Wire Cupping Press

Advanced Wire Cupping System

Servo-Driven Wire Forming

The OTM-5100 employs servo-driven technology to execute a precise four-step wire forming process: shearing, flattening, pre-forming, and final forming. Brass wire is fed continuously, cut into exact segments, flattened into uniform blanks, shaped into preliminary cups, and drawn to final dimensions with smooth edges and consistent wall thickness. Unlike traditional strip forming, which generates significant scrap (yielding ~75% material efficiency), wire forming achieves 95% material utilization, reducing costs and waste. The servo wire shear, servo transfer bar, servo press ram, and servo wire feed provide controllable motion paths, allowing adjustments for tool temperature, forming speed, and head positioning via the Weintek HMI, ensuring repeatability and precision for brass casings and lead core projectiles.

• Process: Shearing, flattening, pre-forming, final forming for uniform cups
• Outcome: 95% material efficiency, consistent dimensions, minimal waste
• Applications: Brass cups for cartridge cases, lead core bullet jackets

Advanced Servo Drives

The OTM-5100 integrates advanced servo drives, optimized for high-tonnage applications. These drives, paired with PLC controls (with an optional Allen Bradley upgrade), deliver real-time feedback, remote access, and multi-program memory for storing forming parameters. The servo system supports quick-change carbide dies and coated tool steel punches, enabling rapid tooling adjustments for various calibers. The drives’ reliability ensures the press can handle hundreds of millions of cycles, making it ideal for high-volume production of brass and lead core components.

• Features: Precision motion control, customizable programs, durable servo motors
• Benefit: Enhances flexibility and reduces maintenance in demanding environments
• Reliability: Ensures consistent performance for continuous operation

Wire Forming for Ammunition

Wire forming, also known as cold heading in ammunition manufacturing, is a cost-effective method for producing brass cups and lead core projectiles. By feeding continuous brass wire (or lead wire for bullet cores), the OTM-5100 eliminates the need for blanking and stamping, reducing scrap and simplifying tooling. For brass casings, wire forming ensures uniform wall thickness and precise cup geometry, critical for reliable cartridge performance. For lead core projectiles, wire forming creates consistent cores that enhance bullet stability and accuracy. The OTM-5100’s servo-driven cold heading adjusts force and stroke dynamically, optimizing for material properties and reducing tool wear, as noted in industry sources on cold heading for ammunition manufacturing.

• Advantages: Higher yield (95% vs. 75% for strip), lower tooling costs, consistent quality
• Applications: Brass casings (380 ACP to 338 Lapua), lead core bullets for rifles and pistols
• Servo Benefits: Dynamic adjustments for temperature, speed, and head position improve forming precision

Robust Press Design

The OTM-5100 features a 100-ton press capacity with a 3-inch stroke, supported by a full machine enclosure, coolant tank with drain system, and uncoiler with expandable arbor for continuous wire feeding. The interchangeable die sets and carbide dies with coated tool steel punches ensure durability and precision, while the servo transfer bar streamlines material movement. The press’s large footprint accommodates high-volume production, with magnetic door interlocks and 3/8″ polycarbonate guarding ensuring operator safety.

• Components: 100-ton servo ram, coolant system, uncoiler, carbide tooling
• Benefit: Ensures long-term reliability and high-throughput production
• Environment: Sealed coolant system and enclosure minimize mess and maintenance