In the metal processing process, by using external force to allow the carbon steel and stainless steel copper, aluminum and other metals go through cutting dies for drawing, their cross-section gets drawn to the required shape and size. This is the most common drawing method.
Drawing process may be classified in two types: dry and wet based on the various tools and lubricants utilized. The most common problems and solutions to wet drawing.
The first thing to note is that the choice of the wet drawing process is usually geared towards small diameters, or the surface finish or metal drawing that has particular requirements for processing technology.
The most common kinds of lubricants for wet drawing include pure oil, synthetic oil, emulsions or paste, and so on.
The choice of a the lubricant for ND Drawing Dies is determined by the thorough analysis of the raw material and mold quality, as well as the surface along with downstream use.
For instance, when it comes to stainless steel drawing pure oil that has high viscosity and specially extreme pressure additives are typically selected. In the case of carbon steel, emulsions are typically used. In the case of non-ferrous metals like copper, pure oil as well as synthetic oils or emulsions may be chosen based on the requirements of the final application. There are specific requirements that can be met by selecting paste.
What kind of issues could arise during the process of drawing metal wire?
In general, during the actual drawing process, whether it's a dry drawing or a wet drawing, there will be a myriad of issues. Let's look at the most common issues encountered in Wet Drawing as well as the solutions that are available:
Coloration in wires: discoloration of the surface caused by copper wire (such such as that of copper) is mostly oxidation discoloration that is caused by inadequate humidity and temperature conditions. It could be due to the concentration of the emulsion is not sufficient or the temperature is too high; or, too many oils are attached to the wire, or the water quality is not a good one; mixing of products from foreign oils and other oil products. To determine the cause of the discoloration, we should make the appropriate adjustments based on the situation. For instance, if the concentration of the emulsion is not sufficient the concentration will be increased to normal levels; When the temperature appears to be not normal then it needs to be adjusted to 35-45 degrees; Inspect whether there is a wire that is drawing oil overflow from the outlet. Then, remove the foreign oil in the emulsion.
Die wear is substantial: The main reason that cause large losses in die is the incorrect working of the machine, and the other reason is the incorrect choice of the lubricant. If the machine fails to operate properly, the operator should be practicing continuously and verify its operation prior to every operation. Lubricant also is a crucial element in assisting and encouraging the process of drawing wires and its choice is crucial. Today, drawing tools made from contact are highly appreciated by numerous companies. On one hand, it offers an extensive range of products, which cover the entire drawing process; on another hand a vial? A representative lubricant that has the benefits of speedy drawing speed, excellent chemical compatibility, no tendency to break wire, and the like, can increase the life span for the mould. In addition, Condat can also customize solutions for lubrication, that are leading the industry of wire drawing.
Broken wire, scratches and burr Broken wire as well as burr and scratching can greatly impact the appearance and the quality of the products. The reason for these issues could be due to contamination of the metal chips, blockage of the die hole, or alteration of the lubricant caused by the direct contact between the metal and die because of insufficient lubrication. The solution to these issues is by filtering equipment that can remove the metal chips, clear the blockage , and then change the oil. For more info about dies for drawing wire, Visit here: www.szwiredie.com
Emulsion delamination and high levels of surface precipitates Invasion of microorganisms, low pH extremely high hardness, and inorganic salts in liquid preparation water, high temperatures of the emulsion can cause stratification or precipitation that is excessive over the entire surface the wire rod. The solutions must be directed. If the problem is caused by microorganisms that are invading, fungicides may be added as well as sodium hydroxide or trimethylamine alcohol could be added. If the pH is too low either trimethylamine or sodium hydroxide solutions must be added. If the hardness and the inorganic salts of the liquid preparation are excessively large, then the liquid used for liquid preparation must be replaced. If the temperature of the emulsion is too high, it requires to be chilled moderately prior to the use.