Once there is not an alignment of the coils, it will cause errors in the subsequent steps and the material wasting or the downtime of the machine. Therefore, when processing the web, the web guiding is necessary for the offset and it is widely used in a bonding machine, a printing machine, a coater, a paper machine, a dyeing machine, etc, which has various requirements for the winding and rewinding processes. An all-in-one web guiding system refers to the technical operation of the coils to keep the edge of the coil neat and consistent during spraying, printing, die-cutting, lamination, slitting, or other coil winding processes. Its wide applications have brought huge benefits to the coil industries. The all-in-one system has automated industries such as corrugated paper, textile, printing, labels, papermaking, plastic film, building materials, tires, and non-woven corrugated paper processing.

The Work Principle Of All-in-one Web Guiding System

The high-precision, high-speed, and high-efficiency coil automatic processing has high requirements for the lateral position of the controlled coil. Equipped with a high-performance automatic web guide system is the key to improving coil production capacity and output. The coil will shift laterally during moving, unwinding and rewinding. Therefore, the web guiding system can be installed in the above three positions for controlling the coil to pass through the designated position accurately.

All-in-one web guide machine adopts high-speed microprocessor, digital, modular and intelligent circuit design. The advanced programming, user-friendly interface, high-performance components and complete circuit protection design, make the system run continuously and stably. The response time of the control system is less than 0.01 seconds and the accuracy of the system itself can reach 0.01mm. During the coil winding process, the web guide sensor detects the position of the edge or line to pick up the deviation signal of the edge or line position.

Then the position deviation signal of the web guiding machine is sent to the web guide controller for logical operation. After the judges and processes of the control unit, it will control the drive motor to skew the web to the correct position.

The Functions & Advantages Of All-in-one Web Guiding System

The high-performance web guide system has a fast response time, high-speed CPU calculation and can support ultrasonic sensors, photoelectric sensors, CCD sensors for the different response of coils. It has the advantages of simple and practical operation, ball screw, high precision, low noise, maintenance-free, long service life, flexible installation.

Center compensation deviation web guiding can quickly guide the high-frequency feed errors. It integrates operation and control technology with a highly compact web guide. The guiding system has an innovative sensor detection real-time display and a real-time feedback system for system detection information.

The all-in-one system is driven by a brushless DC servo motor and precision ball screw, with compact structure, good mechanical rigidity, low inertia, high precision, suitable for high-speed and high-precision web guide in coil processing.

Three Detection Methods Provided By All-in-one Web Guiding System

The All-in-one web guiding system provides three different detection methods, which include edge detection, line tracking, or alignment detection. The drive system is driven by a brushless motor and the drive stroke is strictly proportional to the coil offset. The system can also be used in conjunction with different sensors to meet the needs of different coils, such as ultrasonic sensors, photoelectric sensors, CCD sensors, etc. The microcomputer digital controller provides precise control for the various functions of the guide system.

Daily Maintenance Of All-in-one Web Guiding System

1.Alignment: Tools, workpieces and accessories should be placed neatly. The web guiding system should be equipped with thorough protection equipment.

2. Cleaning: Cleaning inside and outside including all sliding surfaces, guidelines, gears, racks, etc, ensuring all parts will not leak oil, water, air, or electricity.

3. Lubricating: Refuel and change oil timely. The oil quality meets the requirements. Oil tanks, oil guns, oil cups, lumps, tubes should clean and keep complete.

4.Safety: The operation personnel should be familiar with the maintenance structure of the web guide system, complying with the operating procedures and reasonably use the all-in-one system with daily maintenance, carefully maintenance tools to prevent accidents.

For more information, please visit the page of why choose all-in-one web guide system.

XYMJ provides customized tungsten carbide dies. Tungsten carbide has excellent hardness, wear&corrosion resistance, resistance and small expansion coefficient, which increase the service life. The life time of carbide dies is ten times or even dozens of times than the steel dies. XYMJ can provide various types, which including cold heading dies, cold punching dies, wire drawing dies, hexagon dies, spiral dies, etc.

