Lubricated die

A method of forming a component from a powdered metal charge comprising the steps of establishing a mold cavity between an axial wall of a die and radial walls of a pair of opposed punches, positioning said punches to locate said charge in a first zone of said axial wall of said die, compressing said charge while maintaining it in contact with said first zone to an initial density less than a requisite final density, positioning said punches relative to said die to bring a second zone of said axial wall having a lubricant applied thereto in contact with said charge, compressing said charge between said punches to said requisite final density and removing the compressed charge from said cavity.

A toolset for forming a component from a powdered metal charge, said toolset comprising a die, a pair of punches each slidable relative to said die and cooperating with said die to define a mold cavity, said die having an axial wall with first and second zones axially spaced along said die, a first drive to control relative movement of said punches and a second drive to control movement of said die, said first drive and second drive being conjointly operable to compress a charge in said cavity to an initial density less than a requisite final density whilst maintaining said first zone in contact with said charge and said second drive being independently operable to position said second zone in contact with said charge upon attainment of said initial density, whereby said die is selectively moveable relative to said punches to bring either said first or second zone into contact with a charge contained in said chamber.

A method of forming an unsintered component from a high compressibility iron powder charge having less than 0.2% by weight of admixed lubricant comprising the steps of initially compressing said charge in a mold cavity to an intermediate density less than that of a final density, bringing a lubricated wall of a die into contact with said charge, and subsequently compressing said charge to a final density of greater than 7.3 gm/cc prior to sintering thereof and removing said compressed charge from said die to provide an unsintered component.