LSI List of Products and Services

LSI Corporation is a group of experts in surface treatment, including mold polishing and mirror finishing. Our company is characterized not only by our ability to polish surfaces but also by our diverse processing technologies. We also support the production of mold components and the analysis and verification of prototypes using our well-equipped facilities and equipment. Please feel free to contact us when you need our services. 【Features】 ■ Equipped with diverse processing technologies, not just surface polishing ■ Capable of producing mold components and analyzing and verifying prototypes using advanced facilities and equipment *For more details, please refer to the PDF document or feel free to contact us.

In today's precision cutting processing, the characteristics of the mold surface are an extremely important factor that influences product quality. LSI Co., Ltd. derives its name from "Lapping Service Innovator" and provides specialized technology that not only achieves a mirror finish but also removes machining marks while maintaining dimensional accuracy and shape. While there are many polishing companies for general resin molds, our strength lies in our specialization in polishing high-difficulty press molds and forging molds. Through our unique know-how tailored to specific applications (bending, drawing, shearing, etc.), we achieve surface characteristics at a higher dimension that machines cannot reach. *For details on our polishing technology that dramatically changes the lifespan of press molds, please download our materials for confirmation.

Shearing processing applies strong localized stress, so the wear of the mold directly affects the product dimensions. By polishing the surface of the mold to a smooth finish, it is possible to reduce friction resistance with the metal sheet and improve the quality of the shearing surface. Additionally, maintaining uniform edges on the punch and die reduces cutting resistance, achieving both improved processing efficiency and longer mold life. In particular, aligning the sliding direction with the polishing marks minimizes wear. *Please refer to the materials for detailed points on polishing that directly address issues in shearing processing.*

The edge treatment of punches and dies in shearing processes is key to extending tool life. By applying fine R (radius) treatment and chamfering to the edges, we can suppress burr generation and effectively prevent chipping. Our company eliminates the difficulties of R penetration and variation that are challenging in machining through skilled "polishing" techniques, forming a uniform mirror-finished R around the entire circumference. This smooth finish achieved through manual processing removes the starting points of wear and supports stable machining. *Examples of the artisan's skill in "phase alignment" and R processing can be confirmed through document downloads.

Even with an expensive PVD coating, if the condition of the substrate is poor, the original performance cannot be exhibited. To ensure a uniform coating film and enhance adhesion, polishing the surface of the mold, which serves as the substrate, is essential. If the surface has bumps and irregularities, stress will concentrate, making the film more likely to peel off; however, a smooth substrate allows for a consistent film thickness. Additionally, by removing the processed altered layer (white layer) created by wire processing through polishing, we can prevent poor film formation and establish a stable surface. *Details on management items to maximize the effectiveness of the coating are explained in the materials.

This is a case where we struggled with secondary shearing and chipping during the processing of 4.5mm thick plates (SAPH-440-OD). Traditionally, maintenance was required after about 20,000 shots, but our company proposed and implemented a micro R treatment on the cutting edge and polishing before and after coating. As a result of changing the coating type to AICrN, the tool life was extended to an astonishing 150,000 shots. This is a good example of achieving stabilization of part accuracy and reduction of total costs through the optimization of polishing technology. *Please download the materials to check the specific processing conditions and process charts that led to this dramatic improvement.

Coating using the arc ion plating method tends to worsen surface roughness after application. Due to the influence of droplets generated during coating, the surface may become approximately Rz1.0 rougher than the original, leading to early galling and variations in lifespan. Our company improves the roughness to Rz0.353 by incorporating a "polishing" process after coating, dramatically enhancing lubricity. This combination of "pre-polishing + post-polishing" is extremely effective for protecting molds in harsh pressing environments. *Detailed data on the transition of surface roughness (after processing → polishing → coating → post-polishing) is available in the documentation.

