Tungsten Carbide Die
Tungsten carbide dies are a kind of tool used for cutting metals, and shaping metals. They can be made from different materials, including pcd, and so on. Considering the cost and working life, tungsten carbide is the most cost-effective material used for manufacturing dies. And tungsten carbide is extremely hard and durable. Tungsten carbide dies can be used to cut thick metal sheets, pipes, and other materials. Tungsten carbide dies can also use to create threads in metal surfaces.
Advantages of Tungsten Carbide Die
High Strength
Carbide dies can withstand high pressure and high temperatures. As a result, automotive and aerospace industries use these dies in manufacturing processes involving high mechanical stress. The ability of a carbide die to maintain integrity under extreme conditions ensures precision and quality.
Wear Resistance
Extreme hardness and toughness in carbide dies result in high wear resistance. These tools are less vulnerable to wear and tear. They can perform exceptionally well under harsh conditions.Industries can improve manufacturing speed and product quality while reducing downtime and production costs.
Dimensional Stability
Engineering is all about accuracy in dimensions. Jrd factory can achieve a processing tolerance of ±0.005mm.The parts produced with carbide dies often meet high tolerances and specifications. There are limited possibilities of inaccuracies with these tools.
Heat Resistance
A carbide die is heat resistant. The tool maintains its hardness and structural integrity under high temperatures. Unlike steel which begins to anneal when heats up, carbide resists annealing even at temperatures approaching 1000 fahrenheit. The melting point of tungsten carbide is 2870℃ and the boiling point is 6000℃.
Why Choose Us
Our factory
Founded in 1980,cangzhou yicheng wire die co., ltd. Is a comprehensive die professional enterprise integrating r&d, production, sales and maintenance.Through the unremitting efforts of yicheng people, the production scale and service scope of the enterprise are expanding day by day.
Our product
At present, the main products are: Electromagnetic wire drawing die, power transformer wire drawing die, light voltage wire drawing die, wire and cable wire drawing die, diamond coated wire drawing die, stainless steel wire drawing die, etc.
Production market
The company's products are sold to more than 100 domestic enterprises in more than 20 provinces, accounting for 70% of the domestic market share.
R&d team
Cangzhou yicheng wire die co., ltd. Is a comprehensive die professional enterprise integrating r&d, production, sales and maintenance.
Wire drawing dies
The first type is wire drawing dies. They are commonly used to process a roll of steel into pipes, rods, tubes, wires, etc. Companies also use carbide wire drawing dies to produce musical instruments and tailpipes.
The wire drawing operation is very simple. The steel roll is forced through a series of carbide dies to constrict the outer diameter of the steel. The process continues until the desired shape and dimensions like internal and external diameter are achieved.
Some manufacturers also use oil or titanium coatings on carbide dies to ease the friction and smoothen the wire drawing process.
Extrusion dies
Extrusion dies are similar to wire drawing dies. However, they are designed to manufacture products with specific shapes and sizes.
During the extrusion process, a slug of material is pushed through a carbide extrusion die of a particular shape. The temperature is set according to the mechanical of the material such as copper, lead, steel, aluminum, nickel, and tin.
Once a material passes through successive extrusion dies, we get a high-quality finished product with the desired shape.
Cold heading dies
Cold heading dies are popular in the automotive aerospace, and medical industries. Manufacturers prefer these dies to produce high-quality steel products at a high speed. They are also called header dies or cold-forming dies.
In this process, a cold metal slug is placed and forced to pass through a cold heading die to get the desired shape. Rapid and powerful blows are delivered by a punch to liquefy the metal slug and take the form of the die’s cavity. Popular products we can make with cold heading dies are nuts and bolts, screws, nails, and high-precision steel parts.
Hot forging dies
Hot forging dies, as the name indicates, can forge steel at a very high temperature. These dies are mostly used by automotive companies to produce wheels, etc.
The hot forging process usually takes place at a temperature of 700 centigrade. A cast ingot of steel is first heated to its plastic deformation temperature. Low-carbon steel, for instance, begins plastic deformation at 200-400 centigrade. The ingot is then forged between the carbon forging dies to get the finished product with the desired size and shape.
Manufacturers must carefully select the grade for hot forging carbide dies that can retain hardness even in hot conditions.
