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TC Dies


TC Dies

At Sony Metals, we specialize in manufacturing high-quality TCD Dies (Tungsten Carbide Drawing Dies) designed for demanding metal forming applications like wire drawing and deep drawing. Our dies are engineered for durability, accuracy, and smooth performance across a wide range of industrial uses.

Each die is carefully crafted with clearly defined zones to ensure consistent material flow, minimal wear, and excellent surface finish on the drawn product.

Key Zones of a TCD Drawing Die:

🔷 Die Set / Drawing Die:

This is the main body or housing of the die that holds all internal zones together. It ensures mechanical stability and houses precision-ground internal features.

🔷 Inlet Zone:

The entry point for the material (wire, rod, or sheet). It features a larger diameter opening to guide material smoothly into the die without scratching.👉 Associated angle: α₂👉 Guides the material into the reduction zone.

🔷 Reduction Zone:

Also referred to as the approach angle or reduction cone, this is the area where the primary deformation of the material occurs. The material is reduced in cross-section through a conical shape. 👉 Associated angle: α₁ 👉 Essential for controlling wire tension and die longevity.

🔷 Bearing Zone:

A cylindrical land section that succeeds the reduction zone. It is crucial for stabilizing and sizing the drawn material. 👉 Length denoted as: h₁ 👉 Ensures dimensional accuracy and a smooth surface finish.

🔷 Outlet Zone:

The final exit section of the die. Often includes a slight flare angle to minimize scratching or stress on the finished material. 👉 Associated angle: α₃

Critical Dimensions:

  • H: Total height of the die

  • h₂: Height of inlet/reduction zone

  • h₃: Height of outlet zone

  • D: Inlet diameter

  • d: Outlet diameter (final drawn diameter)


Tungsten Carbide Dies

Our Tungsten Carbide wire drawing dies are the result of expert technology & precision craftsmanship. Tungsten Carbide Dies are desirable in steel wire applications and in other applications where the finish and wear resistance of diamond dies are unnecessary and cost is a priority.

We offer a variety of Tungsten Carbide Dies for your various wire drawing needs, including shaped wire dies & Tube Drawing Dies.

Specifications: Tungsten Carbide Dies

  • Bell angle (a)

  • Approach angle (b)

  • Reduction angle (c)

  • Bearing Length (%d)

  • Back relief angle (e)

  • Exit angle (f)

Details

Parameter

Soft Wire

Hard Wire

Bell angle (a)

70° ± 20°

60° ± 20°

Approach angle (b)

35° ± 5°

30° ± 5°

Reduction angle (c)

16° ± 2°

14° ± 2°

Bearing Length (%d)

20–50

40–80

Back relief angle

10° ± 5°

10° ± 5°

Soft Wire: Copper, Aluminium, Brass, Gold, Silver, etc. Hard Wire: Stainless Steel, Copper Coated Steel, Tungsten, Molybdenum, etc.

Specifications: Tungsten Carbide Blanks/Pellets

Type

D

H

R

Range of Bores

W 102

8

6

2

0.20–0.50

W 103

10

8

3

0.20–0.90

W 104

13

10

4

0.20–1.50

W 105

15

12

5

0.20–2.50

W 106

17

13

6

0.20–3.00

W 107

19

17

7

0.20–4.00

W 108

22

20

10

0.50–5.00

W 109

25

20

12

0.50–7.00

W 110

30

24

14

0.70–10.00

W 111

35

24

16

1.00–12.00

W 112

40

25

20

1.00–13.00

W 113

45

25

22

1.50–16.00

W 114

50

25

24

2.00–19.00

W 115

55

25

26

2.00–22.00

W 116

60

25

28

3.00–26.00

W 117

65

30

30

3.00–30.00

W 118

70

30

36

3.80–40.00

Why Choose Our TCD Dies?

✅ Precision ground for optimal flow ✅ Manufactured using premium-grade tungsten carbide ✅ Designed to reduce friction and wear ✅ Custom sizes and geometries available ✅ Proven performance across automotive, electrical, and industrial sectors


Looking for dies that deliver long life, consistent results, and high accuracy? Get in touch with us today.


Why Choose Sony Metals?

When it comes to wire drawing solutions, selecting the right partner is crucial. Here are some reasons why Sony Metals should be your preferred choice:

1. Quality Assurance

At Sony Metals, quality is our top priority. We adhere to strict quality control measures throughout the wire drawing process. Our products undergo rigorous testing to ensure they meet industry standards. This commitment to quality means you can trust our products to perform reliably in your applications.

