Wire Reduction Ratio Calculator - TechMasterFun

⚙️ Wire Reduction Calculator

🏭 Billet Shape ⬜ Square Billet ⭕ Round Billet 📦 Rectangular

📏 Input Width/Dia (mm)

📐 Input Height/Dia (mm)

🎯 Output Wire Dia (mm)

0 : 1

Click Calculate Button

🏭 Chakan Factory Wire Drawing Guide

Chakan MIDC manufacturers lose Rs 4-6 lakhs weekly from improper die sequencing. Optimal 20-25% reduction per die prevents 90% wire breakage and saves Rs 15 lakhs monthly.

150×150mm billets to 5.5mm wire needs 947:1 total reduction across 45-50 dies. MS steel: 22-25%, SS 304: 15-18% max due to work hardening.

• Wire breakage: >28% reduction per die
• Die wear: <15% reduction (too slow)
• Machine overload: Heavy billets need 18-20% max
• Surface cracks: SS needs annealing every 3-4 passes

❓ FAQ - Production Best Practices

Optimal reduction per die? +

20-25% MS steel, 15-18% SS 304. Chakan average: 22%. >28% = 85% breakage risk.

150mm → 5.5mm needs how many dies? +

947:1 ratio = 47 dies @ 20% or 38 dies @ 25% (riskier).

Why avoid >30% per pass? +

Central burst defects + 85% breakage. Heat fails lubrication, die cracks.