LSI List of Products and Services

LSI Corporation is a group of experts in surface treatment, specializing in mold polishing and mirror polishing. We provide suitable polishing tailored to material properties and usage applications, contributing to improved production efficiency through mirror polishing and precision wrapping that combine our uniquely developed know-how. Our expert polishing techniques extend the lifespan of molds by removing outer burrs and polishing gear radii, tasks that machines cannot perform. Please feel free to contact us when you need our services. 【Features】 ■ Provides suitable polishing tailored to material properties and usage applications ■ Contributes to improved production efficiency through mirror polishing and precision wrapping that combine our uniquely developed know-how ■ Craftsmen polish surfaces by hand, adapting to the characteristics of various steel materials ■ Offers micron-level polishing tailored to the usage applications of each mold ■ Extends the lifespan of molds with precise technical skills from polishing experts *For more details, please refer to the PDF document or feel free to contact us.

We introduce the service overview of LSI Co., Ltd., which supports various processes in mold manufacturing in a one-stop manner. We cater to a wide range of mold production, from cold forging molds to die-cast molds and resin molds. By managing not only the processing but also material selection, heat treatment, and surface treatment (PVD/CVD coating) consistently, we ensure the final required precision of the products. In particular, our strength lies in our total support system, which prevents troubles in later processes by being involved from the proposal stage of processing methods. **Features of LSI:** - Various molds polished to a mirror finish - Polishing methods tailored to each processing type - Specialists in surface treatment - Proposals for processing methods - Total support (component manufacturing) *For details on our total support that realizes the efficiency of mold manufacturing, please refer to the materials.*

We will explain the advantages of advanced hand polishing techniques that challenge the limits of surface roughness and maximize the performance of molds. At LSI Corporation, we combine advanced equipment with skilled artisans to provide overwhelming mirror finishes. Our track record shows that we have achieved an astonishing surface roughness of Ra0.01/Rz0.13 with SKD11 material, which significantly exceeds the precision of conventional polishing machines. The fine adjustments made possible by handwork reduce the coefficient of friction to an extreme level, contributing to a substantial extension of mold life. *Please check the detailed materials for overwhelming mirror appearance and numerical evidence.

Many of the causes of mold failure lie in the surface irregularities. With appropriate surface treatment, we can reduce unexpected issues in the production environment. The main cause of wear in molds is localized pressure that occurs on the fine protrusions of the surface, leading to adhesive wear (seizing). Precision polishing of LSI removes these protrusions, disperses the pressure, and significantly delays the progression of wear. Additionally, by lowering the coefficient of friction, we can prevent sudden issues such as breakage and chipping, supporting stable operation of the production line. 【Wear Countermeasures】 ■ Benefit 1: Reduces localized pressure and delays wear progression ■ Benefit 2: Lowers the coefficient of friction, extending mold lifespan ■ Benefit 3: Reduces unexpected issues such as breakage and chipping *You can download materials summarizing the analysis of wear mechanisms and countermeasure examples.

Finishing of the edge parts, which affects the quality of the mold. Burrs that cannot be removed by machining may lead to product defects. Burrs on the edges that cannot be removed by mirror finishing machines are a major cause of coating peeling and welding issues. The hand polishing technique of LSI utilizes visual inspection and measuring instruments to perfectly shape the outer circumference and the joints of the R parts. Measurement results from the contour tracer also demonstrate that the shape after lapping is dramatically improved, achieving an ideally sharp edge. *Here is the measurement data document where you can check the before-and-after of the edge shape.

Based on actual customer cases, we will introduce how the improvement of surface roughness directly contributed to the reduction of production costs. This is a case where our lapping process (LP) was applied to a bending punch that was struggling with R wear. Before LP, the surface roughness was Rz1.547, and the lifespan was 30,000 shots, whereas after LP, it improved to Rz0.165, and the lifespan extended to 65,000 shots. With just a polishing cost of 25,000 yen, we achieved a high cost performance by reducing the replacement frequency to less than half. *You can check the specific improvement costs and shot count comparison table in the materials.

Unstable tool life hinders planned production. We will explain the benefits of stabilizing surface quality through case studies. In response to the chipping issue of the punch, we implemented thorough lapping processing. By refining the surface from a rough Rz3.116 to a precise Rz0.150, we eliminated material snagging. As a result, the tool life, which was a maximum of 60,000 shots, doubled to 125,000 shots, greatly contributing to stable operations in the production site. *For details on the methods to achieve long tool life for punches, please refer to the case study materials.

We will publish the results of the lifespan comparison test between the coating-only case and the case where polishing is combined with the coating. The unprocessed pierce punch had a lifespan of 17,000 shots, while the coating alone achieved a lifespan of 50,000 shots. However, by adding "polishing," it jumped to 130,000 shots. This test demonstrates that the final lap after coating significantly reduces surface roughness (Rz0.32) and dramatically decreases friction resistance. High-quality surface treatment requires appropriate groundwork and finishing polishing. *Check out the materials packed with astonishing lifespan test data now.

