WCA March 2007

Dies & Die Shops

“Straight as a die” Before the computer revolutionised many of the processes of wire production, the die maker was one of the most prestigious figures in the plant. The advent of the computer has only enhanced that reputation. The sheer variety of materials in current use, together with today’s increasingly rigorous standards and abbreviated lead times, impose demands on the die making operation that have intensified with automation. In one busy old-line wire plant the die shop was always known as the wheelhouse. Today – although looking more like the control room of a Vanguard-class submarine than of a sailing vessel – it still is.

Photo credit: Die Quip Corp

The industrial diamonds employed in wire dies are expensive. Cutting around complex contours to create precision templates is exacting work. Customers are demanding, specifications dictate ever-smaller tolerances, certifiably accurate results must be guaranteed. The responsibility for much of this rests with the die shop. This section of Wire & Cable ASIA reviews machinery, equipment, products, and services from professionals for whom “straight as a die” is more than a handy expression. It is their particular benchmark of quality.

A real gem! Kemet International Limited has developed the next generation of diamond products for polishing diamond and tungsten carbide wire drawing dies. Diamond compounds and diamond suspensions are available in oil or water soluble formulations. They offer high heat stability and excellent lubrication properties. Users have reported up to 30% increase in stock removal compared with conventional polishing. Diamond compounds are mainly used on tungsten carbide wire drawing dies. The die is rotated in a chuck at approximately 1,500rpm. A metal shaped lap (cast iron, mild steel) is entered into the die with coarse diamond compound.

The laps are then changed from metal to hard and soft wood sticks. The grades of diamond compound used are usually 45, 14 and 3 micron. For diamond wire drawing dies, Kemet has developed a thick diamond suspension with a very high diamond concentration. This diamond suspension is far more effective at polishing than conventional methods. Both tungsten carbide and diamond wire drawing dies require diamond products which will withstand heat and pressure without drying out or prematurely breaking down. The Kemet range of diamond products was developed specifically for this purpose and is the preferred choice amongst die polishers.

A complete tooling service from CTR

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manufacture of complete tool kits and offer a fast turn around service, helping our customers achieve their own schedules on-time and in full, which is why we are one of the largest fastener tool manufacturers in the world today.” From segmented dies to a variety of coated punches CTR offer a complete service, which gives customers the option of a sole source of supply if required. And with continued investment in the latest machining techniques and on-going training programmes, the company ensures that they continue to stay at the forefront of a competitive market place.

Kemet International Ltd – UK Fax : +44 1622 670915 Email : sales@kemet.co.uk Website : www.kemet.co.uk

Diamond products from Kemet International

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Complete tool kits Formed in 1973, CTR Birmingham has been supplying fastener tooling to the automotive, aerospace and building industry. Peter Ruitenberg, sales manager, commented: “We specialise in the

CTR Carbide Dies Ltd – UK Fax : +44 121 773 9342 Email : info@ctr-uk.com Website : www.ctr-uk.com

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Wire & Cable ASIA – March/April 2007