A Commitment to Innovation, Service, and Quality
Providing the Right Tools for your Success
USSWiredie Technology
What distinguishes US Synthetic PCD wire dies from the competition? Consider these four key advantages:
1. Advanced Diamond Sintering Processes
Polycrystalline diamond sintering bonds a mass of small diamond particles into a larger, coherent structure. Sintered polycrystalline diamond provides greater toughness and durability when compared to single crystals because the individual crystals in a sintered body are randomly oriented. This prevents cracks from propagating along the weak planes where traditional diamond crystals cleave most easily. The random orientation of the diamond grains provides uniform wear on the die while maintaining the thermal conductivity and hardness of diamond.
2. High-Pressure, High-Temperature Technology
Diamond sintering requires the application of extreme heat and pressure. Typically, diamond is sintered at a temperature of around 1400°C (2550°F). At room pressure, these extreme temperatures would cause the diamond to revert to graphite. Maintaining extremely high pressure during the sintering process allows the diamond to remain in its natural form (see figure). This typically requires pressures of around 60 kbar (nearly 1,000,000 psi)—the equivalent of a 240 km (160 mile) high column of granite.
To achieve these extremely high temperatures and pressures simultaneously, US Synthetic uses proprietary cubic press technology. The cubic press consists of six large pistons, each of which is capable of supplying several thousand tons of force. Each piston pushes on a small tungsten carbide anvil, which in turn compresses a cubic pressure cell that contains the raw materials (carbide and diamond crystals). As soon as the cubic press reaches the desired pressure, electric current flows through a resistance heater embedded in the pressure cell to generate the required high temperatures. These conditions are maintained long enough to ensure complete diamond-to-diamond bonding of the individual crystals.
State-of-the-art manufacturing processes—including proprietary cubic presses that apply nearly 1 million pounds of uniform pressure and generate temperatures of 1,400° Celsius—are used to synthesize US Synthetic wire dies, the industry’s strongest and most durable.
3. New Innovations through Research and Development
At US Synthetic, experienced research and development engineers create new innovations for strengthening and improving our wire die products. We also work directly with our wire mill clients to customize materials and dimensions to meet unique, exacting specifications, all backed by a 100% quality guarantee.
4. One of the World’s Most Advanced Material Testing Facilities
Extensive quality testing ensures every US Synthetic wire die meets the highest quality standards. This includes abrasive wear testing, ultrasonic and electron microscope scans, and other rigorous quality tests. ISO 9000-certified since 1993, our testing lab has the ability to run tests in a variety of materials best suited to the application. The lab performs more than 15,000 hours of testing per year and is capable of conducting more than 400 test programs annually.
In-house abrasion tests have shown US Synthetic Wire Die materials to have dramatically better performance than leading competitors. In fact, in two field case studies using stainless steel wire,
the US Synthetic die lasted more than twice as long as other PCD dies.
Question Answer
How is US Synthetic Wire Die different?
Polycrystalline Diamond Wire Dies from US Synthetic
Welcome to US Synthetic Wire Die. As a business unit of US Synthetic Corporation, we manufacture the longest-lasting polycrystalline diamond (PCD) wire dies available, which allows wire mills to pull or draw more pounds of wire per dollar spent on dies. Our technical expertise in PCD enables development of the unique material used in our wire dies. In fact, we're the only wire die manufacturer and distributor that also presses its own polycrystalline diamond wire die inserts. Pressing the diamond core and finishing the die to exact specifications offers customers a durable, high-performance product that draws more pounds of wire per dollar.
What is a wire die?
There are four aspects of the wire drawing process that determine the quality of the wire: quality of the incoming material, the type of lubricant, the set-up of the machine, and the drawing die. Each area can be investigated at length to improve the end product; the focus here is on drawing dies. Wire Drawing dies are made of several materials:tungsten carbided, natural diamond, synthetic diamond, and polycrystalline diamond. Selection of the type of die often depends on the material being drawn and the desired surface finish of the wire. For example, if a high polish is required on the wire, typically a natural diamond is used. For larger wire dies, tungsten carbide is often used because of the increased expense for a large diamond needed to produce the die. Polycrystalline diamond is often used as a cost-effective alternative to natural diamond and as a long-life alternative to tungsten carbide. Wire drawing dies work well when the tapered hole is highly polished, as this reduces the amount of friction it takes to pull the wire through the die.
A wire die's geometry is critical to its performance. There are several critical aspects of the drawing die geometry:
- The entrance cone – The purpose of the entrance is to properly allow lubricant to enter the die along with the wire. More lubricant typically means less friction and wear on the die
- The reduction area – The reduction area is where the work is taking place in the die. Themetal is cold-worked as it is pulled through the tapered hole. The reduction angle is critical to the performance of the die and changes based on material drawn.