Factors To Consider For Designing Carbide Dies

1. It must have a high yield, good structural shape with high dimensional accuracy.

2. If necessary, all the bottom and upper of the carbide dies should use tungsten carbide through the analysis of the most worn parts. In some cases, you can adopt tool steel and tungsten carbide in combination under the situation that has punch difficulty processing or fixed in order that the mould manufacturing and application must be the most reasonable and economical.

3.Under the allowed processing conditions of tungsten carbide die, the mosaic structure is more economical, easy to process and repair.

Tungsten Carbide Punch Dies

The carbide punch manufactured by XYMJ has excellent performance, outside diameter, inner diameter, the height of which, are all accurate grinding, tolerance within 0.01mm.

Features

1.Well abrasion Resistance.

2. High Hardness, around 88HRA or even 91HRA.

3. A high compressive strength is greater than 6000MPa.

4. Excellent corrosion Resistance.

5. High precision and high quality, the service life is over 10 times longer than common high-speed steel.

6. A low coefficient of thermal expansion

Tungsten Carbide Wire Drawing Dies

Tungsten carbide wire drawing dies are made from 100% virgin material of WC and Co. It has good wear resistance, high bending strength. It is a good economical choice for steel wire and other large-size wire drawing applications. It is applied for drawing wire, tubes, rod, type as S11, WTA. S13 ect, used for wire drawing of steel, aluminum wire and copper wire.

Advantages Of XYMJ Tungsten Carbide Wire Drawing Dies

1. excellent wear-resistance, adopting GB class A cemented carbide mould core with strength over 2200N/mm 3.

2. More wire rods can be drawn: the size is 20% longer than common mould, which makes XYMJ carbide wire drawing dies can work longer.

3. Tightening connected with the steel jacket: adopting advanced cold bushing technology and interference bushing craft. They are tightening connected with the steel jacket.

XYMJ manufactures tungsten carbide products with 100% virgin material with high stability and high performance. All carbide products manufactured by XYMJ meet the ISO quality standard. Also, skillful workers and advanced equipment enable XYMJ to have the ability to provide all kinds of customized carbide parts. XYMJ take great efforts to increase quality rather than quantity to promote the flexibility of competing in the world market. Always satisfying customers, providing them with high quality and grade product as well the service is our aim.

Tungsten Carbide Strips

The main composition of tungsten carbide strips is tungsten powders and cobalt powders. It has have many excellent characteristics such as high hardness and strength, good wear and corrosion resistance and very stability under high temperature, widely used in many fields such as woodworking, machining of refractory alloys, stainless steel, high manganese steel, for processing cast iron, non-ferrous metal and aluminum section bar, etc. XYMJ has various types including carbide strips with more than 300mm, carbide strips with angle, STB blanks with US Standard, etc.

Tungsten Carbide Rod

Carbide rods can be used for making end mills, various drill bits, automobile special cutter, engine special cutters, horology, processing special cutters, integral vertical milling cutter, graver and etc. Also, the tungsten carbide rod can be made into hard alloy punches, mandrels, centers, and perforation tools.

Features

(1) Good wear resistance, higher toughness, high precision, better deformation and fracture resistance.

(2) Advanced automatic extrusion equipment to produce.

(3) HIP sintering and precision grinding to ensure have good performance.

(4) Both blank and finished conditions available.

(5) Can reach a mirror effect surface after accurate grinding and polishing.

Tungsten Carbide Plate

Carbide plate has high hardness, good abrasion resistance and toughness, heat and corrosion resistance. It is widely used in the following fields:

1. The production of cast iron rolls and high chrome roll knife.

2. Suitable for the production of discharge plate, stamping die, cold punching die, such as electronic stamping die.

3. Used in the production of copper, aluminum, stainless steel, cold rolled sheet, El board, Q195, SPCC, siliconsteel plate, metal, standard parts, upper and lower punch and otther high-speed mold.

