THE ADVANTAGES OF USING OUR “SV” VACUUM HARDENING FURNACE
Our furnace has two heat-exchangers (nitrogen/water) as you can see on the offer layout; our competitors use only one heat-exchanger (since it is cheaper!)So, our competitors, to reach a good hardening on the material force the customer to INCREASE THE PRESSURE AND SO the quantity of nitrogen (and so the customer has to expend much more money) OR otherwise he has to LOAD LESS MATERIAL.
Moreover, to INCREASE THE PRESSURE during cooling has a big inconvenient: THERE ARE MORE DEFORMATIONS ON THE DIES.
So, summarizing, the competitors use only one heat-exchanger and so, in that way, the furnace is less expensive but: For each cycle, the customer spends 100% more on nitrogen - that is the double - because it is forced to increase the pressure (for example, by using a good cooling system, as we do, we can work at only 2.5 bar while our competitors have to work at 5 bar!!!) Each die, due to the high pressure, suffers a higher DEFORMATION and so, the customer has to leave more machining allowance and then rectify a higher thickness to remove the deformation. So, for each die, the customer must buy more material and so he has to spend more time on carrying out rectifications in order to get the same dies.
Another big difference is that we perform cooling from the bottom and from the top while A LOT OF OUR COMPETITORS do it from all around by using circular chambers.
By cooling all around, DEFORMATIONS INCREASE, but the cylindrical chamber is easier to be manufactured and it is CHEAPER!
Why there are more deformations by using the cylindrical chamber? Let’s try to imagine only an example by loading 2 or more moulds (dies).
Each mould is closer to the other but the dies placed on the right and on the left of the batch have THREE free sides (down, up plus another side) while the pieces placed in the middle have only down and up free.
What does it happen during the cooling phase, i.e. fast cooling? It happens that all the pieces on the sides that have three sides free are invested by the cooling gas at a high pressure on these three sides while the four sides are not invested on the same way. What does it happen? It happens that the die IS EXTREMELY DEFORMED since the cooling speed is not UNIFORM on the 4 sides.
So, even in such case the competitor SPENDS LESS MONEY TO MANUFACTURE THE FURNACE, but then the customer SPENDS MUCH MORE since he has to increase the machining allowance and also he has to spend much more time on RECTIFYING OPERATIONS.
By using our system, the dies are loaded in the furnace "standing" (that is, as you put dishes on a washing machine) and in that way, the cooling is performed from down and from the top on ALL DIES, even on those placed on the most external zones of the batch are invested WITH THE SAME QUANTITY OF GAS and in a COMPLETELY UNIFORM WAY.
SUMMARIZING, our competitors manufacture these furnaces by spending much less money than us but then, the customer must spend much more money if he wants to reach the same quality!!