Implementation of asymmetrical bearing length design achieved sharp 90° corners and ±0.02mm dimensional stability for square brass wire.
The Challenge
A producer of square brass wire for electronic pins struggled with rounded corners and uneven sizing. Standard die designs resulted in asymmetrical wear, causing the profile to drift out of tolerance quickly.
Titan Engineering Solution
We implemented our foundational design philosophy: Asymmetrical Bearing Lengths. By shortening the bearing at the corners (where friction is highest) and lengthening it on the flats, we balanced the drag forces across the profile.
Fig 1. Analysis and Implementation
The Results
The new dies achieved sharp 90° corners and maintained ±0.02mm dimensional stability across production batches. Die life increased by 40% due to even wear distribution.
Key Takeaways
- Intelligent bearing design balances material flow.
- Uniform wear extends profile die life.
- Sharp corners require specific stress-relief geometries.
Facing a similar issue?
Our application engineers can audit your current setup and propose a similar high-performance tooling solution.
- 24-hour drawing analysis
- Custom geometry simulation
- Performance guarantee