4. Wear resistance of tungsten carbide plate is higher, suitable for hardwood, logs, aluminum, copper rods, cast ironiron processing for the production of various types of motors, electronic into the mold, stamping electronic mold.

XYMJ is a professional tungsten carbide supplier for carbide mould/dies and all kinds of customized wear parts. Which integrates research & development, production, marketing and services.Our company was founded in 1999 and located in Zigong City,Sichuan province,China. We have more than 20 years experience in researching and manufacturing of tungsten carbide products such as carbide molds & dies, bushings, valve seats, nozzles, inserts & cutting tools, carbide rods and bars, carbide plates & strips and other customized tungsten carbide wear parts etc.

We can produce various products as per customers special requirements. OEM/ODM is welcomed. With high-tech equipment and strict quality test system, We have won a good reputation of high quality in both domestic and overseas markets.

Our tungsten carbide products have been exported to many countries around the world. Being reliable and professional is our value of service. Providing customers with high satisfaction services and high quality products is always our mission. Sincerely welcome the friends all over the world to contact us for WIN-WIN cooperation!

Tungsten carbide blanks production

Good quality carbide products rely on 100% virgin raw materials and advanced wet-milling,pressing machines and sintering furnaces. We put emphasize on every production process of our carbide blanks. To keep good quality of carbide blanks is the base of furtherly machined high precision finished carbide parts.

Finished products machining

XYMJ owns a series of high-precision grind machines, including flat grinding machines, OD and ID machines, Centerless grinding machines and customized grinders. Also we have CNC machines, EDM, Wire-cutting machines and drilling machines etc. With our skilled workers, we can control very high precision of each carbide part.

Inspection and testing process

In order to ensure the quality of all our tungsten carbide finished products, a very strict QC management system has been introduced. With our advanced inspection equipment and our professional inspectors, we are able to do raw materials inspection, on-site inspection and after finishing inspection to ensure 100% good quality of your carbide products.

Packaging and Shipping

Special-designed packing boxes and tubes will be used properly for the standard and customized carbide products to ensure the safety of the goods during the transportation process. A wide range of shipping ways can be available for your shipments, for example we can ship goods by Sea, by air and by Express companies like DHL/FedEx/UPS/TNT/Aramex etc.

When adopting high function and high-speed molds for production, the mold is required to have a long service life. In recent years, high-precision and high reliability are required even if for a small amount of production. Carbide dies with high durability will be the best choice.

Tungsten carbide wire drawing dies have the following features which ensure the high durability

1. Strong power resistance

The mold should be given a very large extrusion, bending stress, impact and other messy loads during the extrusion process. Therefore, the material selected will have high power resistance after heat treatment. The mold material should have outstanding hardenability to ensure that the mold can be hardened and uniform.

2.Excellent wear resistance

The mold should have high wear resistance to ensure normal service life and produce large quantities of extruded parts. In general, the hardness of steel is proportional to wear resistance under certain conditions. Therefore, mold materials must have sufficient hardenability. In addition to the hardness, The decisive factors are the thickness, composition, amount of excess for the matrix after heat treatment and the amount, size, type, dispersion, red hardness of carbide. The tungsten carbide has a content of more than 80% of WC, the wear resistance of which is several times higher than steel. So to get a long service life for the drawing mold, and carbide is mostly adopted for the materials.

3.Sufficient thermal stability

For continuous production, the temperature of the mold sometimes will reach 200 ° C, which will reduce the strength and hardness, so that the mold material should have outstanding thermal stability. Carbide drawing dies have sufficient thermal stability for high-temperature resistance.

4.Excellent processability

Cold extrusion mold has a long manufacturing time with high accuracy requirements. Usually, it is necessary to cast, cutting, heat treatment, grinding or other fine finishing. So only the materials that have good processability can meet the production needs. The excellent process of carbide molds will be the best choice.

Tungsten carbide wire drawing dies have high hardness, excellent thermal stability, high durability and long service life and are one of the best mold materials.

