**Abstract**
For many years, the drawing of large-diameter metal wires has been a long-standing challenge in the industry. Currently, the main method used for this process involves hard alloy wire drawing dies. However, these materials come with several limitations—such as high running speeds, non-reusable mold repairs, and uneven wire quality—which have become increasingly problematic for manufacturers.
To address these issues, polycrystalline diamond (PCD) wire drawing dies have emerged as a promising alternative. These tools offer superior wear resistance and precision, making them ideal for high-tension applications. However, the production of large PCD drawing die blanks is still dominated by a few global players, such as Sumitomo Electric in Japan. Their products are expensive, which limits widespread adoption. Meanwhile, domestic manufacturers using six-sided top presses have struggled to produce similar high-quality blanks due to several key challenges.
First, the size of the PCD blank is constrained by the synthesis cavity. Domestic six-sided presses are generally smaller than foreign two-faced presses, limiting the maximum size of the blanks that can be produced. Second, ensuring uniform performance across all parts of a large PCD blank is technically challenging. Third, the entire manufacturing process must be meticulously controlled. Even minor deviations in parameters can lead to defects like cracking, delamination, surface burning, or internal sintering issues.
In most cases, large-diameter PCD blanks are made by embedding a polycrystalline diamond core into a hard alloy mold sleeve through a special process. This combination allows the tool to withstand higher tension, enabling the drawing of thicker wires.
To tackle these challenges, Sifangda has conducted extensive research and successfully developed the "Big Mac" series of PCD drawing blanks, specifically designed for large-diameter wire drawing. The company’s largest PCD blank, with an outer diameter of up to 67mm, a PCD core diameter of 40mm, and a thickness of 25mm, has been officially recognized as a technological achievement. It has reached international advanced levels and is now being widely adopted by customers. Only Sumitomo Electric and Sifangda can currently produce such large blanks.
Compared to imported alternatives, Sifangda’s solution is more cost-effective and based on domestic technology, offering greater technical flexibility. This breakthrough not only replaces imported carbide drawing die blanks but also expands the company's product range. The new series includes various specifications, different diamond particle sizes (from 1 to 50μm), and thermal stability options—both metal-based and ceramic-based. These products cater to a wide range of applications, including hard wire, cord, and large-diameter wire drawing, meeting diverse customer needs effectively.
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Wuxi Winsun Automation Instrument Co., Ltd , https://www.winsunwx.com