To achieve both improved product quality and cost reduction in press processing, managing the surface condition of molds, particularly the "polishing," is essential. This document delves into the role of polishing in press molds from the perspective of reducing secondary processing efforts through friction reduction and improving processing efficiency. In particular, when applying PVD coating, it explains in detail how the underlying surface roughness affects the adhesion and lifespan of the film, along with the mechanisms involved. This book is packed with essential knowledge for suppressing variations in mold lifespan and establishing a stable production system. *Please feel free to download the explanatory material summarizing practical polishing tips that can be immediately useful on-site for free.*

The edge shape in shearing processing is not simply about being sharp. Rather, appropriate treatment is the key to longevity. Applying a fine R treatment to the punch edge is extremely effective for chipping prevention and burr suppression, but its quality heavily depends on the operator's "polishing" skills. Our company provides a smooth and uniform R shape that can only be achieved through manual processing, thanks to strict management using phase alignment and contour shape measuring machines, thoroughly eliminating the starting points of wear. This enables high-dimensional durability that was difficult to achieve with conventional processing machines, as well as ensuring a stable shearing surface. *Please obtain our free materials that explain in detail the dramatic effects of edge treatment on tool life right now.

LSI Corporation is a professional group specialized in "hand polishing" of press mold parts and machine parts. In recent years, the increase in difficult-to-process materials such as high-tensile steel, titanium, and aluminum in mold manufacturing has led to challenges that cannot be addressed solely through design and manufacturing ingenuity. The company proposes precise finishing through skilled manual work, significantly improving the durability (lifespan) of molds and the effectiveness of coatings. They offer unique technologies that can accommodate complex shapes like gears, which cannot be easily replicated by other companies. *For detailed information on the artisan technique of "hand polishing," please download and check this document.*

In the mold industry, "polishing" is an extremely important process that affects product quality and production costs. The minute irregularities on the surface of molds and workpieces generate localized pressure during pressing, leading to adhesive wear and seizing. By thoroughly removing these surface irregularities with skilled techniques, it is possible to prevent these issues in advance and significantly extend the lifespan of molds. The reliable technological capabilities of LSI are attracting considerable attention from many mold manufacturers. *For details on the effects of "polishing," which directly relates to cost reduction in molds, please refer to the materials.

Even with existing mold components, there are cases where dramatic performance improvements have been achieved through re-polishing of LSI. In one instance with a punch component, there were issues with burr formation on the work cross-section, and the shot count was limited to around 10,000 to 20,000 shots. By applying a precise curve (R) to the cutting edge of the punch, the company improved the sliding properties and successfully eliminated the burrs. As a result, the manual burr removal process was reduced, and the shot count dramatically increased to 150,000 shots. *Details of successful cases including specific improvement figures are available in a full-color document.

The polishing of LSI is mostly done by skilled artisans, capable of handling complex shapes that machines would typically reject. Even for intricate shapes like shear punches and gears, we achieve the desired precision by utilizing grinding stones, buffs, and sometimes even bamboo or disposable chopsticks. While it does not require large-scale equipment, we have introduced advanced devices such as 3D measuring machines and contour tracers to ensure precision at the micrometer level. We provide high value-added processing that merges the artisan's intuition with advanced measurement data. *Details of our track record in handling complex shapes and our precise measurement system can be found in the documentation.

Not only do we provide polishing process outsourcing, but LSI has also established a support system from the design stage. In the production of new mold parts, we consistently support the design of "polishing allowances" considering ease of polishing and precision, as well as the selection of coatings and materials. Additionally, we are capable of "reverse engineering," which involves measuring existing parts and creating drawings. By designing in-house and processing through a reliable network of partner manufacturers, we respond to a wide range of customer needs with a one-stop solution. *For details on our total solution that optimizes everything from design to processing, please refer to the materials.

At LSI, both young and veteran professionals are honing their skills daily as "pros" in their respective fields. From the very beginning of his employment, Mr. Norinobu Onishi has continued to learn the art of hand polishing, and in the manufacturing area, there is a constant awareness that "no two parts are the same" as they engage with the blueprints. A meticulous attention to detail that does not rely on past experiences and does not overlook tolerances measured in micrometers supports the company's high reliability. Through collaboration with the design group, which values the voices from the field, we consistently deliver high-quality products that are continually refined. *We are distributing interview materials that detail our efforts in technical inheritance and the thoughts of our staff.