On-site audit identified misaligned guides and incorrect drafts, raising yield from 65% to 92% for a mid-sized profile wire plant.
The Challenge
A mid-sized plant received a large order for profile wire but experienced high scrap rates (35%). They suspected the dies, but the dies measured within tolerance.
Titan Engineering Solution
Titan provided a 'Profile Optimization Service.' Our engineers visited the site and identified that the inlet guides were misaligned and the back-tension was too high, causing the wire to twist before entering the die.
Fig 1. Analysis and Implementation
The Results
After realigning the machine and adjusting the tension parameters according to our recommendations, the yield increased from 65% to 92%. The customer successfully fulfilled the order on time.
Key Takeaways
- The die is only one part of the system.
- Correct machine setup is vital for profiles.
- Expert on-site support solves systemic issues.
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
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