- The bearing –The bearing sets the size of the exiting wire. The bearing length (often expressed as a percentage of the diameter) depends on the material drawn. Harder materials typically have longer bearing lengths.
- The back relief – The polished back relief ensures that the wire comes out the die with as little scuffing as possible. A well poslished surface will reduce fines and shaving.
- The exit cone – The function of the exit cone is to support the bearing area and help distribute the stresses that occur during drawing.
What is the wire drawing process?
Wire drawing is the process used to manufacture wire for all types
of applications. Wire is found in appliances, home wiring, phone lines,
calbes, tires, motors, light bulbs, and many other unseen places. It
allows us to enjoy many of today's modern conveniences. There are a
variety of metals that are made into wire, the most common being steel,
copper, brass, aluminum, stainless steel, and tungstun.
During the wire drawing process, the metal starts as a thick rod that is cleaned
just before being pulled through a die that is slightly smaller than the rod's
original size. The rod becomes smaller in diameter and slightly longer. A
series of drawing dies is used to draw the wire down to the desired diameter.
During the wire drawing process, no material is shaved off, the wire simply gets longer. The material is cold-worked and hardens (and also increases in tensile strength) through each step. Frequently wire mills will run the wire through a number of dies, then anneal it (a process of heating and then slow cooling) to help it return to its more ductile state.
What does the ADDMA have to do with wire dies?
ADDMA 8911 refers to the original standards published by the American Diamond Die Manufacturers Association. These standards were established during the early adoption of PCD for use in wire drawing dies to ensure that dies labeled using the D- designation are consistent in size. The standards define the minimum dimensions allowed for each D- designation used on the PCD inserts. Currently, the majority of PCD inserts used in wire dies exceed these dimensions.
Polycrystalline Diamond Core Minimum Dimensions |
||
|---|---|---|
| Core No. | Diameter [mm] | Thickness [mm] |
D-6 |
0.80 |
0.80 |
Please submit any additional questions you have about our product or business approach. We will post your question here along with our response to it.
Exec test Entry
Nunc at faucibus orci? Nunc sagittis ullamcorper felis ut rhoncus? Ut sit amet metus nisi. Curabitur mollis semper malesuada. Vestibulum at lacus sit amet erat bibendum consequat? Praesent molestie euismod eleifend. Donec sit amet tempor libero. Mauris lectus erat, placerat ac sagittis et, imperdiet non augue! Vivamus ut odio risus. Nulla sed pulvinar est. Donec blandit viverra nulla quis vestibulum. In lorem urna, convallis fringilla luctus tempor, tempus a ante. Aliquam tortor est, viverra id ultricies vel, ultrices ut tortor. Nunc at faucibus orci? Nunc sagittis ullamcorper felis ut rhoncus? Ut sit amet metus nisi. Curabitur mollis semper malesuada. Vestibulum at lacus sit amet erat bibendum consequat? Praesent molestie euismod eleifend. Donec sit amet tempor libero. Mauris lectus erat, placerat ac sagittis et, imperdiet non augue! Vivamus ut odio risus. Nulla sed pulvinar est. Donec blandit viverra nulla quis vestibulum. In lorem urna, convallis fringilla luctus tempor, tempus a ante. Aliquam tortor est, viverra id ultricies vel, ultrices ut tortor. Nunc at faucibus orci? Nunc sagittis ullamcorper felis ut rhoncus? Ut sit amet metus nisi. Curabitur mollis semper malesuada. Vestibulum at lacus sit amet erat bibendum consequat? Praesent molestie euismod eleifend. Donec sit amet tempor libero. Mauris lectus erat, placerat ac sagittis et, imperdiet non augue! Vivamus ut odio risus. Nulla sed pulvinar est. Donec blandit viverra nulla quis vestibulum. In lorem urna, convallis fringilla luctus tempor, tempus a ante. Aliquam tortor est, viverra id ultricies vel, ultrices ut tortor. Nunc at faucibus orci? Nunc sagittis ullamcorper felis ut rhoncus? Ut sit amet metus nisi. Curabitur mollis semper malesuada. Vestibulum at lacus sit amet erat bibendum consequat? Praesent molestie euismod eleifend. Donec sit amet tempor libero. Mauris lectus erat, placerat ac sagittis et, imperdiet non augue! Vivamus ut odio risus. Nulla sed pulvinar est. Donec blandit viverra nulla quis vestibulum. In lorem urna, convallis fringilla luctus tempor, tempus a ante. Aliquam tortor est, viverra id ultricies vel, ultrices ut tortor.
