WIRE
DRAWING
SIR ABDUL QADIR
MANUFACTURING TECHNOLOGY
AYESHA RIAZ ( D-1 9 /F - MME- 5 7)
INTRODUCTIO
N
Wire drawing is a metal processing process. In
metal
pressure processing. Under the action of external force
to force the metal through the die, the metal cross-
sectional area is compressed, and to obtain the
required cross- sectional area shape and size of the
technical processing method, called the metal wire
drawing process. A tool that changes the shape of
a metal surface and its dimensions is called a wire
drawing die .
CONSTRUCTION OF WIRE DRAWING
DIE Modern dies are made out of
tungsten
carbide, ceramic, diamond or hard alloy.
A cross-section of tungsten carbide die
consists of a tungsten carbide nib imbedded
in a casing made out of medium carbon
steel. The dimensions of nib and casing are
standardized for standard wire diameters.
Tungsten carbide dies are used for
drawing wires of small, medium and large
size, for large diameter wires hard steel
alloy dies are also used.
PREPARATION OF STEEL WIRE ROD FOR
DRAWING
For manufacture of steel wires, the
raw material is the wire rod which is a hot
rolled bar. The wire rod has hard oxide
layer or scale on its surface, which must be
removed, because otherwise, the abrasive
scale will decrease die life as well as
damage the surface quality of drawn wire.
METHOD EMPLOYED FOR REMOVAL OF
SCALE
The following methods are employed for removal of scale:
(i) Chemical reaction with dilute hydrochloric or sulfuric
acid.
(ii) Mechanical methods which are given below:
(a) Shot blasting.
(b) Loosening the scale by bending over pulleys followed by
brushing.
CHEMICAL REACTION
The disadvantage associated with this method
is that along with scale the metal is also attacked
by acid. The reaction releases nascent
hydrogen some of which gets absorbed by the
material of wire resulting in making the wire
material brittle . And secondly, the wire surface
may get pitted by reaction of acid, which spoils
the surface quality of drawn wire .
MECHANICAL
The mechanical methods consist of loosening the
scale followed by:
Brushing or shot blasting: which has to be carried out
in different planes so that scale is removed all around
the circumference. These methods do not have
the disadvantages of pitting and hydrogen
embrittlement. But in spite of all the care in
mechanical methods, some specks of scale are left on
the wire surface, which get into the die and
increase die wear. After scale removal the wire is
prepared for lubrication.
LUBRICATION IN WIRE
DRAWING
LUBRICATION IN WIRE DRAWING
1. Wet drawing: the dies and wire or rod are completely immersed in lubricants
2. Dry drawing: the wire or rod passes through a container of lubricant which coats
the surface of the wire or rod
3. Metal coating: the wire or rod is coated with a soft metal which acts as a solid lubricant.
4. Ultrasonic vibration: the dies and mandrels are vibrated, which helps to reduce forces and
allow larger reductions per pass
5. Roller die Drawing (also referred as Roll drawing): roller dies are used instead of fixed
dies to convert shear friction to rolling friction with dramatic reduction in the drawing
forces as reported by Lambiase . When roller dies are adopted, the drawing
stages are composed by 2-4 idle rolls and the wire is pulled within the rolls clearance.
This type of solution can be easily adopted also to produce flat or profiled drawn wires.
Wire drawing
machinery
Draw Drum Bench
Bench
Large diameter Small
wires and diameter
straight bars wires which
are generally can be wound
drawn on are drawn
DRAW BENCH
MACHINERY
Draw benches and drawing machines use
tensile forces to reduce the size of metal
sheets, wire, tubes, and rods by drawing
metal strips through a drawplate or dies.
Metal draw benches and drawing
machines can be used to form ductile
materials, including aluminum, copper,
nickel, mild steel, stainless steel, and
magnesium.
DRAW BENCH
MACHINERY
Wire draw benches
and drawing machines
draw stock through a
die mounted on the
draw bench to
reduce the diameter
and increase the length.
The end of the work-
piece is placed in grips
and the rest is pulled
through the die of the
draw bench or drawing
machine .
DRUM BENCH
MACHINERY
The rotation of circular drum or block on
which the wire is wound pulls the
wire through the die . The draw
blocks are slightly tapered toward top
so that the wire loops may slip along as
the new loop is wound at the bottom of
the drum. The drawn wire is taken off
from
of thethe top It
drum. endmay be fed to another
die and drum placed in succession.
DRUM BENCH MACHINERY
A wire drawing machine may have one or more draw blocks. In high speed wire
drawing,
the wire gets quite hot and contact of wire with the metal drum helps in cooling
the
wire. Double drums are sometimes used to increase contact time in order to cool
the wire. Besides, other cooling devices may also be used.
