Polycrystalline Diamond Wire Drawing Dies

We are a famed Polycrystalline Diamond Wire Drawing Dies Manufacturer, Exporter, and Supplier in India. Polycrystalline Diamond Wire Drawing Dies with polycrystalline diamond (PCD) blanks can be used for ferrous and non-ferrous wire drawing applications. Sizes of Polycrystalline Diamond Wire Drawing Dies are available for drawing applications ranging from ultra-fine wire to large drawn rod. This size range includes, but is not limited to, 0.025 to 10mm. Polycrystalline diamonds, abbreviated as PCD, are man-made sintered diamonds and can be used for almost any type of wet or dry wire drawing application and are available in three main groups: Unsupported and Supported Metal Filled, and Thermally Stable. For each group, several PCD blanks are available that match your wire surface finish needs as they are offered in various grain sizes. All PCD blanks contain randomly oriented diamond particles. The result is a perfectly round wear pattern for each die, ensuring that your wire remains round. Key benefits of Polycrystalline Diamond Wire Drawing Dies

• Available for almost any type of wire drawing operation, from rod-size to fine-size
• Can be used for wet and dry drawing applications
• Predictable wire surface quality
• Contain randomly oriented diamond crystals, making certain that wire remains round; even with significant wear the wire remains round
• Blank dimensions are guaranteed, hence maximum recut dimensions can be predicted

The company offers a range of Solid Enamelling Dies with Tungsten Carbide and PCD Insert. The company has developed special enamelling dies with PCD inserts, which is a boon to the enamelling copper wire industry. Perfect profile ensures uniform coating, smooth and continuous flow of enamel on the copper wire. The company offers standard and customized designs in both aluminum and stainless steel bodies. Enameling dies achieve a more accurate and consistent enameling application on enameled wire. Our tapered internal geometry allows easy threadability for even the smallest sizes. These dies are available in standard shapes and also custom made. We provide our clients with Re-cut Services along with reaming and polishing services. These services are provided for all the PCD, Natural and Mono diamond dies. Our best services are known for eliminating the defects and the wear in the die, when the wire drawing operation takes place. In this operation, each die has also been calibrated to a completely new size as per the requirements of the customers. The dies can also be re-polished in order to keep the original diameter, which allows a longer service life and these are done when the defects are not major. We use advanced technology for providing unmatched re-cutting as well as polishing services for the various die types. This also ensures higher productivity in the various drawing processes along with excellent wire quality. These services eliminate defects and wear marks in the die after the wire drawing operations. Whenever possible and provided that the defects are not severe, the dies are re-polished by keeping the original diameter, allowing, for a longer lifetime. The recutting and polishing services for the above mentioned die types are executed with state-of-the-art technology. This ensures high productivity in the drawing process and an excellent wire quality. We carefully inspect each received die to analyze wear and recutting factors, often discovering abnormal wear or usage that may be affecting your productivity. We apply the same technology, precision craftsmanship and quality controls used in the original die manufacture to ensure that the accuracy of your recut die's geometry and bearing lengths meet your specifications. We also do Recutting of Multi-wire die sets along with elongation matching required by customers. Applicability Polycrystalline diamond blanks as a base material can be successfully applied in almost any wire drawing operation, from rod-size to intermediate and fine size wires. The randomly oriented sintered diamond crystal structure makes these nib types stay round during use and its longevity is known to outperform both natural and synthetic single crystal diamond dies. When die life and wire production efficiency take precedent over wire surface finish, consider a Poly-Di wire die. Poly-Di wire dies are manufactured with polycrystalline diamonds, a durable synthetic material with a highly polished surface finish that minimizes friction for an exceptional resistance to die wear, cracking and breakage. You get significantly longer die life, excellent wire roundness and highly predictable die wear with a good wire surface finish. For fine wire and ultrafine wire applications demanding a superior wire surface finish, nothing performs better than a single crystal. The first to use diamond x-ray orientation, Fort Wayne Wire Die is uniquely skilled at properly mounting the diamond inside the die casing to ensure precise profiling, exceptionally accurate hole sizing and maximum wearability that all combine to yield unmatched wire quality. You get the very best performance for optimum wire reduction uniformity and wire roundness, minimum die pull and virtually flawless. Our extensive inventory boasts ample supplies of R1 to an R14 Tungsten Carbide blanks available with various standard geometries and Cobalt contents. These large and diverse inventory levels allow us to offer short lead times that give our customers the competitive edge when quoting. Our exacting manufacturing standards, developed by more than 65 years of experience and focus within the wire manufacturing industry, results in unsurpassed quality carbide products manufactured to the tightest tolerances. Our Tungsten Carbide Wire Drawing Dies are available as Rough Core or Finished Dies, with I.D. sizes ranging from .005 to 5.000�, are continually recognized as the most consistent and reliable throughout the industry. The key to successful wire drawing starts and ends with the proper wire drawing die and reduction geometry. Our Wire Drawing Dies feature the most accurate and optimal geometry available to assure the required wire deformation is accomplished correctly. By properly drawing the wire through the tightly controlled and appropriately designed approach angle section of the die the user reduces the diameter through plastic deformation which is by definition the process of wire drawing. For good wire deformation, it is necessary to select the proper drawing die with the appropriate profile. This will ensure that the die will hold a thin film of lubricant between itself and the wire surface which is essential to minimize friction and maximize die life. Wire Drawing Dies are specifically designed for either ferrous or non-ferrous materials as well as heavy or light drafting. Some materials for which the wire drawing dies were designed require areas where approach angles, bearing surfaces and back relief angles intersect to have high polish blends of these transitions. Our Wire Dies have smaller radii or sharper transitions for harder materials and larger more rounded radii for softer materials. Most Wire Die wear takes place in the approach angle by immediate abrasion at the meeting point or the area of the approach angle where incoming material and approach angle intersect. To achieve proper and efficient wire drawing it is most critical to calculate this intersecting area correctly. At first the highly polished approach angle will show only small signs of wear at the intersection point but they increase as material continues to collide at the meeting point of the two materials. This wear is characterized by the increasing development of a �wear ring� within the approach angle and at the place that the angle and incoming material intersect. Once the wear ring has developed within the approach angle the die must be withdrawn for re-sizing or re-cutting. For products where additional draws are needed to reach the desired finish diameter an average area of reduction per die of roughly 20% (area not diameter) is typical. Steel wire work hardens during plastic deformation and ductility is reduced while tensile strength increases. The total area of possible reduction without intermediate annealing depends solely upon the composition of the steel. It is possible through multiple subsequent or sequential draw passes through ever smaller dies to reduce cross sectional areas of the wire by up to 90%. These types of extreme areas of reduction will require intermediate annealing to restore the materials ductility. Precision, high quality and fast turnaround are the hallmarks of our company. We support everything that we manufacture with a staff of knowledgeable personnel. Each team member is always ready to assist you in planning your die needs or with any technical issues.