Test Release
Carbide Supported PCD Dies Proin posuere sapien nec neque aliquam tristique. Duis tortor massa, blandit at condimentum eu, tempus vel ante. Vestibulum ante
Proin posuere sapien nec neque aliquam tristique. Duis tortor massa, blandit at condimentum eu, tempus vel ante. Vestibulum ante ipsum primis in faucibus orci luctus et ultrices posuere cubilia Curae; Nunc ultrices scelerisque ante, id tristique orci tincidunt in. Quisque imperdiet orci sed nibh auctor pulvinar. Nullam vehicula, neque eget congue eleifend, enim purus tempor massa, ac mattis mi mi et lorem. Vestibulum sem tortor, tempor vel vestibulum sed, mattis ac tellus. Fusce sit amet ipsum velit. Suspendisse in lectus vel est dignissim volutpat id eget justo. Sed quis enim nibh.
Going to the show
Lorem ipsum dolor sit amet, consectetur adipiscing elit. Maecenas at vestibulum felis. Nunc ullamcorper, diam vitae ornare sagittis, leo dui vestibulum elit, sed vulputate enim nunc sit amet mi. Maecenas faucibus lobortis arcu, sit amet mattis erat semper vel. Nulla facilisi. Nunc nec urna orci, in volutpat ante. Fusce leo leo, rutrum at faucibus eu; luctus eu ligula. Quisque volutpat auctor nisi eu porttitor. Cras quis lectus purus. Aenean metus justo, pulvinar nec posuere vitae, laoreet ut orci? Aliquam vehicula hendrerit nibh, vitae pulvinar nibh tincidunt sed. Nulla luctus placerat placerat. In iaculis pharetra hendrerit? Donec consectetur est quis justo tincidunt ullamcorper. Integer vel felis enim, id laoreet nibh. Nulla sem mi, varius non adipiscing sed, sodales at nisi! Donec condimentum mi id nibh porta ac lacinia justo commodo. Fusce placerat odio non ante ullamcorper quis iaculis lorem rutrum. Suspendisse sit amet odio vitae tortor ultrices condimentum.
Test Event
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Pull more pounds per dollar
Freestanding PCD Dies Nulla vestibulum, nisi ut placerat tincidunt, magna elit scelerisque nibh, ac accumsan elit metus in sem! Phasellus rhoncus moll
Nulla vestibulum, nisi ut placerat tincidunt, magna elit scelerisque nibh, ac accumsan elit metus in sem! Phasellus rhoncus mollis sollicitudin. Donec nec velit eros, et viverra nisl. Etiam ipsum lacus, vehicula ut scelerisque nec, pretium quis nisl. Praesent quis mi diam. Class aptent taciti sociosqu ad litora torquent per conubia nostra, per inceptos himenaeos. Lorem ipsum dolor sit amet, consectetur adipiscing elit. Aenean et massa libero, in malesuada quam. Praesent lectus erat, ornare lacinia pellentesque eget, posuere ac lorem. Suspendisse nec enim quam, in tincidunt lacus. Nullam dapibus nunc et tortor fringilla vitae iaculis libero pretium. Mauris laoreet elementum sapien; vel euismod massa semper vitae. Class aptent taciti sociosqu ad litora torquent per conubia nostra, per inceptos himenaeos. Nulla lacus metus, rhoncus non gravida et, vestibulum et urna.
Wire Expo 2010
Wire 2010 Dusseldorf
Technical Details
Currently diamond wire dies are available with inserts D6 through D30 (ADDMA 8911 standards). D6, D12, D15, and D18 are offered in free standing; D15 through D30 are offered with a tungsten carbide support ring.
PCD inserts of various grain sizes are pressed at US Synthetic. Coarse grain inserts (25 micron average grain size) typically produce the longest life dies. Coarse grain PCD produces metal fines that are easier to filter out than fines produced using finer grain inserts; The fine grain insert (5 micron average grain size) typically produce a better finish on the wire than coarse grain. The medium grain insert (12 micron average grain size) is often a compromise between the other two that offers acceptable life and finish. The following table indicates the grain sizes available in each insert size as well as the approximate hole sizes for each insert size.
| Grain sizes available in the following PCD insert configurations (micron) | |||
|---|---|---|---|
| Blank size | Freestanding insert | Thermally stable freestanding insert | Carbide supported insert |
| D6 D12 D15 D18 D21 D24 D27 D30 |
5, 12, 25 5, 12, 25 5, 12, 25 5, 12, 25 |
5, 12, 25 5, 12, 25 5, 12, 25 5, 12, 25 |
5, 12, 25 5, 12, 25 5, 12, 25 5, 12, 25 5, 12, 25 5, 12, 25 |
The key to the long life of US Synthetic wire dies is the unique polycrystalline diamond (PCD) core used in each die. This PCD material is manufactured by US Synthetic using proprietary diamond presses.
Recommended Bearing Diameter Range
* The largest hole size is based on the geometry of the hole. The numbers given here are determined using typical values for tire cord and copper wire.
