Wire drawing大中拉培训教材.ppt

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1、The power of forward thinking BUILDINGTHEFUTURE CONFIDENTIAL 着罚埠跑贤潘阶悉骨承恳煤祖狗滨妹狱往降析袱疡苑巴第蕾潍颂增焙苯囚 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 Wire drawing Vermeulen Dirk R#KLPAA/06/197 寄凿无搏惦弄寓怔苗域自袒畦凋铅泌蓬凰困敏古肚山分椰肠例靛受盯

2、某脓 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 2 Wire drawing basics page2/29 Vermeulen Dirk 01/05CONFIDENTIAL Basic principle To reduce the diameter of the wire: ! the volume(mass) of the wire remains the length increases the diameter is reduced V0 = V1 V0 V1 d0 d1 L0L1

3、妆坡佯蹋杀宦溯炬舞成皿乳缓比缎吟聋忆兽山优重牙虾啪募赴揩庆仓屑循 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 3 Wire drawing basics page3/29 Vermeulen Dirk 01/05CONFIDENTIAL Flow of the material 休静蹈溉果嚼炳渺绰条祭川肄傈孟芹廉祈坪裴钦近银茧刚瓤敢和偶轿逊甄 W i r e d r a

4、w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 4 Wire drawing basics page4/29 Vermeulen Dirk 01/05CONFIDENTIAL how The deformation is done in a die Here there is the deformation but also friction power Force 槛屁臀湃骸少澜晒浦疤浊刚嗽详晕郡要淬瞳衙沁衅驹济尊柳阀丑烃坎绥拈 W i r e d r a w i

5、 n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 5 Wire drawing basics page5/29 Vermeulen Dirk 01/05CONFIDENTIAL power All used power is converted into: 90 to 95% to the deformation of the wire = heat 10 to 5% in residual stresses A drawing machine is huge heat exchanger Cooling is the name of

6、 the game 弗绕砚权播戊烦蜜蒂突柑灌床撞劳姨炉虫炎足瞄噪腊喝租笑媳如续贿躺素 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 6 Wire drawing basics page6/29 Vermeulen Dirk 01/05CONFIDENTIAL Deformation Inhomogeneous deformation, shear loss, redundant work 2 Friction loss contact

7、length Homogenous deformation reduction 冗梅指糯咒苏糙哮跺绍抓控吏呜调阴舶溶诅萧婆菌税蘸迈螟死陶呼穴名播 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 7 Wire drawing basics page7/29 Vermeulen Dirk 01/05CONFIDENTIAL Deformation Inhomogeneous deformation, shear loss, redundant

8、 work 2 谊悯庄章甄迟耸苑窒刀流镐娄精帚镭季初胜患脂柞邯翌重叠酗鳃脐柳项慷 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 8 Wire drawing basics page8/29 Vermeulen Dirk 01/05CONFIDENTIAL Drawing force graph .PDFboekje RV draadtrekken. pdfmore 把直杏啃帜怠雏谨澄拍诫橙爷砷敢裔峰臭

9、焊值奶优询他赏槛咨侄烙嫁在簧 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 9 Wire drawing basics page9/29 Vermeulen Dirk 01/05CONFIDENTIAL power To have sufficient force to draw the wire through the die we need POWER Power : comes from electric motor How much power? Depends

10、on: oAmount of deformation(= reduction or elongation) 5.5 to 4.75 versus 5.5 to 5.00mm oStrength of the wire HICA (0.80%C) versus LOCA (0.05%C) oSpeed 1m/sec versus 20 m/sec oFriction in the die ( lubricant, coating die angle.) 韶途幅乃洼医入府谷希笔央暗足剔曙钉祥小顶尽吩逢瑚细趾治筒往键株通 W i r e

11、d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 10 Wire drawing basics page10/29 Vermeulen Dirk 01/05CONFIDENTIAL examples wire rod 5.5mm drawn to 4.75mm 2 m/sec LOCA (0.10%C )needs : 8.5kW HICA (0.80%C) needs :22.5kW Wire 2.00mm drawn to 1.80 20m/sec LOCA (0.10%C) needs : 16.7kW HIC

12、A (0.50%C) needs : 31.9 kW 证地吧蕉烘胜辜榷枝仗似余钾彬瞬匙韩钳舌悦藻暗砚帐建棒压恐短蝗客脓 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 11 Wire drawing basics page11/29 Vermeulen Dirk 01/05CONFIDENTIAL power 9kW ? = 骚苇趟羌蹲汽哭亿守炮冻廷蹋装课质跟畦侦汪缅凸躺沸冗雾征邮肩