Carbide wire drawing dies adopt high-quality tungsten carbide as the core, which has high hardness, good thermal conductivity and low friction coefficient. Tungsten carbide wire drawing dies are simple to produce with corrosion-resistant, impact-resistant, and low cost which is the outstanding feature of this product. It is suitable for the drawing of ferrous metals, large-size wires, and occasions with poor wire drawing conditions.

The Brands And Applications Of Tungsten Carbide Wire Drawing Dies

Wire drawing is the manufacturing process for reducing or changing the cross-section of the metal wire by using a series of stretched plates or molds. Carbide wire drawing die is a kind of tungsten carbide dies with wide applications in various fields.

Brands: YG6X

Applications

Suitable for the production of carbide dies with drawing inner holes which are smaller than ¢ 6.00mm.

Brands: YG6

Applications

Used for the non-ferrous metal round bar which has drawing inner holes that are smaller than ¢ 20mm and the drawing dies which has inner holes that are smaller than ¢ 10mm.

Brands: YG8, YG10

Applied for drawing steel and the production of non-ferrous metal round bars & pipes.

Brands: YG15

Used for the drawing of steel rod and pipe which have a high shrinkage.

The Precautions And Maintenance Of Tungsten Carbide Wire Drawing Dies

1. Ensure the stability of the drawing machine

Each drawing drum, over-line guides should be smooth, flexible, strictly controlled for beating tolerance. If the drum is found, the guide wheel has a worn trench and the drawing dies should be repaired in time.

2.Good lubrication

Good lubrication is important to ensure the surface quality of the wire and extend the service life of the mold. The lubrication index should be checked frequently, removing the copper powder, impurities in the lubricant, so that the equipment hole can not be polluted. If the lubrication doesn’t work, it must be replaced in time and clean it.

3. Reasonable allotype

Reasonable allotype is to ensure the surface quality of the wire and control size accuracy, reducing the wear of wire drawing drum and equipment operating load. For sliding wire drawing machines, it is necessary to familiarize with the mechanical elongation of the equipment. The sliding coefficient is reasonably selected, which is the primary step of fitting mold.

4. Appropriate adjustment of the size for the compression angle

The surface reduction rate of each drawing and the material of the drawn wire are also closely correlated with the compression angle of the respective mold. The size of the compression angle is appropriately adjusted according to the size of the surface reduction rate.

5.The timely replacement of the aging drawing dies

When the drawing die reaches the service life, please replace it in time for repairing treatment to avoid excessive causing scrap the wire.

For more professional knowledge, please visit the article page of high quality tungsten carbide wire drawing dies.

Tungsten carbide is widely used in various industries due to its unique high hardness and strong wear resistance. What are its common applications?

1.Cutting tools

Tungsten carbide can be used as a variety of cutting tools. Because of its high hardness and strong resist compression performance, tungsten carbide is one of the best material choices for cutting tools. The tungsten carbide cutting tools include carbide drill bits, small circular saw blades, carbide rotary burr and so on. As the material of cutting tools is the most widely used field for tungsten carbide.

2. Mining tools

The cemented carbide for mining accounts for about 30% of the total tungsten carbide production. Thanks to the high hardness, strong impact toughness, outstanding bending strength and excellent wear resistance, carbide mining tools are usually applied in geological exploration drill bits, roller cone drills and coal cutters for petroleum and gas fields, engineering excavation road tools, percussion drilling in the building materials industry.

3. Tungsten steel mold material

Under normal circumstances, the proportion used in the manufacturing of various molds accounts for about 8%, which includes carbide drawing dies, cold heading dies, cold punching dies, cold extrusion dies, hot forging dies and drawing mandrels. Usually, the cemented carbide applied for making molds is selected from medium and high cobalt, coarse grain grades.

4. Wear parts

The tungsten carbide wear parts include carbide nozzles, carbide balls, tungsten carbide valve seat & valve sleeves, carbide tire cleats, carbide guide rails and so on.