PCD Insert Dimensions
Insert size |
Grain sizes available |
PCD thickness* |
PCD diameter |
Carbide diameter |
Standard casing size |
|---|---|---|---|---|---|
D6 fs D12 fs D15 fs D18 fs D15 D18 D21 D24 D27 D30 |
5, 12, 25 |
.040 inch |
.128 inch |
- |
1-1/8 x 3/8 |
* Dies with thicker PCD inserts are available upon request.
The key to the long life of US Synthetic wire dies is the unique polycrystalline diamond (PCD) core used in each die. This PCD material is manufactured by US Synthetic using proprietary diamond presses.
Recommended Bearing Diameter Range
* The largest hole size is based on the geometry of the hole. The numbers given here are determined using typical values for tire cord and copper wire.
PCD Blank Dimensions
Blank size |
Grain sizes available |
PCD thickness* |
PCD diameter |
Carbide diameter |
Standard casing size |
|---|---|---|---|---|---|
D6 fs D12 fs D15 fs D18 fs D15 D18 D21 D24 D27 D30 |
5, 12, 25 |
.040 inch |
.128 inch |
- |
1-1/8 x 3/8 |
* Dies with thicker PCD blanks are available upon request.
Charitable Involvement
US Synthetic Wiredie and its employees are working hard to enhance the lives of people throughout the world. The company and employees are lending a helping hand to extremely impoverished women in Kenya, through Yehu microfinance. Through generous donations, Yehu microfinance provides financial and other support services for small businesses owned by very poor women in the rural coastal region of Kenya. Yehu is an organization for the poor, run by the poor.
US Synthetic Wiredie and Yehu work in conjunction with Choice Humanitarian, an international NGO specializing in village development. Yehu was created based on the principles and procedures of the world-renowned Grameen Bank.
Yehu combats poverty by empowering poor rural women in Kenya to lift themselves out of poverty through enhanced accessibility to sustainable financial services. This includes enabling them to save and earn interest while giving them access to micro-loans, which can be used to start or expand their small businesses. Other services that are provided by Yehu are micro-insurance, as well as many other services, as they are needed, to improve the lives of its members. Ultimately, Yehu provides hope and a hand up to those who have been marginalized by society.
Helping one another succeed is a strong part of the US Synthetic Wiredie's culture. Many of US Synthetic Wiredie's employees have donated their time and financial resources in helping this worthwhile cause. To find out how you can help, visit Yehu Microfinance.
What is our commitment to service?
A Commitment to Innovation, Service, and Quality
State-of-the-art diamond sintering processes-including proprietary cubic presses that apply nearly 1 million pounds of uniform pressure and generate temperatures of 1,400° Celsius-are used to synthesize the industry's strongest, most durable wire dies. In-house abrasion tests have shown US Synthetic Wire Die materials to have dramatically better performance than leading competitors. In fact, in two stainless steel wire mills, U.S. Synthetic dies lasted more than twice as long as other PCD dies. We work directly with our wire mill clients to customize materials and dimensions, all backed by a 100% quality guarantee. If a US Synthetic wire die doesn't perform as expected, we'll replace it for free.
History
The US Synthetic story started in 1978, when Louis Pope founded a small diamond grit manufacturing company. Over the years, Louis and his team of synthetic diamond experts expanded and evolved the business-by developing innovative proprietary cubic press technology-by developing innovative proprietary cubic press technology for high-pressure, high-temperature diamond synthesis and manufacturing polycrystalline diamond cutters (PDCs) for the oil and gas exploration industry.
Throughout the 1990's, an unwavering commitment to innovation, quality, and personalized customer service fueled US Synthetic's rapid growth and success. In 1993, US Synthetic became the first PDC manufacturer to become ISO 9000 certified. The company introduced many of the decade's most significant innovations and advances in the use of diamond for oil and gas drilling. And by 1997, US Synthetic had become the industry's leading supplier of diamond products.
Today, US Synthetic is actively expanding this leadership position by developing innovative new diamond solutions and exploring new uses for diamond both inside and outside the oil and gas drilling industry. This includes finding new uses for diamond inserts in roof bolt mining equipment, industrial bearings, wire drawing dies, and exploring innovative new gem enhancement technology.
US Synthetic was recently acquired by Dover Corporation, joining the Energy Products Group within Dover Resources.
For more information about US Synthetic, visit http://www.ussynthetic.com.
Breakthroughs in Wiredrawing PDF
US Synthetic Wiredie authors paper in industry magazine
US Synthetic Wiredie magazine ad
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Wiredie Brochure
USS Wire Die Parent Company, US Synthetic Signs Exclusive License Agreement with Mitsubishi Material
USS Wire Die Parent Company Signs Exclusive License Agreement with Los Alamos National Laboratory
USS Wire Die Parent Company, US Synthetic Names Rob Galloway as Chief Operating Officer
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Events
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Contact Information
US Synthetic Corporation
1260 South 1600 West
Orem, Utah 84058
Phone: (801) 235-9001
Fax: (801) 751-0062
Email:.(JavaScript must be enabled to view this email address)
Contact Us
Thank you for your interest in US Synthetic Wire Die. We hope you learned more about us, and how we can help you. We would be interested in discussing how we can help you operate more efficiently using our dies. Please contact us using one of the methods below.
