How often should the dies in a straight-through wire drawing machine be replaced?
There is no fixed standard for the die replacement cycle of a straight-through wire drawing machine. It mainly depends on three core factors: the processed material, process parameters, and die material. Specifically, it can be divided into the following situations:
By processed material:
- Stainless steel wire (hardened): Stainless steel has high hardness, which causes significant wear on the die. If processing hardened stainless steel wire with a diameter of ≥1mm using ordinary cemented carbide dies, the replacement cycle is usually 20–50 hours; if processing fine-diameter wire (≤0.5mm), the die wears out faster, and replacement may be needed every 10–30 hours.
- Stainless steel wire (soft temper): Soft temper stainless steel wire has good ductility and low wear, extending the replacement cycle of ordinary cemented carbide dies to 50–100 hours.
Classified by mold material:
- Ordinary cemented carbide molds: High cost-effectiveness, moderate wear resistance, and the most commonly used type on the market. The replacement cycle is based on the duration corresponding to the material mentioned above.
- High-performance cemented carbide molds (such as ultra-fine grain cemented carbide): Wear resistance is improved by 3–5 times, and the replacement cycle can be extended to 100–300 hours, suitable for continuous mass production.
- Diamond molds: The strongest wear resistance, specifically for stainless steel wire processing. The replacement cycle can reach 500–1000 hours, but the cost is higher, and they are mostly used for fine-diameter wires or high-precision processing applications.
Distinguished by process parameters:
- If the reduction in area during wire drawing is too high (large diameter reduction per pass), the drawing speed is fast, and cooling and lubrication are insufficient, the wear rate of the die will increase significantly, and the replacement cycle may be shortened by 30%–50%. Conversely, reasonably controlling the reduction in area and ensuring sufficient lubrication can effectively extend the die life.
Practical Judgment Techniques:
Besides considering the usage time, a more direct method of judgment is to observe the quality of the finished product:
When the surface of the finished steel wire shows scratches, burrs, or excessive diameter fluctuations;
Or when the frequency of wire breakage during the drawing process increases significantly, or the drawing force increases abnormally, the die needs to be replaced immediately.