Why Do I Use Tungsten Carbide Dies?
There are many different types of dies in modern industry. Different applications can be wire drawing dies, cold heading dies, hot forging dies, gripper dies for making nails, and so on. And according to different materials, you can choose pcd dies, enameling dies, tungsten carbide dies, and so on.
The main reason for choosing tungsten carbide dies is their hardness. Tungsten carbide is one of the hardest tool materials in the world. And it is almost three times harder than steel and it is of higher density than titanium. This means that tungsten carbide dies have superior wear resistance compared to dies made out of other materials. Longer service life is equal to reducing the cost of replacing wire drawing dies and decreasing downtime for machinery waiting for new dies to be installed.
The hardness of tungsten carbide is between hra88 and 92. Although diamond has a hardness rating of 10, and tungsten carbide has a hardness rating of 9, diamond is not as versatile as tungsten carbide. And diamond is obviously a very expensive dies material. As diamond has the highest hardness and thermal conductivity of any bulk material, it can be widely used in industrial applications as cutting and polishing tools.
Tungsten carbide dies can be used in different grades. These different grades have different properties so that they are made for different applications. The amount of tungsten compared to the amount of carbon in these grades is what makes this difference. By adjusting the tungsten-to-carbon ratio, carbide dies with better wear properties or greater resistance to impact can be manufactured.
In general, superior hardness combined with the versatility of tungsten carbide results in its wide usage in many industrial applications. Products produced by using tungsten carbide dies include tubing, nails, and nuts. Actually, a list of these products would be very long, and that’s where the versatility part of the equation comes into play.
Using tungsten carbide dies has lots of advantages, because tungsten carbide has many great properties such as excellent corrosive resistance, wear resistance, and high hardness. Therefore, they can be available in a large range of sizes and are very cost-effective production.
There are many different types of tungsten carbide dies, each designed for different purposes. Some tungsten carbide dies can work by using their hardness to cut metals, such as the tungsten carbide die cutters used for making nails. During cutting, tungsten carbide dies to make friction with the metals, so the cutting process may create a lot of heat. The dies are usually cooled with water or oil to prevent them from overheating. Generally, dies can last for a long time if they are properly cared for and used correctly. Some dies are made for cutting soft metals like aluminum, and can also be designed for cutting hard metals, like steel.
Tungsten carbide dies can be also used in a variety of industries, including automotive, manufacturing, aerospace, engineering, and construction. They are vital tools for many different types of businesses and can be used to create parts and components that are strong and durable.
Nowadays, tungsten carbide dies can be used in a variety of industries, and can also be applied for automotive manufacturing to stamping metals. Compared to traditional steel dies, tungsten carbide dies have many advantages.
However, when we are applying tungsten carbide dies, we should have some safety considerations:
1. Tungsten carbide may generate high-level heat and friction when used. This can lead to burn or fire if the area around the die is not properly ventilated;
2. Tungsten carbide dust may be harmful if inhaled or ingested. It’s important to wear proper respiratory protection when working with tungsten carbide dies.
3. Dies can be sharp, so it's important to handle them with care to avoid cuts or punctures.
4.By these safety guidelines, you can help ensure that these dies are used safely and effectively in your workplace.
Precautions of Tungsten Carbide Die
Forging equipment
According to the different weights of the forgings, the tonnage of the die tools forging hammer should be appropriately selected, and the hammer head and hammer drill should be preheated before forging.
The preparation of the blank
Cold sawing is appropriate when blanking the blank. According to the different requirements of various powder metallurgy molds, the carbide segregation level should be considered when selecting raw materials, and the appropriate forging process should be used. Generally, the increase can be increased every three times of upsetting. 1-1.5 level.
The heating of the blank
The heating should be carried out slowly to prevent rapid heating to avoid over-burning. When heating, strictly control the upper limit temperature. If overburning is found, the temperature should be lowered in the furnace before forging. When multiple pieces are heated, there must be a gap between the pieces, and they must be turned frequently during the heating process.
Mold Cleaning And Anti-corrosion Treatment
●Mold cleaning: Molds will accumulate metal chips, lubricant residues, etc. During the use process, which will affect its surface quality and processing accuracy. Therefore, regular mold cleaning is very necessary. Use a soft cloth or brush to clean the surface of the mold to remove surface dirt and residues. Clean the mold surface with detergent or solvent to remove dirt and grease thoroughly. After cleaning, wipe the mold surface with a clean soft cloth to ensure the surface is dry.
