August 2023 Volume 5

EQUIPMENT & TECHNOLOGY

CNC machines for small- to medium-size forging dies. Over the decades, FDTC modified and adapted their machinery to handle additional weights of larger die blocks. Laser probes are utilized for all milling setups to reduce any chances of human error. The computer controllers and machines are laser calibrated, making the machines increasingly precise. Die blocks to be milled are set in the CNC machine with match edges set as reference points for the milling tool paths as set by the CAD/CAM designs. Larger cutting tools that mill away more material are used first, of course, followed by progressively smaller cutting tools for the finer details of the die cavity. Some dies, which will have areas predictably prone to high wear, are designed to allow for hard face welding or harder material inserts (specified by the forger) to improve the overall service life of the die. Misuraca says, “The tools we use to cut the dies in the CNC machines are extremely important, and we consult with the cutting tool experts a lot. One of the innovations we have experienced over the years are the improved rates of cutting tool performance. Through the use of carbide tools and coatings, cutting rates on CNC machines have improved from 20-30 in./minute to 120-180 in./ minute, depending on a number of factors.” Finally, John Misuraca mentions that, starting in the 1990s, the inspection of dies changed dramatically with the use of CMMs (coordinate measuring machines). In their modern form, CMMs involve laser scanning for three-dimensional accuracy. FDTC uses FaroArm technology for inspection and quality control not only of dies, but of machine tools as well.

A Faro Arm inspection is part of quality control. Courtesy Forge Die and Tool Corp. A Twenty-Fold Tightening in Tolerances

In a similar context, we interviewed David Soltow, who started his career in forging die production in 1977 and, less his time in the U.S. Navy, has been sinking dies for decades. “Back when I started,” said Soltow, “the 100-mile radius around Lansing supported the highest concentration of forge shops and press and hammer repair businesses in the country. In the late 1970s we had Cincinnati Hydrotel machines and a drill press and we made dies.” In 1971, Jack and Howard Soltow opened S & S Die Co. (SSD) in Lansing, Michigan. They represented the third generation of the Soltow family in the machining profession, that started with their grandfather, Oliver Soltow, who retired in 1959. Oliver’s sons, Howard and Dan, continued in their dad’s profession and opened the D & H Die Company. A large EDM fire in 1968 resulted in the loss of this business but, undaunted, Howard and his son Jack opened SSD. Today, more than a half-century later, Jack Soltow’s son David and daughter Diana Hurst own and operate the business, representing four generations of machinists. David’s son also works in the business and represents the fifth generation in machining and the fourth in forge tooling.

A finished die being polished. Courtesy Forge Die and Tool Corp.

FIA MAGAZINE | AUGUST 2023 17