Partnership-based knowledge advantage in tool and mould making

Competition in the tool and mould making industry is strong. This makes valuable partnerships all the more important, especially for medium-sized companies. Whether dealers, suppliers, or customers – all sides benefit from mutual support. Three companies from Pforzheim and the Enz district – Hermann Hauff GmbH & Co. KG, ProForm GmbH, and ZECHA Hartmetall-Werkzeugfabrikation GmbH – live this cooperation every day in a coordinated process for the production of plastic injection moulded parts.

With 130 years of combined experience, state-of-the-art technologies, and the highest quality, the partners implement optimum solutions for unique applications. Precision tool manufacturer ZECHA supplies reliable micro-cutting, stamping, and forming tools for a wide variety of materials. Originating in the chronograph industry, the company‘s uncompromising focus on miniature tools is reflected not only in its extensive stock program, but also in a broad range of special tool solutions.

Through the use of these tools, the recognized manufacturer of plastic injection moulded parts, Hermann Hauff GmbH & Co. KG, offers reliable product solutions taking into account plastic-compatible design. Quality is defined as an overall concept comprising perfectly planned processes, know-how, on-time delivery, and precision. Focussing on the latest technologies, the subsidiary ProForm GmbH of Hermann Hauff GmbH & Co. KG supports the continuous 3D production of injection moulds.

In the everyday work of Hauff and ProForm, the production of graphite electrodes plays an essential role. Anastasia Chichlow, CAM user at ProForm, reports on her daily work: "Our ever-increasing challenges with respect to surface quality and precision are what pushes us forward and allows us to constantly surpass ourselves." This is where the high-precision tools from ZECHA are used. With its three teeth, the 576.T3 end mill with corner radius from the SEAGULL® family, which originated in the company‘s own research and development department, is unique in the market. Its combination of geometrical characteristics and flute dimensions creates generous chip space for material removal and high machining volumes during roughing, as well as the most intricate engagement conditions for finishing. This reduces flute pressure when machining small and deep geometries and allows excellent surface qualities and maximum service life to be achieved. The geometry, specially designed for graphite, allows a concentricity of 0.003 mm and diameter tolerances of - 0/0.010 mm with a diameter of less than 6.0 mm. The unique long long flute run-out with a variety of new corner radii ensures material removal even in deep contours and represents a suitable tool for every electrode undersize.

Paired with the know-how of Hauff and ProForm, the graphite electrode production thus produces excellent surfaces qualities with the utmost precision. The solution-oriented cooperation among the three companies began using the example of a graphite electrode: on an electrode with a grain size of 3 μm, roughing tools with diameters ranging from D = 6.0 mm to 0.05 mm achieved a spark gap of 0.01 mm. "With tolerances of 0.01 mm on the plastic injection moulded component, we have almost ZERO tolerance on the tool," emphasizes Jörg Vetter, Technical Director of Proform and Hauff, the required accuracy. 

The technical staff is pushing the boundaries in the micron range not only in electrode production – use of ZECHA tools is in full swing also for hard milling at ProForm and Hauff. In this area, too, the focus is on maximum precision and best surface quality. On the mould insert, surface qualities of Ra 0.05 mm are being achieved in conjunction with the greatest accuracy. This decisive advantage over the competition contributes to Proform‘s success in the market.

The PEACOCK series used by the tool manufacturer is especially impressive in the processing of particularly demanding materials. The milling cutter design of the PEACOCK family offers the highest machining efficiency due to maximum performance and wear resistance to accommodate a vast range of materials, alloying components, and material hardness values up to 70 HRC. In addition to a significant increase in service life due to their stable shaft and flute geometry, the WAD-coated cutters produce the best surface qualities – even with fine contours. The micro milling cutters perform convincingly, with a maximum shape accuracy of 0.005 mm and a maximum concentric accuracy of 0.003 mm, which achieves a high dimensional precision of the component.

The cooperation among the three experts results in precision products that represent ideal components in terms of resilience, reliability, and profitablity. Modern machines, high-end measuring and testing technologies, and carefully selected materials from leading manufacturers ensure the exceptional precision of the end products. Through cooperative testing, evaluations, and further developments, the customers of the three experts will continue to benefit also in the future.

 

ZECHA Hartmetall-Werkzeugfabrikation GmbH

ZECHA Hartmetall-Werkzeugfabrikation GmbH has been a pioneer and trendsetter in the field of micro cutting, stamping and forming tools for over half a century. The company's origins in the chronograph industry can be seen not only in its uncompromising specialisation in the production of miniature tools of the highest precision, but also in its special tool solutions.

Precision and quality are key for the international employment in different industries, such as, for example, in medical and dental technology, the chronograph industry, automotive industry, or in tool and mould making. Experts in the company's own research and development department are constantly developing ground breaking geometries and tools for sophisticated applications and cutting-edge materials.

In addition, tool reproducibility is also guaranteed even for years on account of the life number stamped at the end of the shaft of every tool.

Modern CNC machines, high-end measuring and testing technologies and carefully selected hard metals from leading manufacturers as well as an intensive cooperation with our customers and partners ensure the exceptional perfection of our Tools.

For more information:
ZECHA Hartmetall- Werkzeugfabrikation GmbH
Benzstraße 2
75203 Königsbach-Stein
Tel: +49 (0)7232 3022-0
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