PCD Dies
- Manav Loomba
- Sep 27
- 4 min read
PCD COMPACTING DIE Watson Woodburn offers a range PCD Compacting Die designs Jumbo PCD Dies, Normal PCD Dies (Japan) and Elongation variations (USA). Round PCD Compacting Dies (as attached).
Figure below shows typical die profile for PCD compacting dies. The profiles designed such a way that as many (40+) wires directly from the Conductor Stranding Machine to PCD Compacting Die to get better compacting ratio, as compared to compacted with Rollers.
A carbide cap is also provided at the top of entry die to give better entry of wires into the die.
Advantages of Using PCD Compacting Dies over Rollers or Tungsten Carbide Compacting Dies:
Better Compaction Ratio: Higher compaction ratio is achieved with PCD Compacting Dies as compared to Rollers, resulting in lower electrical resistance (CR value) of the conductor. This is due to uniform deformation of final conductor. These also employ a “stabilization” cut.
Dimensional Control of Finished Conductor: Superior control of Conductor’s diameter is achieved with less ovality of finished Conductor. This is not easily obtained with PCD Compacting Dies as compared with Rollers.
Surface Condition of Conductors: Excellent surface finish is achieved with PCD Compacting Dies. This helps in better process stability.
Tool’s Life and Its Effect on Process Stability: The life of PCD compacting die is more than 500 times higher as compared to tungsten carbide compacting die. In addition, operation cost, set-up stability and rules of process stability are improved.
Illustration :Conductor Size – 300 mm sq (Round)Alum Grade – Material
Particulars | Old Values (Tungsten Carbide / Rollers) | New Values (Watson Woodburn PCD Compacting Die) |
Finished compacted dia. | 19.800 mm | 19.800 mm |
CR value at 20°C | 0.100 Ohm/km @ 20°C | 0.100 Ohm/km @ 20°C |
Total used for compaction | 20,000 km | 1,000,000 km |
Ovality | Approximately 0.05 mm | Less than 0.010 mm |
Surface condition of conductors | Mark visible on conductor surface | Mirror finished conductor surface |
Improvement in process stability | Not stable, breakdown frequently | Stable process, reduced breakdown frequency |
End use of conductor | Suitable for conductor application | Suitable for conductor application |
Die life over 5000 km | Less | High |
PCD Compacting Dies have helped our customers get higher compaction, better surface finish, improved process stability and lower consumption in manufacturing process. Contact us to know how we can help you with your application.
POLYCRYSTALLINE DIAMOND DIE Polycrystalline Diamond dies have changed the wire industry substantially in the past 30 years when they began to arrive in the market. Watson Woodburn is amongst the few companies who developed the techniques required to achieve the high surface finish required to meet the demands of today’s market.
Watson Woodburn has established production capabilities to process the “jumbo” robust size of the market. We have the ability to produce PCD dies in a size range of 0.05 mm to over 50.00 mm diameter for potential use in drawing, stranding, bunching, or tube drawing.
Specification and Tolerances of Polycrystalline Diamond Die
Size Range (mm) | Total Tolerance (inches) | Quality Tolerance (inches) | Casing Dimensions (inches) |
0.010 – 0.025 | 0.0001 | 0.00005 | Ø 0.312 × 0.125 |
0.025 – 0.075 | 0.00015 | 0.00008 | Ø 0.312 × 0.125 |
0.075 – 0.150 | 0.0002 | 0.0001 | Ø 0.375 × 0.125 |
0.150 – 0.300 | 0.0003 | 0.00015 | Ø 0.375 × 0.125 |
0.300 – 0.500 | 0.0004 | 0.0002 | Ø 0.437 × 0.156 |
0.500 – 1.000 | 0.0005 | 0.00025 | Ø 0.562 × 0.187 |
1.001 – 2.000 | 0.001 | 0.0005 | Ø 0.750 × 0.250 |
2.001 – 3.000 | 0.0015 | 0.00075 | Ø 1.000 × 0.312 |
3.001 – 5.000 | 0.002 | 0.001 | Ø 1.250 × 0.375 |
5.001 – 7.000 | 0.003 | 0.0015 | Ø 1.500 × 0.437 |
7mm & Larger | 0.004 | 0.002 | Ø 1.875 × 0.562 |
Note: We also supply dies as per customers’ required tolerance & casing sizes.
INNER PROFILE OF A TYPICAL WIRE DRAWING DIE
Upon looking at the cross-section of a typical diamond die, we find six main zones:
Entrance Angle – Entry point for wire into the die. Guides wire into die.
Approach Angle – Reduction zone, guides wire to deformation area.
Reduction Angle – Actual deformation of wire occurs here. Very critical zone.
Bearing Length – Ensures correct sizing of wire. Maintains roundness.
Back Relief Angle – Provides easy exit, prevents scratches.
Exit Angle – Allows wire to leave die smoothly.
Additional zone:7. Conical After Drawing Zone – Ensures stress release, improves mechanical properties.8. Black Relief Angle – Helps smooth transition out of die.
Natural, Mono & Synthetic Diamond Dies
Natural Diamond Dies: 0.010 mm – 1.000 mm
Mono Diamond Dies: 0.020 mm – 0.600 mm
PCD Dies: 0.050 mm – 15.00 mm
Sony metals' s strengths includes:
Rich experience of several years
Proven expertise
Innovative solutions
Focus on QQCD: Quality, Quantity, Cost & Delivery
Single minded dedication to customers
Qualified, technically competent professionals with over 25 years of experience in the industry
Typical Profile of PCD Die
S. No. | Details | Soft Wire | Hard Wire |
1 | Reduction Angle, 2α | 16° – 20° | 10° – 14° |
2 | Bearing Length % | 25 – 30% d | 35 – 40% d |
3 | Entry Angle | 60° ± 10° | 60° ± 10° |
4 | Exit Angle | 60° ± 10° | 60° ± 10° |
