Wire Drawing Machine Research Articles

Predictive maintenance for wire drawing machine using MiniRocket and GA-based ensemble method

Predictive maintenance for wire drawing machine using MiniRocket and GA-based ensemble method

Processing and Properties of Single-Crystal Copper Wire.

The effects of drawing parameters and annealing process on the properties and microstructure of single crystal copper wire are studied using a wire-drawing machine, heat-treatment equipment, microcomputer-controlled electronic universal tester, resistance tester, and scanning electron microscope. The results show that, after drawing the single-crystal copper wire with a single-pass deformation of 14%, the grains elongate along the tensile direction, tensile strength increases from 500.83 MPa to 615.5 Mpa, and resistivity changes from 1.745 × 10-8 Ω·m to 1.732 × 10-8 Ω·m. After drawing at a drawing rate of 500 m/min, the degree of grain refinement increases and tensile strength increases from 615.5 Mpa to 660.26 Mpa. When a copper wire of Φ0.08 mm is annealed, its tensile strength decreases from 660.26 Mpa to 224.7 Mpa, and elongation increases from 1.494% to 19.87% when the annealing temperature increases to 400 °C. When the annealing temperature increases to 550 °C, the tensile strength and elongation decrease to 214.4 MPa and 12.18%, respectively.

Study on the Effect of Cold Deformation and Heat Treatment on the Properties of Cu-Ag Alloy Wire.

The effects of various drawing parameters and annealing processes on the structure and properties of Cu-Ag wires, containing 1 wt% silver, were investigated using specialized equipment including fine wire-drawing machines, very fine wire-drawing machines, heat treatment equipment, tensile testing machines, microcomputer-controlled electronic universal testers, resistance testers, and scanning electron microscopes. The results revealed that continuous drawing of Cu-1%Ag alloy wires led to elongation of the grains, resulting in a uniform and tightly fibrous microstructure. Moreover, the tensile strength of the alloy wire increased from 670 MPa to 783.9 MPa after a single pass with a deformation of 14%. Subsequently, when the wire was drawn at a speed of 500 m/min, the tensile strength further increased to 820.1 MPa. After annealing the Փ0.08 mm Cu-1% Ag alloy wire, an increase in annealing temperature up to 500 °C resulted in the wire's tensile strength decreasing from 820.1 MPa to 377.5 MPa. Simultaneously, the elongation increased from 1.94% to 15.21%, and the resistivity decreased from 1.931 × 10-8 Ω·m to 1.723 × 10-8 Ω·m. Additionally, when annealing was conducted at a rate of 80 m/min, the wire resistivity dropped to 1.635 × 10-8 Ω·m.

Fabrication of wire drawing machine

Wire drawing is a metal working process used to reduce the cross-section of a wire by pulling the wire through a single, or series of, drawing dies. There are many applications for wire drawing, including electrical wiring, cables, tension loaded structural components, springs, paper clips, spokes for wheels, and stringed musical instruments. Although similar in process, drawing is different from extrusion, because in drawing the wire is pulled, rather than pushed, through the die. Drawing is usually performed at room temperature, thus classified as a cold working process, but it may be performed at elevated temperatures for large wires to reduce forces. The main objective of this project is to Fabrication of Wire Drawing Machine for reducing the silver and gold wire diameter.

Analysis of hazards and risks in drawing machines

This work aims to identify the degree of risks based on the dangers to which wire drawing machine operators are exposed. An evaluation is also carried out with the purpose of reducing accidents when workers operate this type of machine. The methodology used for this analysis is carried out using a tool called Operation, Risks Corrective Actions (ORCA). This type of tool is a format implemented by the company and compatible with most of the risks that may exist in each area that makes up the company. Carrying out this risk and hazard analysis will help control and prevent accidents, help implement and improve safety protocols, as well as improve learning to carry out efficient control in preventing accidents that could occur. present and identify the level of risk.

Optimization of wet drawing according to the ratio of breaking stress to draw stress

The paper continues the previous authors’ works in the field of wet wire drawing. The process of wet fine brass-plated steel wire drawing is considered. The subject of the paper is increase of the wire die wearability. The analysis of various wire drawing tools (hard alloy dies, synthetic diamond dies, natural diamond dies) was carried out for the relevance of its application for small diameter wire drawing. The authors studied the wire die wearability. The research methodology is presented, which include the procedure and conditions for measurements, industrial equipment and type of wire drawing machine. In the paper, the comparative analysis of the experimental data with the results of other authors for similar wire drawing tool was carried out. The authors calculated the main characteristics of the wire die wearability distribution (asymmetry, kurtosis, coefficient of variation). A statistical analysis of the array of experimental data for selection of more than 500 samples was performed. A high correlation of the drawing die wearability with the ratio of breaking stress to draw stress and a weak correlation with the drawing force and stress were revealed. The highest and most stable die life results are achieved when ratio of breaking stress to draw stress has values of 1.9 – 2.5. A formula was proposed for determining the optimal value of the ratio of breaking stress to draw stress, depending on the wire diameter. The formula allows one to determine the maximum die wearability values, depending on the wire drawing schedule. The work results can be used when designing new wet wire drawing schedules using synthetic diamond dies.

