How to check the tolerance of embossing dies that meet DIN 6784 standards?
1. Fillet Radius Tolerance Check
Steps:
Use a radius gauge to fit the fillet area of the mold edge. Select a gauge that fits perfectly against the edge and read the radius.
If using a profilometer, scan the fillet profile. The instrument will automatically calculate the actual radius. Compare it to the specified radius range (e.g., R1.0 ± 0.2mm) to determine if it is within tolerance.
Note: Measure at least three different locations along the fillet, taking the maximum and minimum values to ensure overall consistency.
2. Chamfer Dimension and Angular Tolerance Check
Linear Dimensions (e.g., chamfer side length):
Use a vernier caliper to measure the distance from the intersection of the chamfer bevel and the workpiece surface to the edge vertex (i.e., the "side length") and compare it to the standard value (e.g., C1.5 ± 0.3mm, where C represents a 45° chamfer and a side length of 1.5mm). Angle:
Use the two measuring surfaces of an angle ruler to measure the angle between the two adjacent chamfered surfaces. Compare the angle to a standard angle (e.g., 45°). The deviation must be within the specified tolerance (e.g., ±2°).
3. Chamfer Tolerance Inspection
Chamfering primarily controls the "burr removal range." The chamfer width is typically measured as an indicator (e.g., 0.2-0.5mm). Use a vernier caliper or a tool microscope to measure the chamfer width to ensure it does not exceed the maximum/minimum values permitted by the standard.
Also, visually or through microscopic inspection, confirm that the chamfer is free of residual burrs and excessive cutting (to avoid affecting the accuracy of subsequent embossing).
4. Edge Shape Consistency Inspection
For continuous edges of embossing dies (e.g., pattern outline edges), the uniformity of the chamfer and rounding must be inspected to avoid local dimensional deviations that could cause defects on the embossed workpiece edge (e.g., uneven indentation depth).
A profilometer can be used to scan the entire edge, generating a profile curve to analyze whether the curve fluctuations are within the tolerance band.