Carbide in India

CARBIDE

Carbide is a general term used for Tungsten carbide (WC) which is an inorganic chemical compound containing equal parts of tungsten  and carbon atoms.There is a growing popularity of tungsten carbide rings with some consumers calling the material just tungsten. 

In its most basic form, carbide is a fine gray powder, but it can be pressed and formed into shapes for use in industrial machinery, cutting tools,abrasives, other tools and instruments, and jewelry.

Carbide is approximately three times stiffer than steel, with a Young's modulus of approximately 550 GPa,[2] and is much denser than steel or titanium. It is comparable with corundum (α-Al2O3) or sapphire in hardness and can only be polished and finished with abrasives of superior hardness such as cubic boron nitride and diamond amongst others, in the form of powder, wheels, and compounds.

In India Widia brand was very  popular in the field of hardmetals like tungsten carbide. They made carbide for wire drawing, bar drawing, cold forging industry.Their carbide was of very good quality . Apart from Widia, Sandvik was also a very good supplier of carbide.

Sandvik is not manufacturing wire drawing carbide pellets in India. The pellets are to be imported from Sweden.

On the other hand Widia was acquired by Kennametal in Europe and India. Other acquisitions that expand Kennametal’s capabilities to better serve its customers worldwide include Conforma Clad Inc., a leading provider of engineered components that deliver premium wear solutions, and Extrude Hone Corporation, a supplier of market leading engineered component process technology.

In India,now Kennametal is the major supplier for good quality carbide. The brand Kennametal itself suggest excellent quality.

Electronica is also another company which deal in hard metals.

Now a few companies are also coming up in the manufacturing of sintered tungsten carbide.

For any carbide needs like wire drawing dies or other wear resistance assistance, 
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Heading Dies for Stainless Steel

Heading Dies

The appropriate size of wire is very very important for the good life of a heading die.

Just the other day, one of my clients faced a  problem in the die. When ever he used the die for 5 min or so, the carbide at the top where the head of the rivet is made got chipped off.

He tried many times after facing the die surface.

On closer inspection , it became evident that the wire size used for forging was 5.43mm and the heading die size was 5.45mm.

Thus, we increased the diameter of the die to 5.47mm and the asked our client to use the same die.
This time the die worked fine.

So a little variation in the wire size can lead to die breakage in the heading dies.
Also , for Stainless steel, a special oil is to be used, otherwise the forged piece sticks to the die and can cause die breakage.

I hope that this article will be of good help to all the people in the fastener line.

REGAL CARBIDE DIES PVT. LTD

Sector Shaped Conductor Compacting Dies

COMPACTING DIE FOR SECTOR SHAPE CONDUCTOR

Sector Shape Conductor

We at Regal Carbide Dies Pvt Ltd. are manufacturing Compacting dies in Tungsten Carbide for Sector Shape Conductors.

These Compacting Dies are used in Cable industries for compacting the strands of wires .

Some times these strands of wires are Tin coated. 

The surface finish of the Compacting die is very high so that there are no scratches on the compacted conductor. Also angle in the die has to be high so that the compacting can be done easily without much load on the die. 

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Shaving Die

SHAVING DIE

What is a Shaving Die ?

SHAVING DIE

Many times after the extrusion metals and alloys , the outer surface contain many impurities.
To remove the impurities a shaving die is used to shave the impurities from the extruded rod.
Shaving die is also called as the scalping die.

A sharp edge is made on the shaving die . The material is then drawn from this shaving die. This process is carried out on a draw bench machine generally.
The impurities are shaved off by the die  This is a helpful process as the material now becomes more pure .

For example if the size of the wire is 10mm after extrusion , then the size of the shaving die should be around 9.90mm or 9.85mm.    

Heading Die

HEADING DIE

What is a Heading Die?

A heading die is also called as cold heading dies. This uses the concept of cold forging of wires into rivets, screws, bolts as well as nuts.
A heading die is made of different dimensions based on the length of the piece to be forged, the thickness of the screw or the bolt or rivet which is to be made on the machine.

Thr forging is done on machines called as headers. All machines are having different capacities of length which can be made as well as the thickness of the material which it can forge.

Now a days Heading die is made in tungsten carbide. Earlier people used to use Hardened steel dies which had very little life.

Heading dies are made for

• rivets
• bimetallic rivets
• bolts
• screws
• carriage bolt   etc.

Deep Draw Die

DEEP DRAW DIE

We make carbide deep draw die. These deep draw die is used to make a deep draw out of the thin sheets.
The process is as follows:

• Sheets are fed to hydraulic press which keeps cutting the desired thickness sheets on a regular interval.
• then this small cutted sheet is kept on a deep draw die held on a hydraulic press.
• a punch comes and deep draws the cutted sheet such that the outer diameter becomes equal to the inner diameter of the deep draw die.
• the thickness of the components so formed is determined by the diameter of the punch used in the process.

