| Technical Index | LPG Cylinder Tooling Specifications |
| Target Cylinder Capacity | Suitable for 3kg, 5kg, 6kg, 11kg, 12.5kg, 15kg, and 50kg gas bottles |
| Main Mold Modules | Upper Shell Draw Die, Lower Shell Draw Die, Blanking & Trimming Die, Jogglin/Flanging Mold |
| Accessory Component Molds | Valve Boss (Collar) Punch Die, Valve Guard Ring Mold, Foot Ring Forming Die |
| Die Base Configuration | Heavy-Duty Cast Steel (GG30) / Forged Medium Carbon Steel Frame |
| Draw Ring / Punch Steel | Cr12MoV, SKD11, or specialized DC53 high-wear resistant tool steel |
| Surface Hardening Technology | Thermal Diffusion (TD) Coating / Nitriding (Surface Hardness > 85 HRC) |
Press Integration & Manufacturing Tolerance Metrics
Press Tonnage Compatibility: Built for deep drawing hydraulic presses from 400 Ton up to 1000 Ton.
Thinning Rate Management: Tool geometry restricted to guarantee localized thinning remains strictly under 10% (conforming to global pressure vessel testing regulations).
Trimming & Jogglining Accuracy: Concentricity tolerance of trimmed edges kept within $\pm0.05\text{ mm}$ to ensure perfect automated circumferential welding alignments.
Guaranteed Tooling Lifespan: Engineered to sustain over 800,000 continuous press cycles before major regrinding is required.
Ejection & Cushion Control: Pre-configured for integrated hydraulic die cushions or custom heavy nitrogen spring manifolds.
Engineering Excellence for High-Pressure Vessel Manufacturing
Manufacturing LPG cylinders leaves no room for geometric error. A variation of fractions of a millimeter can lead to automatic welding failures or rejected pressure tests. Here is how our LPG mold designs solve the most common floor problems:
🔹 Eliminating Edge Burrs and Misalignments for Perfect Welding
The automated circumferential welding machine requires a flawless, zero-gap joint between the top and bottom halves of the LPG cylinder. Our trimming and joggling (flanging) dies are engineered with ultra-precise clearance calculations based on your HP295 or SG295 steel chemistry. This guarantees clean, burr-free edges and an exact stepped profile, preventing weld-through or porosity defects during the subsequent welding phase.
🔹 Controlling the Thinning Limit Matrix
Deep drawing high-strength pressure vessel steel pushes the alloy to its plastic deformation limits. If the draw die radius is improperly calculated, the cylinder dome will suffer from excessive thinning, causing failure during hydraulic burst tests. Our engineering team utilizes advanced software to map out customized draw beads and variable blank holder force patterns, allowing the metal stock to flow naturally into the die cavity without necking or structural weakness.
🔹 Extreme Anti-Galling for High-Strength Steel
LPG cylinder production involves intense friction that generates extreme localized heat, leading to severe galling on standard steel molds. We apply a deep-layer Thermal Diffusion (TD) coating or integrate tungsten carbide wear rings on the critical drawing radiuses. This creates an ultra-hard, mirror-like barrier that actively repels metal pickups, maintaining scratch-free cylinder surfaces and saving hundreds of hours in tool maintenance.
FAQ Section for Google Rich Snippets
Q1: Can your molds handle the high-strength steels specifically required for pressure vessels?
A: Yes. Our LPG cylinder tools are explicitly calculated and hardened to stamp high-strength pressure vessel sheets, such as HP295, SG295, P265NB, and DD12. We adjust the die clearances and structural reinforcement based on the exact yield and tensile strength of your raw material.
Q2: What is the typical lead time for a complete 12.5kg LPG cylinder mold set?
A: A standard full-suite tooling order-including the deep drawing halves, blanking, trimming, joggling, valve boss, handle, and foot-ring molds-takes approximately 45 to 60 days. This timeline covers the initial AutoForm simulation, CNC machining, heat treatment, surface TD coating, and final tool trials on our test presses.
Q3: How do you verify the quality of the molds before they leave your facility?
A: Every tool is subjected to a live-action trial on our in-house hydraulic press lines using the exact steel grade specified in your contract. We run a continuous batch of samples, perform physical cross-section measurements to check wall thickness and thinning rates, and send you T1 test videos along with a comprehensive CMM inspection report for your sign-off.
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