●Anti-corrosion treatment: The material of tungsten carbide dies has a certain degree of oxidation resistance, but oxidative corrosion may still occur in a humid environment. Therefore, anti-rust treatment can effectively extend the service life of the mold. Coat the surface of the mold with antirust oil or antirust agent to form a layer of protective film, blocking the contact of air and moisture to avoid oxidative corrosion. Regularly check the anti-rust coating on the surface of the mold and repair or re-coat it in time if it is worn or damaged.
Wear And Fracture Inspection
●Regular inspection: Regular inspection of tungsten carbide dies for wear and fracture can detect problems and take measures to repair them in time, avoiding production interruptions and workpiece quality problems caused by wear or fracture. Check the surface of the mold for obvious signs of wear, such as scratches and abrasions. Check the edges and corners of the mold for cracks or breaks. Use microscope or magnifying glass to inspect the surface of the mold to find tiny wear or cracks.
●Wear marking: Mark any wear or breakage problems found and record the location and extent of the wear or breakage. Use chalk or marking pens to mark the location of wear or breakage on the mold surface. Use a micrometer or micrometer to measure the depth and length of the wear or fracture.
Wear Repair And Replacement
●Wear repair: Tungsten carbide dies that are lightly worn can be repaired to extend their life. Use a grinder or a grinding machine to dress the worn parts and restore the surface finish and accuracy of the dies. Use grinding wheels or abrasive stones to dress the more severely worn parts to eliminate traces of surface wear.
●Mold replacement: For severely worn or broken tungsten carbide dies, they should be replaced in time to ensure smooth production. Replace severely worn or broken dies in a timely manner according to the die replacement plan. Use proper tools and equipment to dismantle and install the molds safely to avoid accidental damage caused by improper operation.
Lubrication And Cooling
●Lubrication: Proper lubrication can reduce the friction between tungsten carbide dies and workpieces and extend the life of the dies. Apply lubricant on the working surface of the mold to reduce friction and wear. Regularly check the working condition of the lubrication system to ensure a smooth supply of lubricant.
●Cooling: Tungsten carbide dies are subject to high temperatures during the working process, proper cooling can reduce the temperature of the mold and slow down the heat damage. Use coolant to cool the mold to reduce the working temperature. Control the supply and pressure of coolant to ensure the cooling effect is as expected.
Regular Maintenance And Records
●Maintenance plan: Set up a regular maintenance plan for tungsten carbide dies to carry out regular inspection and maintenance of the dies to ensure their performance and service life. Set up maintenance intervals, such as monthly, quarterly or semi-annual maintenance checks. Establish a list of maintenance tasks, including cleaning, lubrication, wear checks, cooling system checks, etc. Designate a person to be responsible for maintenance tasks to ensure that maintenance is executed in a timely manner.
●Maintenance records: Establish maintenance records for tungsten carbide dies to record the maintenance process and maintenance results, which will help to analyze the use of the dies and changes in performance. Record information such as maintenance date, maintenance personnel, and maintenance contents. Record the wear and tear, lubrication status, cooling effect and other key parameters of the mold. Analyze the maintenance records to find problems and take timely measures to solve them.
Mould Storage And Custody
●Clean storage: When the mold is not in use, clean and store it to prevent it from being polluted and damaged. Coat the surface of the mold with anti-rust oil or anti-rust agent to form a protective film. Place the mold in a dry and ventilated environment to avoid moisture and mold growth.
●Regular inspection: Inspect stored molds regularly to ensure they are in good condition. Check the surface of the mold for oxidation or corrosion. Check whether the packaging of the mold is intact to prevent external collision or damage.
Maintenance and care of tungsten carbide die is the key to ensure long-term stable operation and productivity of the dies. Through regular cleaning, wear and tear inspection, lubrication and cooling and other maintenance measures, the service life of the molds can be extended, and production quality and efficiency can be improved. At the same time, by training operators and establishing maintenance records, we can keep the molds in good condition. Reasonable maintenance and upkeep strategy is an important guarantee for enterprises to improve the efficiency of using tungsten carbide dies and reduce production cost.
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