Case study: WORLES’ heading dies set new standard in the automotive and aerospace component sector

Heading dies are fundamental tools in the metalworking industry, enabling the mass production of precise and standardized metal components used in diverse applications across different sectors. The heading dies play a vital role in shaping the metal blanks into the specific forms required for each application, ensuring consistency, quality, and reliability in the manufactured products.

WORLES stands out as a renowned manufacturer of high-quality steel and tungsten carbide (TC) heading dies, delivering excellence to its customers for years. This case study delves into the expertise of the Barcelona-based company, focusing on its commitment to crafting custom dies that redefine industry standards.

The challenge
WORLES found itself facing a significant challenge in the automotive & aerospace component industries, a sector where precision is not merely a requirement but a necessity. The task was to create heading dies for the manufacture of components and fasteners destined to these fields of application. Therefore, the customer demanded tools that were not just reliable but also capable of delivering superior performance under highly demanding situations with extreme precision and quality, and practically zero downtime of the customer machine.

The solution: three factors to consider
When deciding how to produce a heading die, there are three pivotal factors to consider: long life, precision, and surface finish. These factors, interwoven with material science and a precise process, dictate the success of the dies.

Tungsten carbide, for instance, is known for its exceptional hardness and wear resistance, ensuring a longer life span for the tools, whereas steel can handle shocks and impact better, and is in general, a more versatile material. 

WORLES selected the best tungsten carbide as per customer drawing, sourcing it from the best suppliers in the world. Additionally, based upon WORLES’ own long-standing and rich experience, the corporate team recommended alternative more suitable tungsten carbide grades. Suggestions were made for split/single piece ranging in impact resistance and hardness from G1 to G6 and in diversified grain sizes ranging from ultrafine to very coarse (application specific). These recommendations were deemed crucial in order to endure the demands of high volume manufacturing typical of the automotive industry, as well as ensure consistent quality. 

Precision is not a mere word at WORLES, but rather a way of life. By using innovative processes, advanced technologies, and high-tech machinery, the company was able to perfectly meet the requirements and tolerances requested by the customer. Achieving superior surface finish involved several elements at play: decades of expertise, use of the right honing and polishing equipment and techniques, intricate handling of various profiles, right selection of abrasive material, and last but not least, effective lubrication techniques. The combination of these methods ensured the final products met the required standards. The dies were then shipped to Germany within less than 3 weeks, for the customer’s delight, living up to its name as the “Troubleshooters” in the market!

Through its meticulous study and know-how, WORLES emerged triumphant, meeting the customers’ expectations on all fronts. 

At the heart of WORLES' success lies a blend of European technology and Indian expertise, combined with an unwavering dedication to quality. As Barcelona's pride and a global leader, WORLES stands as a testament to the remarkable possibilities that precision engineering can unlock, reshaping industries and setting new benchmarks for excellence.