Switching to PCD-tipped composite dies extended tool life from 1 week to 6 weeks for star-shaped decorative wire production.
The Challenge
Producing a complex star-shaped decorative wire was costly because the sharp tips of the profile wore out 5-10x faster than the body. The manufacturer had to replace the expensive solid carbide dies weekly.
Titan Engineering Solution
We introduced a Segmented Die solution. We inserted ultra-hard PCD elements specifically at the high-wear tip locations, while using tougher, cost-effective carbide for the main body of the die.
Fig 1. Analysis and Implementation
The Results
Tool life extended from 1 week to 6 weeks. The segmented design allowed for the replacement of only the worn inserts rather than the entire die, reducing long-term tooling costs.
Key Takeaways
- Wear is rarely uniform in complex profiles.
- Hybrid materials place hardness exactly where needed.
- Modular dies reduce replacement costs.
Facing a similar issue?
Our application engineers can audit your current setup and propose a similar high-performance tooling solution.
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