Irregular Wire Drawing Die With Roughened Corners for Accuracy

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Solution Overview

Problem

The accuracy of irregularly-shaped wires produced using conventional irregularly-shaped dies is low.

Innovation Solution

An irregularly-shaped die with a processing hole featuring a reduction portion and a bearing portion in the wire drawing direction, where the corner portion has a curved shape and a non-corner portion with specific surface roughness values, and the surface roughness of the corner portion is greater than that of the non-corner portion, improving processing accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional irregularly-shaped dies are used, then manufacturing simplicity is maintained, but manufacturing precision of irregularly-shaped wires is low

Engineering Contradiction:

Improveaccuracy of irregularly-shaped wireVSAvoidcomplexity of die structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The die hole is divided into different regions (corner portions and non-corner portions) with different surface roughness characteristics. The corner portions have a first surface roughness while non-corner portions have a second surface roughness, allowing each region to perform its specific function optimally - corner portions guide the wire smoothly while non-corner portions provide sufficient friction for shape formation.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The processing hole is segmented into multiple functional zones including a bell portion, approach portion, reduction portion, and bearing portion, with further segmentation of corner and non-corner portions. Each segment has optimized surface roughness to address specific processing requirements at different locations during wire drawing.

Inventive Principle:

Principle #1Segmentation

2Reliability

If uniform surface roughness is applied throughout the die, then manufacturing simplicity is maintained, but wire breakage increases and lubrication conditions deteriorate

Engineering Contradiction:

Improvereduction of wire breakageVSAvoidsimplicity of die fabrication

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Different surface roughness values are applied to different regions of the die hole. Corner portions have higher surface roughness (first surface roughness) to improve lubrication conditions and reduce wire breakage, while non-corner portions have lower surface roughness (second surface roughness) to maintain manufacturing feasibility.

Inventive Principle:

Principle #3Local quality

3Shape

If corner portions have sharp edges, then shape definition is improved, but surface roughness increases and wire breakage occurs

Engineering Contradiction:

Improvesharpness of corner definitionVSAvoidsurface roughness and wire quality

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The corner portions of the processing hole are designed with curved shapes instead of sharp edges. This curvature prevents excessive stress concentration and wire breakage during drawing, while still maintaining well-defined corner geometry for accurate wire shape formation.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Data Source

PatentUS20250001478A1Irregularly-shaped die

Publication Date: 2025.01.02 A L M T CORP

AI summary

There is provided an irregularly-shaped diamond die for producing an irregularly-shaped wire, wherein a processing hole is provided, the processing hole having a reduction portion and a bearing portion in this order from an upstream side in a wire drawing direction, a corner portion having a curved shape and a non-corner portion located at a position different from a position of the corner portion are provided in a cross section of the bearing portion perpendicular to the wire drawing direction, and a surface roughness of the corner portion is greater than a surface roughness of the non-corner portion. The surface roughness Sa of the corner portion is equal to or less than 0.30 μm and the surface roughness Sa of the non-corner portion is equal to or less than 0.20 μm.