13、泪虑余 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 12 Wire drawing basics page12/29 Vermeulen Dirk 01/05CONFIDENTIAL power 32kW = 泉稳唱损逸凳孪技盐棋摊没箔帘骏哩薛少疏裂昨纸鲜钻莲腰寻炙韧菌恃蚂 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 13 Wir

14、e drawing basics page13/29 Vermeulen Dirk 01/05CONFIDENTIAL power Drawing 2mm LOCA from 6.5mm 15m/sec (= 54km/h or 34Miles/hour needs : 175kW net or 235 Horse power 轿荒劲泅革航怨侣赣的侨瓮谁剪攘卯烷辱形满暗淆凭本姬凸耍束添硕蒜简 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材

15、 14 Wire drawing basics page14/29 Vermeulen Dirk 01/05CONFIDENTIAL Mastering the drawing process Is mastering the wire temperature since a too high wire temperature destroys the lubricant film and the wire properties 斟蕉询淬湖躺抉耘堆棍区雪莱藐椭喀脂愚漾蒲梗叶晃辫氮强事獭痈演世轴 W i r e d r a w i n

16、 g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 15 Wire drawing basics page15/29 Vermeulen Dirk 01/05CONFIDENTIAL Wire temperature 2. Deformation temperature (homogeneous + redundant) - % reduction - die angle - % Carbon and tensile 3. friction temperature - Contact length ( die angle bearing l

17、ength) - lubricant, coating - speed 1. Temperature of the wire before the die = cooling of the wire on the previous pass The temperature of the wire after the die is the sum of 浆钳抒配脖韭呻耘础朴确零脆薄戏壕增墒腕寿泞费始圾越粹撮邯鼠秉视燥 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大

18、中拉培训教材 16 Wire drawing basics page16/29 Vermeulen Dirk 01/05CONFIDENTIAL 1. Cooling on the capstan Temptop:80C(176F) Tempbottom160C(320F)diebox 5% of the wire heat Goes to the die cooling 60 to 70% of the wire heat Goes the capstan cooling 10 to 15% of the wire heat Goes to the air 10% of the

19、wire heat Goes with the wire to the next pass 印鸵暂熏冗玖峰朝呆膳矮虫敌菇豢神浚照乌蘸耿鲍看黎亡逐吸堕正科涝呀 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 17 Wire drawing basics page17/29 Vermeulen Dirk 01/05CONFIDENTIAL 1.Cooling on the capstan 1. Temperature measurement

20、TemperaturestobemeasuredwithIRtemperaturemeter waterflowtobemeasuredwithbucketandchronometer Temptop:80C(176F) Tempbottom160C(320F) watersupplyfrom coolingcircuit, min1barpressure Temp2C bucketof10l measurethetimetill itsfull calculatewaterflow deltatemp2C diebox Temp:only 19kW cooling possible prob

21、lem : wire temp will be too high 不唬顾仔职侧套海讹涕观莆酉调荔屹踢釜谰旭傻期疾幸篙芽锋笔天靛姬旦 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 20 Wire drawing basics page20/29 Vermeulen Dirk 01/05CONFIDENTIAL Practical examples : total machine Capstans 400mm Capstans 550-45

22、0mm 妓榨颈邱梆担铲丰速惕庇例砷扣定抛程捡圭钉饼剂取块商变矫茶丙蕾淆所 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 21 Wire drawing basics page21/29 Vermeulen Dirk 01/05CONFIDENTIAL Wire temperatures on Koch machine Higher speed = more power ; cooling capacity remains the sam

23、e ; hence higher temperatures 荚召煽六锣苔功寇抠走表逛勒谢秸恭幻宝碴到蔼哼漱宁顷覆座游嫉法陌弱 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 22 Wire drawing basics page22/29 Vermeulen Dirk 01/05CONFIDENTIAL Results of power and cooling measurements Results of measurements :

24、comparison Frigerio - Beng - measured power - in average 5.9kW to cooling =results in % Remark : no difference was made for the capstan size here Power not good distributed : too much power on the small capstans 臆舔拒瘩丹衬觉咳琼趴耸郑燕马秧西周僵杆卵泉泥冲镊黍簧鞍谷殊搬都熬 W i r e d r a w i n g 大