Effect of strong flexible polycrystalline diamond abrasive tools in magnetic abrasive finishing of V-grooved ceramic guide rollers

The V-grooved ceramic guide roller, employed in textile cable machines, wire drawing machines, and copper wire guiding machines, is one of the most critical components used in the winding industry. The components used in this industry must have specific properties, such as an ultra-smooth surface and high-precision roundness, to reduce wear and friction. However, achieving both a high-precision roundness and a smooth surface with general machining processes is extremely difficult due to the high degree of hardness and inherent brittleness of ceramic rollers with a complex V-grooved shape. In this work, a novel device for magnetic abrasive finishing (MAF) process was designed to smooth the V-grooved surface of ceramic guide rollers. In addition, the strong flexible polycrystalline diamond (PCD) abrasive tools were used to achieve a high level of precision and accuracy during the MAF process. It was found that a newly developed experimental device of MAF process using strong flexible PCD abrasive tools could produce a V-grooved ceramic guide roller with a low surface roughness (Ra) of 0.03 µm and a high-precision roundness of 0.33 µm after 8 min of finishing.

Features of diseases of the musculoskeletal and peripheral nervous systems in workers of metallurgical production in modern conditions

Manufacturing industries, including metallurgy, are the backbone of the country’s economy. A number of technological operations involve the impact of physical overload, heating microclimate, static load, and often entails the development of diseases of the musculoskeletal and peripheral nervous systems. The clinical picture of such patients is dominated by pain in various parts of the spinal column, in some cases, combined localization. The analysis of the results of the examination of the connection of diseases of the musculoskeletal and peripheral nervous systems with the profession, carried out by employees of a large metallurgical enterprise of the Republic of Bashkortostan (RB), using the archival material of the FBUN clinic «Ufa Research Institute of Occupational Medicine and Human Ecology» was carried out. The group of the main professions of the enterprise includes: wire drawing machine, wire rewinder, caliper, pyrometrist, laboratory assistant for physical and mechanical tests, automatic machine for cold landing machines, mechanic-repairman, sorter-delivery of metal. During the analyzed period, in 117 cases, the workers of the enterprise confirmed the professional etiology of the disease. The nosological structure in 60 % of cases of the first established occupational diseases is represented by diseases of the musculoskeletal system and connective tissue. A significant part of diseases of occupational etiology was detected in persons aged 50 to 59 years. Workers of the studied professional groups are at the highest risk of developing diseases of the musculoskeletal and peripheral nervous systems of professional etiology, which is due to the specific conditions of their professional activity. Establishing a connection between the disease and the profession is characterized by late detection, at the stage of pronounced clinical symptoms with the formation of persistent disability.

Annealer curve characteristics of electrolytically refined tough pitch copper (Cu-ETP) and oxygen free up-cast copper (Cu-OF) for electrical cable wires

Annealing is a critical step during the wire drawing of copper to produce wires with the required ductility and conductivity for electrical applications. In this investigation, the characteristics of commercial annealers for wire drawing of electrolytically refined tough-pitch copper (Cu-ETP) and oxygen-free upcast copper (Cu-OF) wires were assessed through annealer curves with respect to applied voltage and resulting percentage elongation of final products. Experiments were carried out on three M315 Niehoff machines of varying speeds used for medium wire drawing from 2.2 ​mm diameter to 0.66 ​mm and 0.53 ​mm diameters. The results show similarities and differences between annealer curve characteristics of wire drawing machines regarding the required voltage for minimum and maximum elongation of wires without oxidation depending on the type of copper raw material used. In particular, the minimum 18% required elongation of wires was achieved with the same applied voltage irrespective of the machine speed and type of copper. In addition, Cu-OF reached higher maximum percentage elongation without oxidation of the wire compared to Cu-ETP.

