Pattern Roller Die for an Automatic Mask Machine
Cr12 pattern roller die with knurled embossing bands, hardened to HRC 58-62 and ground so the pattern depth stays even across the working face.
Machining details
The pattern roller die presses the welded seam pattern on an automatic mask line. The knurled bands have to sit at an even depth across the full working face, otherwise the seam pattern becomes uneven and the mask edge fails the pull test.
The body and journals were turned from Cr12 in one setup, then the knurled pattern was engraved on a 4-axis machining center so the band spacing stayed constant. After vacuum quenching to HRC 58-62, the journals were ground to IT6 and the roller checked for runout between centers.
A set of 8 dies was delivered in 18 working days, each with a pattern depth record and a runout report. Worn dies are returned for regrinding of the knurled bands rather than being replaced as a whole.
| Material | Cr12 tool steel, vacuum quenched HRC 58-62 |
|---|---|
| Tolerance | Pattern depth ±0.02 mm, runout ≤ 0.03 mm |
| Surface treatment | Vacuum quench, pattern engraved, journal ground Ra 0.8 |
| Process | CNC turning, pattern engraving, heat treatment, grinding |
| Batch size | 8 sets |
| Lead time | 18 working days |