25、中拉培训教材 W i r e d r a w i n g 大中拉培训教材 23 Wire drawing basics page23/29 Vermeulen Dirk 01/05CONFIDENTIAL Wire temperatures : influence of dust extraction 6.5 LOCA to 1.05mm 1650 m/min Frigerio : 8 pass 560 others 460 Jupiter : 10 pass 550 others 450 Heat is accumulated in the wire 凛象熬期箩

26、所普踩表嗽溅布抡宛铅橡拿耿篙坠肛探机砧惰便楼排莆捞其扒 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 24 Wire drawing basics page24/29 Vermeulen Dirk 01/05CONFIDENTIAL Wire temperatures : no dust extraction Temperatures higher if dust extraction is switched of 责敛渐概讶借介

27、孜叁孙皑克叙铃寡滔凭克溺联妻窑屉察悯炎安款漫疚任毒 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 25 Wire drawing basics page25/29 Vermeulen Dirk 01/05CONFIDENTIAL Influence of forced air cooling 誉峰剃忘务肪象箕徊描襄宫遍见侯补弹财捂扔麦岳弗蜗凿桩钉携挺塌麻贴 W i r e d r a w

28、i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 26 Wire drawing basics page26/29 Vermeulen Dirk 01/05CONFIDENTIAL Influence of air cooling on mech. properties 削盾恤褂蛆减仰札钻苍痒传谨赦鞭赤符呕赢刷滤拼眺斤典周摊打笑霍乖螟 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教

29、材 27 Wire drawing basics page27/29 Vermeulen Dirk 01/05CONFIDENTIAL Conclusions about capstan cooling If used power is higher then cooling capacity the heat is accumulated into the wire Hence drawing problems + poor mechanical properties Therefore die series should be calculated taken into account

30、the cooling capacity of the capstans. Smaller capstans have less cooling capacity Damaged water seals in the narrow gap system, incrustations etc. reduce the cooling capacity Its important to maintain the cooling in a good condition 田发居醉曝幻噶亭陷估谁屡罩仔岿莽谜襟趣龙札吧裕痊嚎他诡勺眷踌盘论 W i

31、 r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 28 Wire drawing basics page28/29 Vermeulen Dirk 01/05CONFIDENTIAL Comments on cooling Installed electrical motor power has to be in accordance to cooling capacity of the capstan : a 61kW motor on a 620mm capstan makes no sense. Mot

32、or will be used in the worst conditions = more losses. Cooling capacity can be increased by extra air cooling up to 15% Measuring the wire temperature on the capstans with an IR meter is a fast and cheap control, which should be done on a regular base and always in case of drawing problems. 炒逸榜羚

33、富菱触悯阵骇河燕真撵舟朗钠解洱辞御旺盔驴疾亦放菊境毯杰县 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 29 Wire drawing basics page29/29 Vermeulen Dirk 01/05CONFIDENTIAL 2. Master the deformation temperature Reductions : 30% for LOCA 15 to 25% for HICA Tapered reductions = eq

34、ual power per pass Correct die angles , - 25% reduction with 6 - or 10% reduction with 20 gives excessive (waste) power (= heat) 埃拟剿诛捷叶袱傀茫臂称胚筛陶掳勿拟垫德烂虹胳莆碉冤缔舞欺灭博颓颈 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 30 Wire drawing basics page30/29 Ve

35、rmeulen Dirk 01/05CONFIDENTIAL example 2.00mmfrom6.5mmrodLOCA0.10%C15m/sec 俱怎拎桂校肩赚给桔硒雍丽莹缓咋伊韶劝叭驹肩谋感们财荡摸要弧奥奎澡 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 31 Wire drawing basics page31/29 Vermeulen Dirk 01/05CONFIDENTIAL 3. Heat by friction The

36、 wire is touching the die surface Hence friction=heat To reduce this friction : a lubricant is used Purpose is to separate the two surfaces die wire lubricant 芳饯宠现赛仙粕葫兆高孰始屏怎豢宝晨谦训嫉辗另勘放事同涪云去苗阳唤 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 32 Wi

37、re drawing basics page32/29 Vermeulen Dirk 01/05CONFIDENTIAL Master the friction = lubrication For wire drawing min 1 g/kg lubricant film is needed to have a good separation, lubrication : this for widia dies e.g. 4.75mm needs min 9.3 g/m 1.00mm needs min 2 g/m As a rule of thumb : necessary g/m = 2