Fracture Reduction in Steel Cord Manufacturing Process

Improve quality and productivity performance of a steel cord manufacturing system. The most importuned material of steel cord for tyre manufacturing process and that steel cord have good mechanical properties of high breaking strength, and low thermal coefficient of expansion as compared to nylon. Process for producing a Steel cord for pneumatic tires comprising a bunch of wires and core, the core of which consists of 3wire filaments arranged and bunched together in parallel. Then 6 wire (filament) on Core twisted and bunched in together. While processing on steel cord we faced wire fracture frequently like torsional fracture, power fracture, one filament fracture, entanglement fracture bad winding issue due to interrupted power and improper clamping of spool (wire Bobbin) and machine vibration. In this project have modified to Spool shaft on wire drawing machine. In this shaft, locking position and changed that shaft design. That shaft was reduced the spool wobbling while running on machine. In bunching machine, the circuit have power circuit-1, power circuit-2, control circuit, and commend circuit. The command and control circuits connected by uninterrupted power and power circuits connected with normal power (EB power). When power the cut-off, command and control circuit switchover to uninterrupted power, and it lead to smooth stop in machine. Thus, the changes have leads to reduce the fracture in cord manufacturing process.

Prediction of Hardness in Drawn Copper Wire by Effective Strain from Finite Element Simulation

The study developed a hardness-strain reference curve to be used with the finite element simulation for the prediction of the hardness in the drawn copper wire. The hardness values of the deformed copper specimens from tensile tests were analyzed to construct a relationship between hardness and strain. By using an industrial wire drawing machine, a copper wire was drawn by 5 passes to reduce its diameter from 8 to 4.64 mm. All drawing dies used the same configurations which include an area reduction ratio of 20 percent, an approach angle of 7°, and a bearing length of 0.5 times the feeding wire diameter. The finite element simulations of the wire drawing processes were also performed to predict the effective strains in the drawn copper wires. With the use of the developed hardness-strain curve, the hardness of the drawn wires can be estimated. The results show that the difference between the predicted and measured hardness values is about 10 percent lower in the early stage of the wire drawing process, and the difference increases with the number of passes to about 30 percent higher in the later stage of the process.

Medium carbon fully pearlitic steel: microstructures and properties after wire drawing

ABSTRACTIn the current work, fully pearlitic microstructure was initially developed in a medium carbon steel by isothermal holding at different temperatures. Subsequently, these samples were drawn in laboratory scale wire-drawing machine without any intermediate heat treatment. Microstructures and mechanical properties of as-heat-treated and heat-treated plus drawn samples were characterised. The results were also compared with some commercially produced steel. It was found that the new steel can offer a very good wire drawing behaviour. The steel possesses a good combination of strength and ductility along with a high-value torsion, bending and reverse bending properties after drawn condition as well.

Studies of Influence of Process Parameters on the Strain Rate at High-Speed Wire Drawing

This article presents the results of the effect of drawing speed on the strain rate and resistance to plastic deformation. The wire drawing on modern high speed wire drawing machines significantly increases the required amount of drawing dies. The influence of the technological parameters: speed drawing, half-angle of the die, wire diameter and a single strain on the rate of deformation of the metal. The influence of the technological parameters: speed drawing, half-angle of the die, wire diameter and a single strain on the rate of deformation of the metal. It is found that increasing the resistance to drawing dies and achieve passport velocities drawing, when selecting process parameters drawing guided by the principle of uniform strain over the cross section of the wire by matching the single strain with half-angle dies and friction coefficient on the formula given in the article.

The mechanism of oxide film formation for drawing titanium

Abstract This paper reviews the theories and models of oxide film formation on the surface of titanium. The oxide film plays the role of a sub-lubricating layer that prevents the treated metal from sticking to the tool and holds lubricant on its surface. The production of titanium wire is produced on wire-drawing machines and one of the features of titanium processing is its tendency to stick to the fiber. The study of the mechanism of oxide film formation allows to choose the electrolyte and anodizing parameters (temperature, anodizing time, voltage and current density), which provide an increase in the quality of the finished product.

ノンスリップ型湿式伸線機における張力制御技術

ノンスリップ型湿式伸線機における張力制御技術

Experimental Measurements of System Dynamics Between Two Stages of Wire Drawing Machine

Abstract In multi-stage wire drawing machines productivity growth can be achieved at higher drawing speeds by preventing wire breakage during the process. One disadvantage of high-speed wire drawing is the requirement imposed by machine dynamics in terms of its stability and reliability during operation. Tensile forces in the wire must maintained by fast synchronization of all capstans speed. In this process, the displacement sensors play the main role in providing the control system with feedback information about the wire condition. In this study, the influences between the sensors and actuator driven capstans have been studied, and tuner roll concept of a wire drawing machine was experimentally investigated. To this aim, measurements were carried out on two drawing stages at different drawing speeds and obtained results were presented. These results clearly show the fast changes of the capstans speed and the angular displacements of the rollers that tighten the wire, which only confirms the high dynamics of the wire drawing machine.