5. Structural parts

The carbide structural parts include rotating seal ring, lathe head, grinding machine spindle, bearing, etc, which can effectively solve the problems of mechanical seal ring thermal cracks.

Trustworthy Tungsten Carbide Manufacturer – XYMJ

XYMJ has focused on the production and processing of tungsten carbide products for more than 20 years, the products including carbide dies, bushings, valve seats, inserts & cutting tools, carbide rods and bars, carbide plates & strips and other customized tungsten carbide wear parts. It has superb blank forming and precision machining capabilities with high performance and a low-cost advantage. It has a grinding machine for smooth finish, frosted finish, concave finish, and convex finish, which can better satisfy customer’s requests.

High performance of tungsten carbide, in addition to high hardness, there are also excellent wear resistance, corrosion resistance, high-temperature resistance, etc and can be used as cutting tools, mining tools, wear parts, etc, which are also the reasons for wide applications in various industries.

Tungsten carbide is an alloy which has the main components of tungsten carbide powder with metal bender. It is widely used for manufacturing high-speed carbide cutting tools for hard, tough materials. The high-performance tungsten carbide has excellent characteristics.

of hard, tough materials. The high-performance tungsten carbide has excellent characteristics.

1. High hardness and excellent wear resistance

The hardness of cemented carbide can reach 86 to 93HRA, which is equivalent to 69 to 81HRC. High hardness can be maintained at 900-1000 ℃ with excellent wear resistance. Compared to high-speed steel, the cutting speed can be 4-7 times higher with 5-8 times service life, which can cut hard material with a hardness of 50 HRC.

2.High strength and high elastic modulus

The tungsten carbide has a compressive strength of up to 6000 MPa and an elastic modulus (4 ~ 7) × 105 MPa, which both are higher than high-speed steel. However, its bending strength is low, typically 1000 ~ 3000MPa.

3. Excellent corrosion resistance and oxidation resistance

It is generally resistant to atmospheric, acid, alkali and is not easy to oxidize. There is a wide range of applications in the industries of fluid and chemical, such as various valves used for fluid control including regulating valves, black water valves, lock slag valves, and decompression noise reduction valves, etc.

4.Small linear expansion coefficient

When the tungsten carbide products are working, the shape size the stable

5.The finished products are no longer processed with re-grinding

Due to the high hardness and brittleness, the powder metallurgical formation is no longer cutting or re-grinding, and when the demand is re-processing, it can adopt electric sparks, line cutting, electrolytic grinding and other electric processing or special grinding wheel cutting. It is usually used by a certain specification paper made of cemented carbide, adopting brazing, bonding or mechanical clamping for the blade body or mold.

How To Improve The Performance Of Tungsten Carbide

In order to adapt to the harsh environment under different working conditions, tungsten carbide often needs to be reprocessed to make corresponding changes for the original performance, so what are the methods to change the performance of tungsten carbide?

1. Improve the quality of raw materials

Improve the purity of raw materials

High-strength, high-impact toughness alloys have high requirements for the purity of raw materials, while continuous cutting tool with low impact load but high machining accuracy, have low requirements for raw material purity.

Control the particle size and distribution of raw materials

It should avoid excessively large particles in the carbide or cobalt powder raw materials, and prevent the tungsten carbide from forming coarse carbide grains and cobalt pools during sintering.

At the same time, the size and composition of the particle materials should be controlled to meet the needs of different products. For example, carbide cutting tools should adopt tungsten carbide powder with a fisher particle size of less than 2 microns, wear-resistant tools should use tungsten carbide powder with a particle size of 2-3 microns, and mining tools should adopt tungsten carbide powder with the particle size of larger than 3 microns.

2. Improve the structure of the tungsten carbide

3. Improve or select new hard phase and binder phase

The performance of tungsten carbide is affected by the composition and structure of the hard phase and the binder phase. Generally speaking, when the content of the hard phase is high and the grains are finer, the hardness is high and the wear resistance is good, with poor impact resistance. Improving the hard phase and the binder phase is one method to change the performance.