Deep draw dies are used in industries like

1. Making the cover of speakers.                                       
2. the cover of small electrical motors,
3. the batteries
4. can making
5. perfume can making

Carbide Bush

CARBIDE BUSH

Carbide bush is used as a guide in many industries . Also in some other industries carbide bush is used  for better wear resistance.
For Example:

1. In Stranding machine : Many carbide bushes are used in stranding machine. Some machines use approximate 72 carbide bushes  at one time, some other machines use only about 50 carbide bushes
2. In Jig fixtures also these carbide bushes are used as a wire guide for drills etc.
3. In many industries carbide bush is used as a seal ring.
4. Coiling pay off Guides .

These carbide bushes are highly wear resistant and give very good life. 

Now a days these carbide bushes are used in many sheet metal dies where the cavity is now made in the carbide bushes fitted in the base plates.

Extrusion die

EXTRUSION DIE

Flux Coating Dies

We at Regal Carbide Dies Pvt Ltd, are based in Delhi ,India since 1987.
We make Flux coating dies also called as an extrusion die used for coating of flux on the welding Electrode Rods.
This Extrusion Die is used extensively in the welding electrode industry for many years now.

The toughest grade of Tungsten Carbide  is used ( TH 03 of Kennametal) for the Extrusion die or    Flux Coating dies.
 Extrusion Die is highly polished to give a mirror finish on the die. This helps in easy release of the welding rod as well as very good surface finish of the electrode rod is achieved through it.

Extrusion Nozzles, Cutters , Spinner Dies

Apart from the Extrusion Die, we also make Spinner Dies, Carbide cutters , Extrusion Nipples or Nozzles as well as wire cutting dies used in the Wire straightening and cutting machines.

Carbide Wire Feed Rollers

We also make the Carbide Roller used for pushing of welding electrode rods into the extrusion machine. These carbide rolls have very good life .
Earlier die steel rollers were used in these wire feeders. Because of steel wearing , the machines have to be stopped many times to change these rollers which lead to production losses.
These carbide rolls help to increase the production by reducing the down time .

We make all these toolings as per client's specifications and drawings.

Wire Dies

WIRE DIES

Types of Wire  Dies
1. Tungsten Carbide Wire Dies :  Tungsten Carbide pellet is fitted in steel case in this wire dies. Angles are provided on both the sides of the carbide pellets so that reduction and release of drawn wire is done easily.

These Wire dies are used for drawing of Mild Steel, Low Carbon Steel, High Carbon Steel, Stainless Steel, G I Wire, Brass, Copper, Aluminium and other alloys.
Apart from these wires, coated wires are also drawn from these tungsten carbide wire dies.

Shapes of Tungsten Carbide Wire Dies                              
. Round Tungsten Carbide Wire Dies
. Square Tungsten Carbide Wire Dies
. Hex Tungsten Carbide Wire Dies
. Rectangular Tungsten Carbide Wire Dies
. Strip carbide Wire dies

2. PCD Wire Dies  (Poly Crystalline Diamond Dies).
In  PCD Wire Dies , PCD Blank is brazed on to steel Case. These PCD Wire Dies are used mainly for drawing of Copper, Aluminium, Brass, Aluminium Alloy .
These PCD Wire Dies are used mainly when long production run is used.
PCD Dies give many times more production than Tungsten Carbide Wire Dies.

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Compacting Die

COMPACTING DIE

COMPACTING DIES

We make Tungsten Carbide Compacting Die. The compacting die is used in cable manufacturing.
The stranding of many wires are done with the help of stranding machines. The strands of wires are then passed through a Compacting die .
The main function of compacting die is to remove the air gaps which are formed in the strands.
This helps in better conductivity of the electrical cables.

Types of Compacting die
1. Single piece Compacting die
2. Split Compacting dies ( two piece dies).

Also now a days compacting dies are being made in
1. Tungsten Carbide
2. PCD

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Carbide Roller

CARBIDE ROLLER

WIRE FEED ROLLERS

We make Carbide  Roller used in many industries for feeding of wires.
Industrries where carbide rollers are used are as follows:
1. Spring Machinery for feeding of wire .
2. Welding Electrode industry for feeding of wire rod in the extrusion plant.

This Carbide roller is made in grooved type as well as knurling type.
Finest grade of Tungsten Carbide is used to give good wear resistance.
Very long life is achieved from the carbide roller. This definitely helps to reduce the down time of the machine caused by frequent wear and change of steel wire feed rolls in the plant.

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Carbide Die

CARBIDE DIE

We at Regal Carbide Dies Pvt Ltd , Delhi are in the field of making  Carbide Die since 1987.
Tungsten Carbide , being a very hard material , next only to Diamond is used because of its property of extreme high wear resistance .

Carbide Die is being made with the use of Tungsten Carbide.
 Carbide die consist of a Steel Case . Tungsten Carbide pellet or nib is shrink fitted to the steel case with appropriate shrinkage allowances.