Our Privacy Policy
US Synthetic Corporation is committed to protecting any personal information that you may provide to us. In particular, we believe it is important for you to know how we treat information about you that we may receive from this Web site.
Information Collected
In general, you can visit this web site without telling us who you are or revealing any information about yourself. Our web servers collect the domain names, not the e-mail addresses, of visitors. Our web servers also seek (as many web sites do) to place a "cookie" (a small data file) on your computer's hard drive which allows the server to determine the computer when it visits again, in order to track statistical information about navigation to and throughout certain areas of our site. This cookie is not used to obtain your name or any personal data, and the information that is tracked is used only for internal purposes, such as to improve site navigation, and is not shared with anyone other than US Synthetic. However, if you prefer not to accept cookies, you can set your browser to reject them or to alert you before one is placed.
In addition, there are portions of this web site where we may need to collect personal information from you for a specific purpose, such as to provide you with certain information you request. The information collected from you may include your name, address, telephone, fax number, or e-mail address. We may also ask about your intended use of our products to more quickly make a recommendation, or otherwise serve you well.
Use of Collected Information
Domain name information that we collect is not used to personally identify you and instead is aggregated to measure the number of visits, average time spent on the site, pages viewed, etc. We use this information to measure the use of our site and to improve the content of our site.
When other information is collected from you, such as your name and e-mail address, we generally let you know at the time of collection how we will use the personal information. Usually, we use the personal information you provide only to respond to your inquiry or to process your request (such as to receive information about US Synthetic).
We do not share, sell, or lease personal information about you to any third-parties for their marketing use. We will release information about you if you direct us to do so, if we are required by law to do so, or in other legally limited circumstances (for example, to protect your account from fraud).
Links to Other Sites
The US Synthetic web site may contain links to other sites. While we try to link only to sites that share our high standards and respect for privacy, we are not responsible for the content, security, or privacy practices employed by other sites.
Security of Collected Information
We maintain strict physical, electronic, and administrative safeguards to protect your personal information from unauthorized or inappropriate access. We restrict access to information about you to those US Synthetic workers who need to know the information to respond to your inquiry or request. Workers who misuse personal information are subject to disciplinary action.
Access to Collected Information
You may review and update the information that you provide to us through this web site by contacting us as described below.
Contacting Us
If you have any questions about this privacy policy, please use the Contact Us page. We welcome your questions and suggestions about our privacy policy.
Changes to this Policy
Please check this privacy policy periodically to inform yourself of any changes. Although we reserve the right to modify or supplement this privacy policy, we will provide notice to you on this web site of any major changes for at least 30 days following the change
Site Map USS Wiredie
- How is US Synthetic Wire Die different?
- The Technology behind the Diamond
- Quality Guarantee
- What is our commitment to service?
- How is US Synthetic Wire Die different?
- What is a Wire Die?
- What is the Wire Drawing Process?
- What does the ADDMA have to do with wire dies?
- What is our commitment to service?
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What does the ADDMA have to do with wire dies?
ADDMA 8911 refers to the original standards published by the American Diamond Die Manufacturers Association. These standards were established during the early adoption of PCD for use in wire drawing dies to ensure that dies labeled using the D- designation are consistent in size. The standards define the minimum dimensions allowed for each D- designation used on the PCD inserts. Currently, the majority of PCD inserts used in wire dies exceed these dimensions.
Polycrystalline Diamond Core Minimum Dimensions |
||
|---|---|---|
| Core No. | Diameter [mm] | Thickness [mm] |
D-6 |
0.80 |
0.80 |
What is the Wire Drawing Process
Wire drawing is the process used to manufacture wire for all types
of applications. Wire is found in appliances, home wiring, phone lines,
calbes, tires, motors, light bulbs, and many other unseen places. It
allows us to enjoy many of today's modern conveniences. There are a
variety of metals that are made into wire, the most common being steel,
copper, brass, aluminum, stainless steel, and tungstun.
During the wire drawing process, the metal starts as a thick rod that is cleaned
just before being pulled through a die that is slightly smaller than the rod's
original size. The rod becomes smaller in diameter and slightly longer. A
series of drawing dies is used to draw the wire down to the desired diameter.
During the wire drawing process, no material is shaved off, the wire simply gets longer. The material is cold-worked and hardens (and also increases in tensile strength) through each step. Frequently wire mills will run the wire through a number of dies, then anneal it (a process of heating and then slow cooling) to help it return to its more ductile state.
Questions & Answers
How is US Synthetic Wire Die different?