4. Surface hardening treatment

To solve the contradiction between wear resistance and toughness, hardness & strength of tungsten carbide, surface hardening treatment can be adopted.

The coating is physically or chemically depositing a layer of TiC or TiN on the surface of the cemented carbide to increase the wear resistance. The most rapid development at present is the coated tungsten carbide.

5. Add elements or compounds

6. Heat treatment

For more useful knowledge, please visit the article page of high peformance tungsten carbide

Here, we’ll introduce the common problems that occur in the solvent-free composite and the effective solutions. Adopting the solutions can greatly improve the work efficiency of the solventless laminator.

Knife Line

The main reason is that the coating units are not cleaned up. At this point, the coating unit should be downtown, or the transfer roller is changed, and the blanket is eliminated.

Poor Drying Of Adhesive

1. The adhesive is not configured in accordance with the correct matching requirements.

2. The adhesive has not been working.

3. Mixed glue contains moisture content or a large amount of ethyl acetate.

Composite Membrane Bubble

1. Since the material is not smooth and the ink particles are thick, the glue coating is insufficient. It should use high-quality materials or increase coating.

2. CO2 generated in curing cannot form in a film which has a good barrier property, mainly due to the use of a single-component solventless. So it should use a two-component adhesive.

3. The surface wettability is poor. It should increase the surface wetting tension of the material and improve the wettability of the adhesive.

4. Transfer roller is attached with foreign matter or scars and should be scrapped with bamboo pieces.

Poor Adhesion

1. The adhesive coating is too much, and the Internal curing of adhesive is slow.

2. When using a single-component adhesive, the humidification moisture content is insufficient.

3. The amount of coating is too small and the infiltration of the surface is incomplete.

4. Poor solubility of the ink and the adhesive, such as using polyamide ink.

Here, we give a detailed analysis of the undesirable phenomenon in the solventless composite and solventless laminating machine, such as the uniform winding, poor coating effect, etc and how to solve the problems.

Poor Coating Performance

1. The pressure of the transfer roller is not enough.

2. Mechanical brake adjustment error of transfer roller.

3. The coating roller is not clean well.

4. The poor finish of the glue pressure roller, the transfer roller, or the composite roller.

Poor Coating Performance Of Thin Film Edge

1. The adhesive close to the baffle does not replace for a long time, as long as it often swings the spray nozzle to maintain the adhesive fresh.

2. The coated pressure roller of the composite roller has glue or other impurities.

Uneven Section Of Rewinding

1. The glue amount is too large.

2. The cooling performance of the back film roll which is from the composite roller, is poor.

3. Tension is not suitable.

4. The flatness of the squeeze roll in the rewinding is poor.

5. The glue coating amount in the left and right sides of the film is too large and it is best to control the difference within 0.2g.

6. The paper core is not aligned with the film.

White Spot

1. Low glue coating

There is not enough adhesive to penetrate into ink. At this time, it appears as a small and uniform spot in the entire composite film. The solutions are to appropriately increase the amount of glue and adjust the composite temperature and composite pressure.

2. The glue portion, the composite portion of the rollers have a poor surface finish. At this time, it is expressed as partial intermittent repeated spots. It can be judged by measuring the spacing of the two spots to find that which rolls have foreign matter and clean up.

3.The tension of substrate film is uneven and wrinkles before entering the composite roller, resulting in poor partial composite performance, and the bubbles will appear, the macroscopic manifestation is a white spot. The solution is to adjust the deflection roller and keep the film neat before entering the composite roller. The tension can be appropriately adjusted or replace film.

4.The pressure of the composite portion of the glue portion is not properly set.

5. The solubility of the ink and adhesive is not good, white spots will occur at no adhesive penetrated ink, and the suitable adhesive or ink should be replaced.

For more information, please visit the article page of the undesirable phenomenon in solventless composite.