• Polycrystalline Diamond Die (0.025mm to 7.000)
• Natural and Monocrystalline Diamond Die (0.025 to 0.700)
• Multi-wire Die sets with elongation
• Enamelling Dies
• Die cutting and reconditioning

Single Crystal Natural Diamond Dies are available in the size range from 0.050 mm to 2.00 mm provides premium quality and performance. Each diamond is individually inspected to ensure that all diamonds used are free from internal defects. Each diamond is properly mounted, precisely profiled, highly polished and accurately sized to offer uniform wire reduction, minimum die pull and excellent wire surface quality. Natural diamond is used in fine or ultra fine sizes or as finish Dies when a superior wire surface is required. The company is in the field of manufacturing of various kinds of drawing dies and can supply PCD dies in the size ranging from 0.050 mm to 34 mm. Wirex Dies are meticulously processed in a unique lapidary style for drawing of soft as well as hard wires. Wirex PCD Dies are being manufactured by exclusively using PCD Die Blank approved from ADDMA USA. Sizes of Polycrystalline Diamond Wire Drawing Dies are available for drawing applications ranging from ultra-fine wire to large drawn rod. This size range includes, but is not limited to, 0.040 to 35 mm (.00157 - 1.378"). For each group, several PCD blanks are available that match your wire surface finish needs as they are offered in diamond grain sizes ranging from 1 to 50 microns. All PCD blanks contain randomly oriented diamond particles. The result is a perfectly round wear pattern for each die, ensuring that your wire remains round. Let our experienced sales staff helps you choose the most cost-effective or readily available diamond blank for your application or let us know if you specifically need a Sumitomo-Sumidia or Diamond Innovations-Compax PCD blank. Applicability Polycrystalline diamond blanks as a base material can be successfully applied in almost any wire drawing operation, from rod-size to intermediate and fine size wires. The randomly oriented sintered diamond crystal structure makes these nib types stay round during use and its longevity is known to outperform both natural and synthetic single crystal diamond dies. Typical application areas

• Copper wire
• Aluminum wire
• Tungsten wire
• Molybdenum wire
• Stainless steel wire
• Coated steel wire
• Special alloy and high performance alloy wire
• Precious metal wire
• Various other ferrous and non-ferrous metal wire types

Polycrystalline diamond wire dies (PCD dies) are part of Esteves Group�s diamond wire dies product portfolio. Typical ranges (both smaller and larger sizes are available on request) :

• 0.005 to 2.00 mm (.00019 - .0787â��) - natural diamond wire dies (ND dies)
• 0.010 to 2.05 mm (.00039 - .0807â��) - synthetic single crystal diamond wire dies (SSCD dies)
• 0.040 to 35.0 mm (.00157 - 1.378â��) - polycrystalline diamond wire dies (PCD dies)
• 0.127 to 76.2 mm (.005 - 3.000â��) - tungsten carbide wire dies (T/C dies)

Technical support Call our technical sales support if you wish to receive more information about our products or if you would like to receive a quote for your application. We will manufacture wire dies to standard specifications or customize our products to match your manufacturing needs. The company is a manufacturer of diamond drawing dies with synthetic single crystal diamond (SSCD, also known as single crystals) blanks inside as a high quality, predictable and durable product for drawing ferrous and non-ferrous wires from 0.010 to 1.81 mm (.00039 - .0713�). Larger sizes are available upon request. Like all products from Esteves Group you can expect these products to be manufactured with the highest quality and accuracy standards. Synthetic single crystal diamonds, also called synthetic mono crystal diamond and abbreviated as SSCD or SMCD or MCD, are man-made diamonds, manufactured under controlled conditions and are free from impurities, inclusions and cracks. These tightly controlled quality aspects lead to predictable and constant die performance. The SSCD blanks that Esteves Group uses are all <111> oriented with a divergence in the orientation less than 1°. The result is a close-to-round wear pattern for each die, a quality aspect that previously could only be obtained in small natural diamond dies. Another advantage of SSCD blanks is their availability in several sizes, allowing you to select the diamond blank that best fits your recut program.