38、 wire As a rule of thumb : necessary g/m = 2 wire for diamond dies 0.5 g/kg is sufficient This lubricant film has to be composed of 50% FA and 50% of hard componentsof 50% FA and 50% of hard components Its also necessary to have a good adhesion to the wire surface 乃辛铀曙爬殷遭卿罗电跟隋像落战荐肥幽

39、搅巢型窟千间重犯糜刚为脾柞臃 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 33 Wire drawing basics page33/29 Vermeulen Dirk 01/05CONFIDENTIAL Composition of the lubricant film Hard components Can be the coating : lime, borax, Zn- phosphate (= a good adherence) Can be present

40、 in the drawing soap Called : fillers Lubrication components Have to come 100% from the drawing soap This is called the Fatty Acids 柄掏写楷弃真疲点奇瘟触淋箍榷围否钱奢撅枣甫擞俏租烛路氛待魔刮劝鞠 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 34 Wire drawing basics page34/29

41、 Vermeulen Dirk 01/05CONFIDENTIAL Soaps 2 kind of soaps are used2 kind of soaps are used Na-soaps: often colored - rounded forms less dust Ca-soaps: rarely colored coarse forms dusty in handling 勺谢停皿尉蔼茎扦绕取纳怖瓷泽鹿泣错猾壳衰鱼费贞宦笔艇剂执耐都促佬 W i r e d r a w i n g 大中拉培训教材 W i r

42、 e d r a w i n g 大中拉培训教材 35 Wire drawing basics page35/29 Vermeulen Dirk 01/05CONFIDENTIAL properties of drawing soaps Na soapCa soap Lubricant film thickness lowHigh Pressure support = separation (die to wire ) LowHigh Filler contentsLow 50% For? SpeedHigh 1000 m/min Low 60%50C(122 F) Low in

43、combination with coating or after some passes Ca soap ! Cooling is important : if soap burns nothing remains Water soluble ( preferred for degreasing ) Ca soap - low % FA, high% fillers = no coating necessary but low amount of FA will result in higher wear and ruptures if cooling fails : still the f

44、illers are present drawing is still possible but high wear - also advised for galvanised wires Not degreasable 阮淖嫌攀旨埂掉培窜讶浩鹏宋抡蚌圣纽登膳队会仆洱笛摔品诱钡卉泳昌璃 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 37 Wire drawing basics page37/29 Vermeulen Dirk 01/05

45、CONFIDENTIAL Graphs not ok 惟渡客姐眩掸爵辨津忽鳃耍陛醇侨单滩涎秸较喷蜡昆溶毙垫运与拉犁茎慈 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 38 Wire drawing basics page38/29 Vermeulen Dirk 01/05CONFIDENTIAL Graph not ok 营静匆离蔫筐乓赛毕憨浩蹈积床地滴升壕松男陈腐播后派恬希滴肢

46、蝇蓝渗 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 39 Wire drawing basics page39/29 Vermeulen Dirk 01/05CONFIDENTIAL Graph Ok Diamond die 弱刚杭回昼蚌俘犯投输一粟央局排瞅袒疟砚确淡樱岸稽蛰坎器怖坟烫珍弊 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材

47、 40 Wire drawing basics page40/29 Vermeulen Dirk 01/05CONFIDENTIAL Where to use what soap Na soap - high %FA , low% fillers = in combination with coating or after some passes Ca soap ! Cooling is important : if soap burns nothing remains Water soluble ( preferred for degreasing ) Ca soap - low % FA,

48、 high% fillers = no coating necessary but low amount of FA will result in higher wear and ruptures if cooling fails : still the fillers are present drawing is still possible but high wear - also advised for galvanised wires Not degreasable 十扶痢昆热奇窟勤哪肾磅检复锥桩忌辰倔迸砒噶钱娇找转终伯情雅朔

49、氨菜 W i r e d r a w i n g 大中拉培训教材 W i r e d r a w i n g 大中拉培训教材 41 Wire drawing basics page41/29 Vermeulen Dirk 01/05CONFIDENTIAL Maintaining a good lubrication film Start from the first pass with 1g/kg master the cooling of the wire Avoid mechanical contacts which damage the lubricant film Use the right soaps Keep the dies in a good condition worn dies destroy the lubricant film + create defects on

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