Save money when repairing dies

August 2018 — Multiple wire drawing machines have strongly enhanced the number of drawing heads, mostly those made of PCD: thousands are in use, others in repair and in reserve. All this binds capital. Eder Engineering offers advice, deeds and the technology to save costs here.

Wire drawing has changed tremendously with the use of multiple drawing machines. Thus, the number of dies has also increased, mostly those made of PCD. Thousands of such tools are in operation, and a significant number are on the way to repair. Once again, thousands are in reserve to compensate for fluctuations and ensure ongoing operations.

Even the best PCD dies wear sooner or later, so that trouble-free pulling is hardly possible anymore. In order not to have to buy permanently new dies, it is customary to remove worn tools from the drawing process at an early stage and repair them in a suitably equipped workshop with qualified personnel and then reintegrate them into the work process. To make the worn drawing dies ready for use again: that's why there are no profit on wire drawing and cable works. There are two alternative options.

1. The outsourcing of maintenance initially saves investment in machinery and equipment together with the training of personnel in the drawing workshops. However, it also brings disadvantages and dependencies like
– Loss of cost transparency (repair costs are hardly verifiable and service providers rarely welfare institutions)
– qualitatively uncertain repair results
– Time shortages of drawing dies as well
– Dependence on delivery dates and logistics.

2. In-house die maintenance offers these advantages:
– full transparency and controllability of all maintenance costs
– integrated, in-house independence and increased competitiveness
– At any time flexible Umarbeitungsmöglichkeit the dies
– higher die life and overall productivity
– reduced stock of drawing tools.

Basics to the drawing die repair

The wear begins with the polishing of the polishing at the wire contact point in the drawing cone. If this is not repolished immediately, a wear/draw ring is created, which affects the surface of the drawn wire and can subsequently lead to wire breaks and standstill. Assuming suitable machines, it is sometimes sufficient to post-polish the drawing cone with slightly worn dies alone, with the advantage that the dimension in the die cylinder is preserved and the die can continue to remain in use with the original diameter. For drawing rings of medium to heavy wear, however, the die needs a completely new profile geometry and the next largest dimension in the drawing cylinder. All this requires an adequately equipped die-casting repair shop.

The growing use of multiple drawing machines requires more repair-requiring PCD drawing dies, which can hardly be handled with existing maintenance machines. It needs more powerful concepts. For processing the conical parts (infeed / draw cone / spout) ultrasonic systems are necessary, for reworking in the draw cylinder special wire calibration machines: both as universally applicable, wide range of application, with high throughput and minimum personnel.

Eder Engineering designed the USP-Twin semi-automated two-station ultrasound system as a solution that is simple, one-person operated, and enables twice the throughput of perfectly repaired dies: one station handles 0.05mm to 3 die dies mm, the second larger dimensions from 1 mm to 8 mm. Both are specifically customizable. In order to avoid a jam during the calibration polishing of the drawing cylinder after machining, Eder also offers a semi-automated high-performance wire calibration system equipped with two workstations. The “HGM-21” allows an ideally high calibration speed for PCD drawing dies, adjustable up to 900 strokes/min., High throughput and again the machining in the bore area from 0.05mm to 10mm. The machining concepts were developed with over 70 years of experience. They are ideal for mid- to high-throughput operations, but with limited skilled workload relieved by high-automation-grade, easy-to-use equipment.

Eder Engineering GmbH
Saarplatz 8, 1190 Vienna/Austria
Contact person is Mr. Kurt Eder
Tel.: +43 1 3674949

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