Polycrystalline Diamond Wire Dies from US Synthetic
Welcome to US Synthetic Wire Die. As a business unit of US Synthetic Corporation, we manufacture the longest-lasting polycrystalline diamond (PCD) wire dies available, which allows wire mills to pull or draw more pounds of wire per dollar spent on dies. Our technical expertise in PCD enables development of the unique material used in our wire dies. In fact, we're the only wire die manufacturer and distributor that also presses its own polycrystalline diamond wire die inserts. Pressing the diamond core and finishing the die to exact specifications offers customers a durable, high-performance product that draws more pounds of wire per dollar.
What is a wire die?
There are four aspects of the wire drawing process that determine the quality of the wire: quality of the incoming material, the type of lubricant, the set-up of the machine, and the drawing die. Each area can be investigated at length to improve the end product; the focus here is on drawing dies. Wire Drawing dies are made of several materials:tungsten carbided, natural diamond, synthetic diamond, and polycrystalline diamond. Selection of the type of die often depends on the material being drawn and the desired surface finish of the wire. For example, if a high polish is required on the wire, typically a natural diamond is used. For larger wire dies, tungsten carbide is often used because of the increased expense for a large diamond needed to produce the die. Polycrystalline diamond is often used as a cost-effective alternative to natural diamond and as a long-life alternative to tungsten carbide. Wire drawing dies work well when the tapered hole is highly polished, as this reduces the amount of friction it takes to pull the wire through the die.
A wire die's geometry is critical to its performance. There are several critical aspects of the drawing die geometry:
- The entrance cone – The purpose of the entrance is to properly allow lubricant to enter the die along with the wire. More lubricant typically means less friction and wear on the die
- The reduction area – The reduction area is where the work is taking place in the die. Themetal is cold-worked as it is pulled through the tapered hole. The reduction angle is critical to the performance of the die and changes based on material drawn.
- The bearing –The bearing sets the size of the exiting wire. The bearing length (often expressed as a percentage of the diameter) depends on the material drawn. Harder materials typically have longer bearing lengths.
- The back relief – The polished back relief ensures that the wire comes out the die with as little scuffing as possible. A well poslished surface will reduce fines and shaving.
- The exit cone – The function of the exit cone is to support the bearing area and help distribute the stresses that occur during drawing.
What is the wire drawing process?
Wire drawing is the process used to manufacture wire for all types
of applications. Wire is found in appliances, home wiring, phone lines,
calbes, tires, motors, light bulbs, and many other unseen places. It
allows us to enjoy many of today's modern conveniences. There are a
variety of metals that are made into wire, the most common being steel,
copper, brass, aluminum, stainless steel, and tungstun.
During the wire drawing process, the metal starts as a thick rod that is cleaned
just before being pulled through a die that is slightly smaller than the rod's
original size. The rod becomes smaller in diameter and slightly longer. A
series of drawing dies is used to draw the wire down to the desired diameter.
During the wire drawing process, no material is shaved off, the wire simply gets longer. The material is cold-worked and hardens (and also increases in tensile strength) through each step. Frequently wire mills will run the wire through a number of dies, then anneal it (a process of heating and then slow cooling) to help it return to its more ductile state.
What does the ADDMA have to do with wire dies?
ADDMA 8911 refers to the original standards published by the American Diamond Die Manufacturers Association. These standards were established during the early adoption of PCD for use in wire drawing dies to ensure that dies labeled using the D- designation are consistent in size. The standards define the minimum dimensions allowed for each D- designation used on the PCD inserts. Currently, the majority of PCD inserts used in wire dies exceed these dimensions.
Polycrystalline Diamond Core Minimum Dimensions |
||
|---|---|---|
| Core No. | Diameter [mm] | Thickness [mm] |
D-6 |
0.80 |
0.80 |
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About US
PCD Wire Drawing Dies
As a business unit of US Synthetic Corporation, US Synthetic Wire Die manufactures the longest-lasting polycrystalline diamond (PCD) wire dies available, which allows wire mills to pull more pounds of wire per dollar spent on dies.
Our technical expertise in PCD enables development of the unique material used in our wire dies. In fact, we’re the only wire die manufacturer that also presses its own PCD inserts. Pressing the diamond core and finishing the die to exact specifications offers customers a durable, high-performance product that draws more pounds of wire per dollar.
A Commitment to Innovation, Service, and Quality
State-of-the-art diamond sintering processes—including proprietary cubic presses that apply nearly 1 million pounds of uniform pressure and generate temperatures of 1,400° Celsius—are used to synthesize the industry’s strongest, most durable wire dies. In-house abrasion tests have shown US Synthetic Wire Die materials to have dramatically better performance than leading competitors. In fact, in two stainless steel wire mills, U.S. Synthetic dies lasted more than twice as long as other PCD dies. We work directly with our wire mill clients to customize materials and dimensions, all backed by a 100% quality guarantee. If a US Synthetic wire die doesn’t perform as expected, we’ll replace it for free.
