Stabilized, cooled dies enabled a 30% speed increase for rectangular welding wire production while holding tighter tolerances.
The Challenge
A high-volume producer of rectangular welding wire faced tolerance loss and surface chatter when running above 15m/s. Vibration and heat buildup were distorting the profile.
Titan Engineering Solution
We designed a die with dynamic stability analysis and integrated cooling channels. We used a high-thermal-conductivity carbide grade to rapidly dissipate heat away from the bearing zone.
Fig 1. Analysis and Implementation
The Results
The stabilized, cooled dies allowed the customer to increase line speed to 20m/s (+30%) while actually holding tighter tolerances than before. The chatter marks disappeared.
Key Takeaways
- High speed requires dynamic stability control.
- Integrated cooling prevents thermal distortion.
- Productivity gains are possible without sacrificing quality.
Facing a similar issue?
Our application engineers can audit your current setup and propose a similar high-performance tooling solution.
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- Custom geometry simulation
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