Proprietary "pre-deformed" die cavity design achieved net-shape output for trapezoidal fencing wire, eliminating secondary straightening.
The Challenge
A manufacturer of high-carbon steel trapezoidal fencing wire faced significant shape deviation after drawing. The wire would 'spring back' upon exiting the die, requiring an expensive secondary straightening process.
Titan Engineering Solution
Titan utilized Finite Element Analysis (FEA) to calculate the elastic modulus and springback factor of the material. We designed a 'pre-deformed' die cavity that over-compensated for the expected springback.
Fig 1. Analysis and Implementation
The Results
Upon exiting the die, the wire naturally sprang back into the perfect target geometry. This 'Net-Shape' output eliminated the need for the secondary straightening station, increasing line speed by 15%.
Key Takeaways
- High-tensile materials require springback compensation.
- Simulation prevents trial-and-error die cutting.
- Eliminating secondary processes boosts throughput.
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