Proposed Solution for Random Characteristics of Aluminium Alloy Wire Rods Due to the Natural Aging

In the last 50 years in the worldwide market for power transmission cables, there has been a tendency to replace aluminium cables electrical grade (EC) with steel cables by fully aluminium alloy (AAAC). The advantage in using cable AAAC is mainly economic (least amount of support structures and maintenance), addition to the elimination of the problems of galvanic corrosion and improved abrasion resistance. In order to obtain better mechanical properties, respect to the pure aluminium, aluminium alloyed with magnesium and silicon (AA6XXX series) is used, which by a combination of cold working and heat treatment allows obtaining greater mechanical strength without affecting too much the electrical conductivity. In this development it has worked with AA6101/6101M alloy. The manufacturing of aluminium alloy wire rods for such applications, using the conventional process Properzi, requires heat treatment of solubilized, continuous or discontinuous (batch). During the waiting time of two months or more, the wire coils are exposed to natural aging at room temperature, entering into the wiredrawing machines with different mechanical properties. The wires obtained by the traditional method of manufacture in Argentina, through the wiredrawing, result in significantly higher mechanical properties, not complying with the standards. Furthermore many breaks occur mainly when a high tensile strength wire is processed for wire 2mm in diameter or less. In the proposed method, a part of the initial wiredrawing is replaced by cold rolling and a subsequent partial aging. The results obtained in this study allow us to conclude that in the proposed process better properties and mechanical integrity are achieved than the traditional process, maintaining the electrical conductivity.

Системы управления электроприводами прямоточных волочильных станов: анализ достоинств и недостатков

The analysis of the control systems for straight-through drawing machine with different power supply circuits of the drive motors has been made. It is shown that the main task of the feasibility of the process of drawing – equality-second volume of metal passing per unit of time at each section of the drawing machine is solved either by means of mechanization or via an electric drive and automation tools. The matter has been settled through mechanization at sliding and magazine-type machines. In them, with installation of the simplest systems of unregulated electric drive, the problem is solved in the first case through wire slip on drawing capstans, in the second case – the use of special driver devices. However, such wire drawing machines have significant drawbacks: higher energy costs, low productivity. At straight-through drawing machines the process reliability question has been solved by an automated electric drive. Wire at such machines from the capstan is directed into a die and then to the next capstan without slipping on the capstan or additional bends and twists. In practice for drawing machine’s electric driving, systems with series, parallel and individual drive motor power supply are used. The analysis of schemes with a serial connection of motor armatures revealed possibility of providing self-drawing process, namely invariance countertension speed drawing. But we have found that the deviation countertension substantially influenced the change in resistance and wire deformation conditions in the portage , and due to the different mechanical inertia blocks — acceleration and deceleration of the machine. The errors in the regulation countertension reach unacceptable according to the technological requirements of units. In the case of circuits with parallel motor armature self-drawing process is absent and no specially organized every countertension management systems essentially depends on the motor voltage. Studies of various design options of electric control systems (indirect regulation, countertension sensors, pressure of metal on a die and tension) showed that the best performance can be achieved in the application of automatic control systems, acting as a compensation system abnormalities, leading to breakage of the wire. However, experimental studies have shown that the error in the regulation countertension in any system with parallel connection of the motor armature is also greater than the maximum allowed. Undoubtedly, higher quality indicators drawing process control is achieved with the use of electric drive systems with individual power motors. In such systems, a given drawing speed accuracy and the amount of force countertension provided with closed automated electric control systems. Errors in the regulation of technological origin does not exceed the maximum allowable values, while drawing speed is 5 times or more higher than the maximum achievable on machines with other power supply circuits of motors.

Аналитические исследования влияния технологических параметров на скорость деформации при высокоскоростном волочении проволоки

This article presents the results of the effect of drawing speed on the rate of deformation and resistance to plastic deformation. When wire drawing on modern high speed wire drawing machines significantly increases the required amount of drawing dies. The influence of the technological parameters: speed drawing, half-angle of the die, wire diameter and a single strain on the rate of deformation of the metal. The influence of the technological parameters: speed drawing, half-angle of the die, wire diameter and a single strain on the rate of deformation of the metal. Found that increasing the resistance to drawing dies and achieve passport velocities drawing, when selecting process parameters drawing guided by the principle of uniform strain over the cross section of the wire by matching the single strain with half-angle dies and friction coefficient on the formula given in the article.

Failure Analysis of Tower Axle in the Wet Drawing Machine

The paper presents a failure analysis of tower axle in the water tank wire drawing machine. Material of the tower axle is 40Cr steel. In order to analyze the failure reasons of tower axle in the water tank wire drawing machine, we take experimental means such as morphological analysis, mechanical property testing, micro-metallography and scanning electron microscopy (SEM) of fracture observation, etc. The results show that the fracture of tower axle belongs to brittle fracture. The content of inclusions is more, and the composition is complex in the material. The heat treatment technology is improper. Improper quenched and tempered processing technologies cause more reticular and blocky ferrite in the steel. These are the main reasons for fracture of the tower axle.