Pedrotti mould base made from Toolox round bars

What our customers say

Pedrotti S.p.A is an approved Toolox® dealer and leading global manufacturer that specializes in producing high-quality standard elements and mold bases for plastic injection, die-casting and sheet-metal stamping.

Pedrotti prides itself on using only high-quality materials that meet the requirements of plate workability and rigorous technical performance expected from the mold during its use. The company holds ISO 9001 and ISO 14001 certification, and its products are available in over 100 countries.

Marco Zoia of Pedrotti says this about Toolox®:

”Pedrotti uses Toolox® 33 to manufacture standard and custom mold bases. Over the years, this steel has become recognized by its users for its dimensional stability, machinability and polishability. It’s a success based on the experiences of thousands of satisfied customers.”