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High drawing efficiency
PCD dies can reduce friction and provide an excellent surface finish, which contributes
the smoother wire through the dies, the process of drawing is much faster and more efficient. PCD dies improve the efficiency of drawing, and then increase productivity.
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Consistency in wire diameter
PCD dies can keep the stability of wire sizes during drawing, which means the wire diameters can remain more consistent, and then PCD dies can produce higher quality and more exact wire products. It reduces the changes in wire diameter, improves the technological control, and reduces the extra adjustment or reworks.
PCD dies undergo minimal changes over time, and it ensures the consistency of wire size during drawing. it is particularly advantageous for coil windings. Since the number of winding turns is usually fixed, a rapid increase in the size of the finished wire will result in a significant reduction in the number of winding turns. It requires adjusting the size of the reel constantly, which affects production efficiency. PCD molds alleviate this problem.
Note: It is very important to properly maintain wire drawing dies for their service life and the quality of the wire drawing surface. For PCD dies, we recommend maintaining it every 24 hours. Because within 24 hours, the change of diameter of the inner hole is smallest, it causes the change of wire diameter to change smallest. The diameter compression ratio remains relatively stable throughout the production process, resulting in a high input-output ratio. (For drawing die maintenance, see the article “How to maintain a polycrystalline wire drawing die“)
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Exceptional wear resistance and extended lifespan
PCD wire drawing dies to exhibit exceptional wear resistance compared to TC dies. The hardness of PCD is significantly higher, making it more resistant to abrasion and ensuring a longer lifespan. The lifespan of PCD dies is approximately 30 to 50 times longer than TC dies. This eliminates the need for frequent replacements during the drawing.
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Reduced material waste
The precise and consistent dimensional control offered by PCD dies minimizes the need for trimming or cutting the wire, which reduces material loss and increases the l utilization of materials.
When the wires surface with a metal coat, the coating process continues even when the drawing process stops. This will result in the thickness of the coating exceeding the standard. When the drawing process resumes, the excessively thick wire needs to be cut off, leading to significant waste. The use of PCD dies substantially reduces this waste.
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Reduced labor intensity
Because PCD dies has a prolonged lifespan and slow expansion, they need not be replaced frequently. Compared to the use of carbide drawing dies, PCD dies do not require constant monitoring of changes in wire dimensions, which reduces the labor intensity of workers. To use PCD dies, a single worker can manage 4 to 5 wire drawing machines during the production process.
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Versatility in wire materials
PCD dies can be used with a wide range of wire materials, including copper, aluminium, and various alloys. This versatility allows for greater flexibility in wire drawing operations and expands the potential applications for PCD dies.
By leveraging the advantages of PCD dies, you can enhance drawing efficiency, extend die lifespan, save raw materials, and reduce labor intensity.
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Why do we recommend a PCD wire drawing die instead of the TC wire drawing die?
In addition to the above comparison, let’s take a look at more obvious comparison data.
Under the same conditions, PCD die is 300-500 times more than TC dies for drawing copper wire; 80-100 times more than TC dies to draw the nickel wire; 50-80 times more than carbide die to draw the molybdenum wire; 20-60 times than TC dies for drawing steel wire.
“Time is money”.
Products with superior performance can bring significant improvements to factories. Whether it’s enhancing productivity or ensuring product stability, these factors are the foundation for attracting more high-quality customers.
In this regard, our company plan to provide a sample of 100 standard wire drawing dies at the most favourable price in June, allowing customers to experience the excellent performance of PCD dies.
As you may know, 100 samples are limited in quantity and are expected to be quickly reserved. Please contact us as soon as possible.