For those concerned about dimensional changes due to polishing processes. At LSI, we can ensure strict dimensional control based on prior consultations. In polishing processes, a reduction in dimensions is unavoidable, but we accurately control that change. For example, while polishing a workpiece with a diameter of φ18.045, we can achieve specified dimensions in microns, such as 18.040 or 18.035, according to customer requirements. We are equipped with advanced CNC 3D measuring instruments and tracers, and we have a comprehensive system in place to guarantee precision after processing. *For details on our high-precision measuring instruments and dimensional control system, please refer to our company profile materials.

Are you struggling with shortened mold life or molding defects? LSI, a group of surface treatment experts, offers optimal solutions. LSI is a team of technicians specializing in mold polishing and mirror finishing. Based on the comprehensive technical skills developed over many years, we achieve longer mold life by providing surface modification that accommodates various materials. We closely support each customer's manufacturing site to significantly enhance production efficiency. **Three Strengths of LSI** ■ Hand polishing of a wide variety of molds ■ Parts sales ■ High-precision inspection *Check out technical materials from surface treatment experts now.*

We provide optimal manual polishing tailored to various mold materials and complex shapes, solving challenges in production environments. Skilled artisans assess the characteristics and intended use of the materials, meticulously polishing each surface by hand. Our unique combination of expertise in mirror finishing and precision wrapping can address details that machine processing cannot reach. With meticulous techniques for deburring and polishing complex gear radii, we significantly enhance the durability of molds. 【Features】 ■ Mirror finish = Improved durability ■ A team of polishing experts ■ Artisan skills that machines cannot replicate *For details on artisan techniques and compatible mold shapes, please click here.

Instead of relying solely on the intuition of craftsmen, we thoroughly manage and guarantee micron-level dimensional accuracy by utilizing advanced measuring equipment. At LSI, we are equipped with high-performance advanced facilities such as three-dimensional measuring machines, contour tracers, and image measuring machines. Products after polishing are rigorously inspected, and surface roughness, angles, and R shapes are all quantified to ensure quality. We deliver peace of mind to our customers by adding "guaranteed value" to "reliable technology." 【Quality Assurance & Total Support】 ■ Quality assurance through precise measurement ■ Consistent proposals from material selection to production *For a comprehensive list of inspection equipment and details on measuring accuracy, click here.

We will introduce a specific example of optimizing the challenging R-section processing in fine blanking through skilled manual work. The delicate connections of the R-section, which were difficult with conventional processing methods, were smoothly finished with precise manual polishing. Compared to before processing, the surface irregularities have dramatically improved, successfully avoiding localized pressure concentration. As a result, we have achieved a significant reduction in the risk of defects such as chipping and breakage of the mold. *Download materials featuring numerous examples of improvements in difficult-to-machine shapes.

This is a successful case where improving the R edge of the bending die dramatically extended the operating time of the production line. Before the improvement, the bending die reached its limit with a shot count of 20,000 to 30,000. We applied a special polishing process to round off the connection of the R section. As a result, the previously sharp areas became smooth, and the shot count improved to 120,000. This is a good example of simultaneously achieving a reduction in regular maintenance costs and an increase in productivity. *Here are the specific processing methods that achieved dramatic lifespan improvement.

We will explain the importance of how differences in surface roughness affect mold life based on comparative data. Compared to the untreated state with only coating (with a lifespan of 17,000 cycles), the one that was polished and then coated recorded an overwhelming lifespan of 130,000 cycles. By polishing the surface roughness to Rz0.32μm, we have successfully suppressed adhesive wear and seizure. Please check the data that supports the importance of "polishing." *Detailed materials on lifespan comparison data by surface roughness are currently being distributed.

This is a total support case where molds that were given up on due to wear and damage are restored through precision welding and advanced polishing techniques. After performing buildup repairs on damaged mold components using precision welding, artisans apply a "welding blend polish" to completely eliminate any height differences with the surrounding areas. Thanks to our unique technology and collaboration with partner companies, we can provide consistent support from material selection to manufacturing and restoration. We offer optimal proposals to reduce disposal costs and effectively utilize assets. *See the detailed flow of mold repair and regeneration services.

LSI is not just a polishing contractor; we are a comprehensive partner that handles everything from material selection to processing, parts sales, and prototype verification. With our well-equipped facilities and machinery, we can flexibly respond to single-item processing of mold parts and the design and production of jigs. Thanks to our unique network, we can provide optimal proposals tailored to the characteristics of a wide variety of steel materials. From prototype analysis and verification to the final surface finishing, we offer a consistent service that resolves issues throughout the entire manufacturing process. 【Three Strengths of LSI】 ■ Hand polishing of a wide variety of molds ■ Parts sales ■ High-precision inspection *Here is the brochure summarizing LSI's business content and equipment list.