LSI Product Lineup

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.

• Processing Contract

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.

• Processing Contract

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.*

• Processing Contract

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.

• Processing Contract

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.*

• Processing Contract

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.

• Processing Contract

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.

• Processing Contract

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.

• Processing Contract

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.

• Processing Contract

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.*

• Processing Contract

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.

• Processing Contract

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.

• Other molds

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.

• Other molds

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.

• Other molds

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.

• Other molds

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.

• Other molds

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.

• Other molds

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.

• Other molds

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.*

• Other molds

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.

• Other molds

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.

• Other molds

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.

• Other molds

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.

• Other molds

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.

• Other molds

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.

• Other molds

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.

• Other molds

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.*

• Other molds

LSI Corporation is a group of experts in surface treatment, including mold polishing and mirror polishing. Using high-performance measuring equipment such as three-dimensional measuring machines and contour tracers, we ensure dimensional accuracy of products after polishing. We provide "micron-level polishing" and "value-added assurance." Please feel free to contact us when you need our services. 【Features】 ■ Ensures dimensional accuracy of products after polishing using high-performance measuring equipment ■ Provides "micron-level polishing" and "value-added assurance" *For more details, please refer to the PDF document or feel free to contact us.

• Surface treatment contract service
• Other molds
• Processing Contract

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.

• Surface treatment contract service
• Other molds
• Processing Contract

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.

• Surface treatment contract service
• Other molds
• Processing Contract

LSI Corporation is a group of experts in surface treatment, including mold polishing and mirror polishing. We provide appropriate polishing tailored to material properties and usage applications. By combining our uniquely developed know-how, we contribute to improved production efficiency through mirror polishing and precision wrapping. Additionally, we respond to the production of mold components and the analysis and verification of prototypes using our well-equipped facilities and machinery. [Our Strengths] ■ Hand polishing of a wide variety of molds ■ Parts sales ■ High-precision inspection *For more details, please download the PDF or feel free to contact us.

• Surface treatment contract service
• Other molds
• Processing Contract