2. Custom Solutions

Every business has unique needs. We understand that one size does not fit all. That’s why we offer custom wire drawing solutions tailored to your specifications. Whether you need a specific diameter, material, or finish, we can work with you to create the perfect product.

3. Expertise and Experience

With years of experience in the industry, our team of experts is well-equipped to handle any challenge. We stay updated on the latest trends and technologies in wire drawing, ensuring that we provide you with the best solutions available.

4. Timely Delivery

In manufacturing, time is money. We understand the importance of timely delivery and strive to meet your deadlines. Our efficient production processes and logistics ensure that you receive your orders on time, every time.

5. Customer Support

Our relationship with customers doesn’t end with a sale. We pride ourselves on providing exceptional customer support. Whether you have questions about our products or need assistance with an order, our team is here to help.

Applications of Wire Drawing Solutions

Wire drawing solutions are used in a variety of industries. Here are some common applications:

Automotive Industry

In the automotive sector, wire is used for various components, including electrical wiring, springs, and cables. High-quality wire ensures safety and reliability in vehicles.

Electronics

The electronics industry relies heavily on wire for connections and components. Our wire drawing solutions provide the precision and quality needed for electronic devices.

Construction

In construction, wire is used for reinforcement, fencing, and other applications. Durable wire products are essential for ensuring the structural integrity of buildings and infrastructure.

The Wire Drawing Process at Sony Metals

At Sony Metals, we take pride in our wire drawing process. Here’s a closer look at how we ensure quality and efficiency:

Step 1: Material Selection

We start with high-quality raw materials. Our team carefully selects the best materials to ensure that the final product meets your specifications.

Step 2: Advanced Technology

We utilize state-of-the-art technology in our wire drawing process. Our machines are designed for precision and efficiency, allowing us to produce high-quality wire consistently.

Step 3: Skilled Workforce

Our skilled workforce plays a crucial role in the wire drawing process. With extensive training and experience, our team ensures that every step is executed flawlessly.

Step 4: Quality Control

Quality control is integrated into every stage of production. We conduct regular inspections and tests to ensure that our products meet the highest standards.

Step 5: Packaging and Delivery

Once the wire is drawn and finished, we package it carefully to prevent damage during transit. Our logistics team ensures that your order is delivered on time and in perfect condition.

Case Study: Successful Partnership with a Leading Automotive Manufacturer

To illustrate our commitment to quality and customer satisfaction, let’s look at a case study involving a leading automotive manufacturer. This company approached us with a need for high-quality wire for their electrical systems.

The Challenge

The manufacturer required a specific diameter and tensile strength for their wire. They also needed a quick turnaround time to meet production deadlines.

Our Solution

We worked closely with the manufacturer to understand their requirements. Our team developed a custom wire drawing solution that met their specifications. We utilized our advanced technology and skilled workforce to produce the wire efficiently.

The Result

The manufacturer was thrilled with the quality of the wire. It performed exceptionally well in their applications, and they were able to meet their production deadlines. This successful partnership led to ongoing collaboration and trust between our companies.

Sustainability in Wire Drawing

At Sony Metals, we are committed to sustainability. We understand the importance of minimizing our environmental impact. Here are some of the steps we take to promote sustainability in our wire drawing process:

1. Energy Efficiency

We invest in energy-efficient machinery and processes. This not only reduces our carbon footprint but also lowers operational costs.

2. Waste Reduction

We implement waste reduction strategies throughout our production process. By recycling materials and minimizing waste, we contribute to a more sustainable future.

3. Eco-Friendly Materials

Whenever possible, we source eco-friendly materials for our wire drawing solutions. This commitment to sustainability extends to our entire supply chain.

The Future of Wire Drawing Solutions

As technology continues to evolve, so does the wire drawing industry. At Sony Metals, we are excited about the future. Here are some trends we anticipate in the coming years:

1. Automation

Automation is set to play a significant role in wire drawing. By incorporating more automated processes, we can enhance efficiency and reduce production times.

2. Advanced Materials

The development of advanced materials will open new possibilities for wire drawing solutions. We are committed to staying at the forefront of these innovations.

3. Increased Customization

As industries become more specialized, the demand for customized wire solutions will grow. We are prepared to meet this demand by offering tailored products that meet specific needs.

Partnering with Sony Metals

Choosing Sony Metals as your partner for wire drawing solutions means choosing quality, reliability, and expertise. We are dedicated to helping you succeed in your industry. Our commitment to customer satisfaction and innovation sets us apart from the competition.

If you are looking for premium wire drawing solutions, look no further than Sony Metals. Contact us today to learn more about how we can support your business.


 
 
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