ブロックマシン 金型 – レンガ機械金型工場
Operating automatic concrete block plants in Southeast Asia presents severe operational challenges. High ambient humidity combined with highly abrasive local volcanic aggregates and river sand causes rapid mold erosion. Standard steel molds often lose their dimensional tolerances within a few months. This structural degradation leads to high product rejection rates and costly factory downtime.
To address these regional challenges, DRAX engineered a high-performance, wear-resistant hollow block Machine mold specifically optimized for the Qunfeng QFT10-15 block machine. This case study outlines how our advanced metallurgy and precision engineering helped a major concrete producer in Southeast Asia maximize their manufacturing ROI.
1. Client Challenge: Rapid Mold Erosion and Short Lifespan
Our client, a tier-one concrete products manufacturer in Indonesia, operates a high-speed Qunfeng QFT10-15 production line. Their primary output consists of standard load-bearing hollow blocks for local infrastructure development.
However, their existing third-party molds were failing prematurely due to several key factors:
- Highly Abrasive Aggregates: The localized crushed stone and volcanic sand acted like sandpaper, rapidly scraping the inner walls of the mold cavities.
- Dimensional Deviations: Within 40,000 production cycles, the mold core walls thinned significantly. This caused the hollow blocks to bulge, exceeding the strict geometric tolerances required by municipal building codes.
- Wet Concrete Adhesion: High tropical humidity caused the concrete mixture to stick to the mold liners. This friction delayed the demolding cycle and caused micro-cracks on the edges of the finished blocks.
2. The DRAX Solution: Customized Material Upgrade and CNC Precision
The engineering team at DRAX conducted a thorough analysis of the client’s raw materials and machine vibration parameters. We delivered a fully customized replacement mold tailored specifically for the dynamic forces of the Qunfeng QFT10-15 framework.
Premium Alloy Steel & 62HRC Carburizing Heat Treatment
Instead of utilizing standard structural carbon steel, DRAX manufactured the mold cavities using specialized heavy-duty alloy steel. The completed mold underwent a multi-stage carburizing heat treatment process. This thermal processing infused carbon deep into the steel surface, achieving an ultra-hard casing of 60-63 HRC (Rockwell Hardness). While the outer shell resists extreme aggregate abrasion, the interior core remains shock-absorbing to withstand the high-frequency compaction of the Qunfeng machine.
qunfeng QFT10-15 block machine mold
Precision CNC Wire-Cutting for Perfect Core Tapers
To eliminate demolding friction, we utilized automated multi-axis CNC wire-cutting machinery to manufacture the core assemblies. This method maintains an exact tolerance of ±0.2mm and creates a highly optimized internal taper. The smooth surface ensures the Qunfeng tamper heads compress the mix uniformly and eject the finished hollow blocks instantly without sticky residue.
Modular Core Assembly Design
DRAX implemented a modular engineering layout for the hollow core boxes. Instead of constructing a single welded structure, the components feature replaceable tamper shoes and core liners. If a specific section experiences localized wear over time, the client’s maintenance team can swap out individual parts rather than purchasing an entirely new mold assembly.
3. Production Results and Maximized ROI
The custom DRAX Qunfeng QFT10-15 hollow block mold delivered immediate, measurable improvements to the client’s manufacturing facility:
- Extended Operational Lifespan: The mold successfully exceeded 120,000 production cycles while maintaining exact dimensional tolerances—a 200% lifespan increase compared to their previous third-party molds.
- Zero Product Rejections: Thanks to the precision CNC-milled walls, block dimensions remained perfectly uniform. The factory achieved a 99.8% product acceptance rate on-site.
- Faster Cycle Times: The anti-adhesion surface properties reduced demolding friction, slicing 1.5 seconds off each vibration cycle and boosting overall daily factory output.
4. Technical Specifications of the Shipped Project
| Parameter | Specification Details |
|---|---|
| Machine Compatibility | Qunfeng QFT10-15 / QFT10 Automatic Block Machine |
| Molded Product Type | Standard 3-Core Structural Hollow Blocks (Custom Dimensions) |
| Material Base | Premium Wear-Resistant Chromium-Manganese Alloy Steel |
| Surface Hardness | 60 – 63 HRC via Multi-Stage Carburizing Heat Treatment |
| Machining Tolerance | Within ±0.2 mm via Multi-Axis CNC Milling |
Upgrade Your Qunfeng Machinery with DRAX Moulds
Your block quality is only as good as the mold inside your machine. Investing in cheap tooling leads to frequent replacement costs and lost production hours. Partner with DRAX to secure precision-engineered, case-hardened concrete molds built to survive the harshest regional environments. Contact our international engineering office today to request a custom blueprint and factory pricing for your Qunfeng production lines.