Shaped dies
Dies with any shape to transform round (or shaped wire) to shaped wire. Shaped dies are used in both drawing and extrusion machines where material is forced under pressure through the die. These dies are constructed in the same way as dies for round wire.
Blank (Nib) material
Shaped dies can be made of tungsten carbide (TC) and can also be made of polycrystalline diamond (PCD).
Casing
Stainless and cold rolled steel.
Dimensions depend on the size of the holder in the machine.
Sizes generally range from 25 mm to 75 mm (1” to 3”).
Geometry
The minimum size of shaped dies is limited by the wire size of a spark erosion machine. These machines are used to cut the shape and profile in the die.
The shape is also restricted by the ability to polish the finished profile.
The size of large shaped dies is only limited by the size of the blank and the capabilities of the machine it is used in.
The size tolerance is generally plus or minus 1% of the size.
Angle range is generally 6 to 24 degrees plus or minus 1 degree.
The radiuses and blend of shaped dies vary widely and depend on the application and specifications of the customer.
Split dies
These dies are split in two halves in order for the die to be placed around the wire and bolted back together, without the need to re-string the wire through the die. Split dies are generally used in bunching and stranding machines where considerable effort and down-time are a consequence of the use of standard dies.
Parts of the die:
Blank (Nib) material
The blank material is carbide, generally larger than R5. PCD blanks that are appropriate for the needed diameter can be used.
Casing
Material is cold rolled steel or stainless steel.
Dimensions are based on the blank size and the holder size in the machine.
Geometry
Size ranges from 0.380 mm to 25 mm ( .015” to over 1”) depending on the cable size being manufactured.
Tolerance is generally plus or minus 1% of the hole diameter.
Angle range is generally between 18 to 24 degrees plus or minus 2 degrees.