US Synthetic
US Synthetic Wire die is a business unit of US Synthetic which has been in the diamond business since 1978. US Synthetic leads the industry in the development and production of polycrystalline diamond cutters (PDCs) for oil and gas exploration. Our uncompromising commitment to constant innovation, outstanding quality, and superior customer service allows us to meet the highest performance standards and match the requirements of the world's most demanding oil exploration and development projects.
We are focused on the development of diamond inserts for use in drill bits for oil and gas exploration. We also provide a variety of diamond-enhanced components for use in downhole exploration and production.
US Synthetic employs 250 people, and is located in Orem, Utah. US Synthetic is part of Dover Corporation (http://www.dovercorporation.com). We are part of the Energy Products Group of Dover Resources.
More information about US Synthetic Corp. can be found at www.ussynthetic.com
Technical Specifications
The key to the long life of US Synthetic wire dies is the unique polycrystalline diamond (PCD) core used in each die. This PCD material is manufactured by US Synthetic using proprietary diamond presses.
Recommended Bearing Diameter Range
* The largest hole size is based on the geometry of the hole. The numbers given here are determined using typical values for tire cord and copper wire.
PCD Blank Dimensions
Blank size |
Grain sizes available |
PCD thickness* |
PCD diameter |
Carbide diameter |
Standard casing size |
|---|---|---|---|---|---|
D6 fs D12 fs D15 fs D18 fs D15 D18 D21 D24 D27 D30 |
5, 12, 25 |
.040 inch |
.128 inch |
- |
1-1/8 x 3/8 |
* Dies with thicker PCD blanks are available upon request.
What is a Wire Die?
There are four aspects of the wire drawing process that determine the quality of the wire: quality of the incoming material, the type of lubricant, the set-up of the machine, and the drawing die. Each area can be investigated at length to improve the end product; the focus here is on drawing dies. Wire Drawing dies are made of several materials:tungsten carbided, natural diamond, synthetic diamond, and polycrystalline diamond. Selection of the type of die often depends on the material being drawn and the desired surface finish of the wire. For example, if a high polish is required on the wire, typically a natural diamond is used. For larger wire dies, tungsten carbide is often used because of the increased expense for a large diamond needed to produce the die. Polycrystalline diamond is often used as a cost-effective alternative to natural diamond and as a long-life alternative to tungsten carbide. Wire drawing dies work well when the tapered hole is highly polished, as this reduces the amount of friction it takes to pull the wire through the die.
A wire die's geometry is critical to its performance. There are several critical aspects of the drawing die geometry:
- The entrance cone – The purpose of the entrance is to properly allow lubricant to enter the die along with the wire. More lubricant typically means less friction and wear on the die
- The reduction area – The reduction area is where the work is taking place in the die. Themetal is cold-worked as it is pulled through the tapered hole. The reduction angle is critical to the performance of the die and changes based on material drawn.
- The bearing –The bearing sets the size of the exiting wire. The bearing length (often expressed as a percentage of the diameter) depends on the material drawn. Harder materials typically have longer bearing lengths.
- The back relief – The polished back relief ensures that the wire comes out the die with as little scuffing as possible. A well poslished surface will reduce fines and shaving.
- The exit cone – The function of the exit cone is to support the bearing area and help distribute the stresses that occur during drawing.
PCD Wire Drawing Dies
Currently diamond wire dies are available with inserts D6 through D30 (ADDMA 8911 standards). D6, D12, D15, and D18 are offered in free standing; D15 through D30 are offered with a tungsten carbide support ring.
PCD inserts of various grain sizes are pressed at US Synthetic. Coarse grain inserts (25 micron average grain size) typically produce the longest life dies. Coarse grain PCD produces metal fines that are easier to filter out than fines produced using finer grain inserts; The fine grain insert (5 micron average grain size) typically produce a better finish on the wire than coarse grain. The medium grain insert (12 micron average grain size) is often a compromise between the other two that offers acceptable life and finish. The following table indicates the grain sizes available in each insert size as well as the approximate hole sizes for each insert size.
| Grain sizes available in the following PCD insert configurations (micron) | |||
|---|---|---|---|
| Blank size | Freestanding insert | Thermally stable freestanding insert | Carbide supported insert |
| D6 D12 D15 D18 D21 D24 D27 D30 |
5, 12, 25 5, 12, 25 5, 12, 25 5, 12, 25 |
5, 12, 25 5, 12, 25 5, 12, 25 5, 12, 25 |
5, 12, 25 5, 12, 25 5, 12, 25 5, 12, 25 5, 12, 25 5, 12, 25 |
The key to the long life of US Synthetic wire dies is the unique polycrystalline diamond (PCD) core used in each die. This PCD material is manufactured by US Synthetic using proprietary diamond presses.