The inner Diameter of the carbide pellets are lapped as per the required approach angle and exit angles in the   die. Bearing length or band length is then made in the carbide die which depend upon the material to be drawn as well as the speed of the machine on which it is to be drawn.

After lapping and rough finishing, the carbide die is then fine polished with the aid of Diamond lapping compounds, diamond powders and Diamond Paste so as to give a mirror polish on the carbide die.

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Carbide Wire Guides and Coiling Fingers for Spring Industry

CARBIDE WIRE GUIDE AND COILING FINGERS

CARBIDE WIRE GUIDE

CARBIDE WIRE GUIDES

We at Regal Carbide Dies Pvt Ltd, Delhi are manufacturers of Full Carbide Wire guides, Carbide lined Wire Guides as well as coiling fingers for various spring making machines.

Apart from it, we also make wire feed rollers in Hardened Steel as well as in Full Carbide.

We have been making these toolings for many years now.

We carefully select the grade of Tungsten Carbide which should be used in these applications.

Wire guides and roller grooves are highly polished for giving smooth surface finish of the wire.

www.regaldes.com

Draw Die and Plugs

DRAW DIE AND PLUGS

CARBIDE PLUGS

We at Regal Dies make Draw die for pipe drawing. We make draw dies for sinking process as well  for tube draw process where a plug is used along the die to maintain the Inner bore of the pipe.

We make these plugs in fixed types like brazed or mechanically fitted plugs , or we make floating plugs as well.
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Die Manufacturer

BAR DRAWING DIES

We at Regal Carbide Dies Pvt Ltd are a Die Manufacturer since 1987. We  make Bar Drawing dies , Wire Drawing Dies, Extrusion dies in tungsten carbide. These dies are used to draw various ferrous and non ferrous materials.
Dies are used to draw round wire and bars , square bars, hexagonal bars, rectangular bars as well as all types of profiles as per client's drawings and requirements.

Being a die manufacturer we are committed to provide good quality to all our clients on a shorter notice.
A die manufacturer in the field of carbide die making involves machinery like
Polishing Machines
Lapping Machines
Cylindrical Grinder
Surface Grinder
EDM Machine

Apart from these machinery , a die Manufacturer may also need to get some work outsourced from machines like Wire Cut , Vertical Milling machines etc.
Die manufacturing is a very challenging field, as every day one has to look for improving the existing quality to a new level.

We consistently try to work on our quality and have created a  good name as die manufacturer of carbide dies. in India.
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PCD Dies

PCD DIES

PCD DIES

PCD Dies

We at Regal Dies are manufacturing PCD Dies used in the wire drawing of Copper, Aluminium, GI Wire, SS wires. Also dies are made for tube drawing as well as for Compacting of cables.

We have many satisfied customers . We value quality and timely delivery.
www.regaldies.com

Carbide Dies for Co2 wire / Mig Wire

CARBIDE DIES FOR CO2 WIRE / MIG WIRE

CARBIDE DIES

We are specializing in the manufacturing of  Tungsten Carbide dies used in manufacturing of Mig wire / Co2 wire.
We have done extensive research on the geometry of the die which gives very good results.
Our dies have these advantages  like:

1. Very good Production                                                  
2. Good surface finish of copper coating.
3. Uniform coating with no scratches.
4. Our dies do not heat and leave flux.

We have many satisfied customer's in this field.
Our aim is to be a world renowned player in the manufacturing of Mig wire draw dies.
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Schaublin , Nomura, Citizen Sliding head Collets

We have been making collets and guide bushes for sliding head machines. We are capable of making these collets and guide bushes in steel and in carbide lining .
We have detailed drawings of various machines like Petermann, Tornos, Schaublin, Nomura, Citizen etc.
We can also make asymettric collets and guide bushes as well for machines like G. D Wieler etc.
Minimum bore which we hade made is 0.6mm.
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T.C Strip dies for DPC Wire for copper and Aluminium

T.C STRIP DIES

We make Tungsten Carbide Dies for DPC wires in aluminium and copper .
We make these dies for strips. The paper is easily covered on the strips as the corners are rounded for the purpose of paper covering.

Apart from these dies we also make dies for copper and aluminium bus bars.. Commutator sections
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Carbide Lined Collets and Guide bushes

CARBIDE LINED COLLETS AND GUIDE BUSHES

CARBIDE LINED COLLET AND GUIDE BUSHES

We make Carbide lined guide bushes and Collets for sliding head machines.
We have drawings of many machines like Petermann, Tornos, Citizen, Behler, Star, Strohm etc.
These machines are used in precision turned components used in Watch industry, Carburattor , and many other auto component industry.
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Tungsten Carbide Wire Guides

TUNGSTEN CARBIDE WIRE GUIDES

CARBIDE WIRE GUIDES

We at Regal Dies are manufacturers of Tungsten Carbide Wire Guides. These Wire guide are used in Compacting machines used in Electrical Cable making.
These guides are used in Coiling Pay Off Machines.
Excellent wear resistance is considered to be of most importance for these wire guides.
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