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Esteves Group - The global die company

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Extrusion Tools

Features tools

For many years, the Esteves Group has been supplying natural diamond and tungsten carbide extrusion tools to the cable industry.

Continuous improvement in our production process and the increasing requirements of our customers, help us to develop products of the highest quality.

Recently extrusion tips (wire guides) with PCD inserts have been added. PCD inserts allow for the use of diamond extrusion tips at sizes as large as 3.6 mm (.1417").

State-of-the-art sintering technology and accuracy in concentricity, within 0.0025 mm (.0001”), depending on the type of tool and design, give our product the highest performance during cable manufacturing.

How to order extrusion tools

 

Wire guide's and extrusion dies, structure and materials

The Esteves Group has identified the most critical areas in its manufacturing process. If some of the below mentioned areas are not well defined or controlled, quality of the wire insulation can be affected.

Body

One of the most important things in the insulation process is the production speed. The Esteves Group is always using high resistance and homogenous materials (specially treated steel or first class T/C) in order to help the insulation flow. High level polishing of the bodies is provided.

Insert location

The location of our inserts is always as close as possible to the edge (only 0.7mm / .0273”) of the tip´s end keeping a minimum distance in order to avoid insert breaks and to ensure perfect guiding of the wire.

No sharp edges

This is necessary to ensure smooth threading up and to avoid wire breaks.

Accurate concentricity

This is one of the most important parameters. It guarantees that the wire will be perfectly centered within the insulation material. This tight tolerance (0.0025mm / .0001”) is one of the keys in the quality of our tools.

Marking area

High definition laser marking area with diameter and other important customer details (upon client request).

 

Recommendations and advantages

1. Use wire guides (tips) with natural diamond insert for diameters smaller than 1.90 mm (.075”)
2. Better consistency of the final customer product is obtained when using a ND insert. The concentricity of the cable is maintained longer because the wire guide is subject to less wear.
3. Lifetime of wire guides with natural diamond insert is between 2-4 times longer than with tungsten carbide insert or solid carbide (price is not even double).
4. There are two clear advantages of using a natural diamond insert.

Cheaper with a short pay-back time. Compared with T/C tools, a tool cost saving (per meter of coating) of 25 % can be achieved in a short period of time. Less tool inventory is needed, because of the longer tool life.

More production. Longer life will mean less machine downtime, no need to change the sets as often as when using tungsten carbide inserts.

5. The wire guide´s lifetime with a PCD insert is around 6 times longer than with a tungsten carbide insert. PCD inserts only work with straight line drawing-extruding machines, that are fully insulated with no “static electricity”. This is very difficult to obtain and for this reason PCD inserts are not very common and not usually recommended.
6. How to acquire the most suitable tool for your needs:
- A. Specify the bore diameter in mm / inches.
- B. Provide an accurate drawing of the tool. We can supply standard drawings for sets of tools 2/6, 4/6, 12/16 & 14/20.
- C. Specify the material to be extruded (PVC, PE, rubber, etc…)
- D. Specify the preferred raw material (ND insert, T/C insert, insert solid, etc…). If you are not sure, contact us for a recommendation.

 

Extrusion tools maintenance

Proper tooling maintenance and cleaning saves money and should therefore be a priority.

Following the recommendations below will extend tool lifetime and protect the tool for future use.

Maintenance recommendations

1. When production stops for a period of time, always remove the tooling from the extrusion head (before the coating material becomes solid).
2. The correct procedure to remove the extrusion guide from the extrusion head is to cut the wire, leaving a small part inside the wire guide. This will avoid the flowing material to get into the tool.aterial to get into the tool.
3. When disassembling the tool from the extrusion head, NEVER hit the tools directly with a hammer or heavy material. Use always a soft material (nylon, wood, etc...). Always tap the tools from the back of the tool, NEVER from the front (insert area). Use a safety tray to place the tools on when you take them off the extrusion head.
4. Once the wire guide is out of the machine pull the wire out into the direction of the extrusion line.
5. Try to remove the insulating material from the tool when it is still warm and soft. You can use a wire brush, but use the brush carefully. Avoid leaving marks on the tool body.
6. When the insulating material is cold and has become hard, a solution could be to heat the tools in an oven with a controlled temperature (200º - 250º C). Never use a torch as this can seriously damage the tool structure (mounting, welding, insert, etc.)
7. Once the insulating material is removed, clean the extrusion tools in an ultrasonic cleaning machine using water and washing liquid.
8. Dry the tool carefully, removing all water marks and coat the tool with lubricant oil.
9. For future use, keep the clean and lubricated tools in a safe place (wooden case, tubes, etc…).

 

How to order extrusion tools

Please provide the following information:
• Bore diameter in mm/inches and quantity required
• Drawing to be provided by the customer
• Material to be extruded (PVC, PE, rubber, etc…)
• Material preferred in the tools (if not we will suggest the most suitable one)


Types of wire guides (Tips)

A. Steel body natural diamond insert
B. Steel body tungsten carbide insert
C. Steel body PCD insert (risk of static electricity sparks)
D. Solid tungsten carbide
E. Solid hardened steel or special steel alloys


Types of extrusion dies

A. 100% tungsten carbide
B. Steel body tungsten carbide insert
C. Steel body ceramic insert
D. Solid hardened steel or special steel alloys.

 

In case of doubt, contact us for assistance in choosing the most suitable material for your extrusion tools.

In case no tool drawing is available, send us a used wire guide or extrusion die.

How to order extrusion tools

 

Esteves Group SSCD dies - Synthetic monocrystalline diamond drawing dies (111 oriented) Download product leaflet
extrusion tools
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