Recommended Bearing Diameter Range
* The largest hole size is based on the geometry of the hole. The numbers given here are determined using typical values for tire cord and copper wire.
PCD Insert Dimensions
Insert size |
Grain sizes available |
PCD thickness* |
PCD diameter |
Carbide diameter |
Standard casing size |
|---|---|---|---|---|---|
D6 fs D12 fs D15 fs D18 fs D15 D18 D21 D24 D27 D30 |
5, 12, 25 |
.040 inch |
.128 inch |
- |
1-1/8 x 3/8 |
* Dies with thicker PCD inserts are available upon request.
Quality Guarantee
Choosing US Synthetic Wire Die as your source for durable, high-performance dies is a sound business decision. This decision places you on the path to improved total cost of ownership, competitiveness, and profitability. We are building upon the 28-year reputation of US Synthetic Corporation for product innovation, customization, "dock-to-stock" quality, and on-time delivery. If a US Synthetic wire die doesn't perform as expected, we'll work with you to ensure the best quality possible.
The Technology behind the Diamond
What distinguishes US Synthetic PCD wire dies from the competition? Consider these four key advantages:
1. Advanced Diamond Sintering Processes
Polycrystalline diamond sintering bonds a mass of small diamond particles into a larger, coherent structure. Sintered polycrystalline diamond provides greater toughness and durability when compared to single crystals because the individual crystals in a sintered body are randomly oriented. This prevents cracks from propagating along the weak planes where traditional diamond crystals cleave most easily. The random orientation of the diamond grains provides uniform wear on the die while maintaining the thermal conductivity and hardness of diamond.
2. High-Pressure, High-Temperature Technology
Diamond sintering requires the application of extreme heat and pressure. Typically, diamond is sintered at a temperature of around 1400°C (2550°F). At room pressure, these extreme temperatures would cause the diamond to revert to graphite. Maintaining extremely high pressure during the sintering process allows the diamond to remain in its natural form (see figure). This typically requires pressures of around 60 kbar (nearly 1,000,000 psi)—the equivalent of a 240 km (160 mile) high column of granite.
To achieve these extremely high temperatures and pressures simultaneously, US Synthetic uses proprietary cubic press technology. The cubic press consists of six large pistons, each of which is capable of supplying several thousand tons of force. Each piston pushes on a small tungsten carbide anvil, which in turn compresses a cubic pressure cell that contains the raw materials (carbide and diamond crystals). As soon as the cubic press reaches the desired pressure, electric current flows through a resistance heater embedded in the pressure cell to generate the required high temperatures. These conditions are maintained long enough to ensure complete diamond-to-diamond bonding of the individual crystals.
State-of-the-art manufacturing processes—including proprietary cubic presses that apply nearly 1 million pounds of uniform pressure and generate temperatures of 1,400° Celsius—are used to synthesize US Synthetic wire dies, the industry’s strongest and most durable.
3. New Innovations through Research and Development
At US Synthetic, experienced research and development engineers create new innovations for strengthening and improving our wire die products. We also work directly with our wire mill clients to customize materials and dimensions to meet unique, exacting specifications, all backed by a 100% quality guarantee.
4. One of the World’s Most Advanced Material Testing Facilities
Extensive quality testing ensures every US Synthetic wire die meets the highest quality standards. This includes abrasive wear testing, ultrasonic and electron microscope scans, and other rigorous quality tests. ISO 9000-certified since 1993, our testing lab has the ability to run tests in a variety of materials best suited to the application. The lab performs more than 15,000 hours of testing per year and is capable of conducting more than 400 test programs annually.
In-house abrasion tests have shown US Synthetic Wire Die materials to have dramatically better performance than leading competitors. In fact, in two field case studies using stainless steel wire,
the US Synthetic die lasted more than twice as long as other PCD dies.
How is US Synthetic Wire Die different?
Polycrystalline Diamond Wire Dies from US Synthetic
Welcome to US Synthetic Wire Die. As a business unit of US Synthetic Corporation, we manufacture the longest-lasting polycrystalline diamond (PCD) wire dies available, which allows wire mills to pull or draw more pounds of wire per dollar spent on dies. Our technical expertise in PCD enables development of the unique material used in our wire dies. In fact, we're the only wire die manufacturer and distributor that also presses its own polycrystalline diamond wire die inserts. Pressing the diamond core and finishing the die to exact specifications offers customers a durable, high-performance product that draws more pounds of wire per dollar.
Technology for Tighter Times
Much tighter budgets and leaner sales have everyone scrambling to tighten their belts. Choosing PCD drawing dies from US Synthetic Wire Die is a sound business decision that will improve your total cost of ownership and your overall profitability.
Because of the added die life, it's the perfect technology for
tighter times. Request a free consultation to see how
our dies can help your business today
Learn what makes our wire drawing dies the perfect technology for tight economic times.
