EuroWire November 2023

Dies, Cones & Die Maintenance

A guide to wire die maintenance Die specialist Ajex & Turner offers an exploration of wire die maintenance, focusing on both carbide and diamond solutions, and giving an insight into the intricacies of maintaining wire dies to perfection.

compromising wire quality. Regular maintenance is important to prevent such issues and to control drawing costs • Periodic die maintenance: routine maintenance involves microscopic inspection to discern wear patterns; decisions on re-polishing or resizing based on wear; and the use of equipment such as automatic semi-ultrasonic die grinding machines, wire polishing machines, ultrasonic cleaners and microscopes. The drawing die – a cornerstone of wire manufacturing – refines metal wire from coarse to fine, achieving the desired size. Depending on the metal, raw materials such as carbide, polycrystalline diamond, natural diamond, mono diamond and VNT nano are employed. Regular inspections determine die wear and the subsequent course of action: continued use or repair. A structured maintenance schedule, where dies are periodically inspected and refurbished if needed, is essential. Ajex & Turner Wire Technologies Pvt Ltd www.ajexturner.com

The key maintenance insights are: • Documentation: always have a handy guide for swift repairs • Cleaning: utilise ultrasonic cleaners combined with the specialised Ajex Solution for optimal results. The wire drawing drums and wire guide wheels should be smooth and flexible, and their run-out tolerances should be strictly controlled and repaired. Good lubrication conditions are important to ensure the surface quality of the wire and extend the life of the die • Microscopic inspection: examine the die meticulously for polishing quality, size, scratches, rings and more • Maintenance operations: die main- tenance is not a singular task, but involves many operations To produce high-calibre wire and manage costs effectively, the following should be considered: • Equipment smoothness: ensure wire drawing drums and guide wheels operate seamlessly. Strictly control Tungsten carbide dies pioneer

Model UPM-350 automatic ultrasonic PCD ND die-shaping and polishing machine

run-out ensure lubrication to guarantee wire surface quality and prolong die lifespan • Maintenance significance: a slight ring abrasion can escalate quickly, tolerances and

Dies and re-cutting services Fort Wayne Wire Die, Inc was founded in 1937 as a manufacturer of precision single-crystal natural diamond dies. The product line has since expanded to include polycrystalline diamond dies, tungsten carbide dies, shaped profile dies, extrusion tips and dies, and other wear parts for the wire industry. The company also provides re-cutting and reconditioning services for diamond and carbide dies, and supplies new and re-cut matched elongation die sets for high-speed, multi-wire drawing machines. It offers a complete line of equipment for die maintenance, measurement and inspection of wire drawing dies, to give customers worldwide the necessary equipment and tools to operate an in-house re-cutting service. Fort Wayne Wire Die’s corporate offices, including engineering, research and development, and administration, are located in Fort Wayne, Indiana, USA. The company’s products are sold by direct sales engineers in North America; through sales offices Fortek GmbH (Europe), Fort Wayne Wire Die (Philippines) Inc (Asia) and Fort Wayne Wire Die (Shanghai) Inc (China); and through a network of independent agents and distributors around the world. Fort Wayne Wire Die, Inc www.fwwd.com

Kay Pee Dies, formed in 1968, had a modest start, but was also a pioneer in manufacturing tungsten carbide dies in India. The company now serves the wire drawing, bar drawing, fastener and other industries with both dies and lubricants. Since 2008, Kay Pee has been the exclusive India/SAARC countries agent/distributor for wire drawing lubricants and surface coating compounds from M/S Pan Chemicals SpA, Italy. Kay Pee Dies has installed the latest German automatic die grinding/polishing and finishing machine for improved quality and uniformity in dies, and says that this is the only machine of its type installed anywhere in India. The company is managed by a qualified and experienced father and son duo, and can meet the industry’s needs for tungsten carbide dies, wear parts and cone rings; lubricant and surface coating compounds; die shop machines and consumables; and consultancy for die management and optimisation. Kay Pee exports 40 per cent of its products to SAARC countries, the Middle East and Africa. Kay Pee Dies India Pvt Ltd www.kaypeedies.com

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November 2023