Effect of Drawing Speed on the Reliability of Drawing Dies

Abstract

Reliable drawing dies are crucial for successful modern wire production. If these parts fail, repairs can be time-consuming and costly. This study examines how drawing speed affects die reliability within a standard commercial range of 50 to 400 m/min. We tested 750 tungsten carbide dies using various methods, including Weibull reliability analysis. Fifty dies were tested at each of 15 different speeds. Our results show a strong inverse relationship between die lifespan and drawing speed, and a significant direct relationship between operating temperature and wear rate. As drawing speed increased from 50 to 400 m/min, the average die life decreased by 65%, the wear rate increased exponentially, and the average operating temperature rose linearly. We identified three failure zones: a moderate wear phase (50–150 m/min), a rapid failure stage (300–400 m/min), and a period of accelerated degradation (150–300 m/min). In each zone, different wear mechanisms may occur. These findings help manufacturers extend die life, improve efficiency, implement predictive maintenance, and develop new die technologies that could reduce costs by 15–25%.