Wire tools
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Vassena has designed and manufactured a new pressure die to improve the lubrication between the wire and the die at high drawing speed. This provides an added value in that it also ensures a better quality of the drawn wire and a longer die life.
Vassena has been working closely with wire and wire rope manufacturers for over 60 years with the specific goal of developing ingenious solutions to improve the efficiency of their processes and increase their competitiveness. Guided by an inner drive for innovation, - clearly visible in the numerous patents filed over the years - Vassena has always worked hard to discover innovative materials, geometries, and state-of-the-art technology to meet the most diverse specifications and often anticipate market trends and demands. Amongst the latest technologies developed by the Italian toolmaker is a pressure die designed to drastically improve the lubrication between the wire and the die at high drawing speed: "The new market challenges highlight the importance of conjugating the need for higher drawing speed with better surface quality - notes Davide Vassena, owner partner of Vassena - especially taking into account how increasingly difficult to machine are the raw materials and how strict are the environmental regulations for lubricants nowadays".
Process evolution through product evolution, and vice versa
A good drawing process requires not only optimal die geometry, but also constant lubrication according to the drawing speed variations. This is especially true when drawing at high speed. Another important factor is the die cone operating temperature, which must be just right to prevent lubricant solidification during machine downtime. “This stainless steel titanium-coated pressure die - Mr. Vassena highlights - has a gap between the wire and the die hole of about one millimeter. The distinct geometry of the die is what guarantees efficiency and constant lubrication”. An evolution of the VG402R system, the new VG402R.1 is a patented tool studied and optimized by Vassena's R&D department to achieve further operational advantages such as:
- higher pressure with the same gap and the same pressure die size;
- high lubrication even at low drawing speeds;
- extended die life due to the lubricant being more compact on the wire, thus resulting in lower friction coefficient between the wire and die;
- better cooling and less friction on the wire;
- minimum lubricant losses.
Even more interesting are the operating results that can be achieved by combining the VG402R.1 pressure dies with the "L" type dies with long reduction cones, also by Vassena.
"The whole drawing process - Vassena explains - consists of three components: homogeneous work, friction work, and redundant work. The latter two are the ones that negatively affect the mechanical properties of the wire and increase the energy required for the drawing process. In this case, the peculiar geometry of the L type die, in conjunction with the pressure die, reduces redundant work with consequent benefits".
To sum up, the use of a drawing die with the correct geometry can help achieve a stable and high performance process, avoiding further steps and potential issues (e.g. wire cleaning). Compared to traditional dies, L type dies offer more technical advantages (durability, reliability, better final quality) and huge savings (lower operating costs and lower energy consumption).
Efficiency and better performances in healthier workplaces
Following its usual penchant for innovation, Vassena released last year a further evolution of its patent, the VG402R.2, a new pressure die that grants even better adhesion of the lubricant on the wire (200%). “As mentioned before, the structure of the new pressure die VG402R.2 - concludes Vassena - reduces the friction coefficient, which brings with it a higher drawing speed, a better quality of the drawn wire, and a longer life of the die itself". Other advantages include the elimination of the candle effect in the soapbox and a healthier working environment for the entire staff, from the operators to the management team and owners.
