The most common methods for wire drawing mold matching are as follows: 1. The absolute sliding coefficient matching method (j method) is applied. The application basis is that the
Wire Drawing Machine continuously pulls wires, and the volume of the wire per unit time is equal on each tower wheel. 2. The traditional theoretical mold matching method (C-method mold matching) used to define symbols starting from the incoming line. For the convenience of computer calculation (using Excel spreadsheet), the opposite is true, starting from the export mold. 3. The new theoretical mold matching method (X-method mold matching) is based on the application of safe (continuous line) and smooth (continuous) wire drawing, while also minimizing sliding. The three mold matching methods have their own characteristics. C method does not have strict requirements for equipment and molds; The x method and j method have high requirements for equipment accuracy, strict requirements for mold tolerance, and high requirements for the operator's operational level. The combination of x method and series of mold sets can achieve better results
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Summary: Drawing die matching is the process of determining the drawing pass, drawing die hole size, and shape based on the size of the billet and wire during metal wire drawing, also known as the development of drawing procedures or drawing routes. It can be divided into single pass wire drawing and multi pass wire drawing. The main steps of wire drawing and mold matching include the following four steps: 1. Select the blank; 2. Determine the number of intermediate annealing times; 3. Determine the elongation coefficient of the drawing pass and distribution pass; 4. Mold matching verification. The article specifically introduces the steps and calculation methods for wire drawing and mold matching in two cases: circular section metal drawing and irregular section metal drawing.
2. Introduction to the principle and calculation examples of sliding wire drawing machine mold matching
Summary: Drawing die matching refers to the method of selecting each drawing die during the drawing process. There are two key points to a reasonable mold configuration, one is mechanical; The sliding wire drawing machine has a fixed wire drawing wheel speed ratio. Through the calculation example of the actual moving wire drawing machine mold, the relevant data for pulling 7.2mm copper rod to 1.6mm copper wire is calculated;
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Written in front: There are many methods for wire drawing and mold matching, which can easily cause confusion, and the most fundamental one is the value problem of the sliding coefficient. What are the advantages and disadvantages of taking a bigger one, and what are the advantages and disadvantages of taking a smaller one? Once you understand, you will be able to handle your work with ease. It is impossible to achieve a certain point in practice. It's not just a simple calculation, just use a formula to calculate it. If your factory has 50 machines. If drawing 6 or more specifications of wire, and following a certain formula to die, consider the minimum number of molds to be equipped. After the wire drawing mold is completed, it is necessary to estimate which mold may cause wire breakage. Which mold will shrink the thread. To estimate the reason for the wire breakage, do not just make a copper rod hollow. In fact, more than 70% of the hollow copper and wire breakage are caused by self drawing.
There are three most common methods for matching wire drawing molds:
1. The application of the absolute sliding coefficient mold matching method (j method) is based on the continuous wire drawing of the wire drawing machine, and the volume of the wire per unit time is equal on each tower wheel.
2. The traditional theoretical mold matching method (C-method mold matching) used to define symbols starting from the inlet line. Here, for the convenience of computer calculation (using execl spreadsheets), the opposite is to start from the outlet mold
3. New theoretical mold matching method (x method mold matching), application basis: that is, safe (continuous line) and smooth (continuous line) drawing, while minimizing sliding. Each of the three mold matching methods has its own characteristics. The c method does not have strict requirements for equipment and molds; The x method and j method have high requirements for equipment accuracy, strict requirements for mold tolerance, and high requirements for the operator's operational level. The combination of x method and series of mold sets can achieve better results
Below is a specific introduction to these three mold matching methods:
1. Application of absolute sliding coefficient matching method (j method)
Application basis: The wire drawing machine continuously pulls wires, and the volume of the wire per unit time is equal on each tower wheel.
U1 * s1=un * sn (u1: speed of wire on the constant speed wheel, s1: cross-sectional area of wire on the constant speed wheel)
that
τ N=vn/un
Un=vn/tn, u1=v1
Assuming: Absolute speed ratio kn=v1/vn
Safety sliding coefficient τ 2= τ 2; The rest τ 3= τ 2+0.001 τ N= τ N-1+0.001
a. Determine the mechanical parameters of the wire drawing machine:
Each type of wire drawing machine manual has equipment parameters, mechanical elongation (or different names), which is the ratio of adjacent tower wheel growth of the wire drawing machine. Some manuals have instructions for calculation. The growth rate ratio of the lh-280/17 wire drawing machine is:
1.20:1, (last line: 1.15:1).
b. Sliding coefficient:
1. Safety sliding coefficient τ 2= τ 2=(1.2/1.15) * 1.005=1.049
two τ 3- τ N takes: τ 3= τ 2+0.001 τ N= τ N-1+0.001 (leave relative sliding amount during threading)
c. Determine the specifications of the incoming and outgoing lines: incoming line: 2.80; Outgoing line: 1.00
d. Mold configuration calculation:
1. Assuming v1=1000 for the fixed speed wheel, calculate vn by using the growth rate ratio of adjacent tower wheels
2. Calculate kn by using the absolute speed ratio kn=v1/vn
3. By dn=d1 ×√ Kn* τ n. Calculate the specifications of each mold. (It is very convenient to use Excel in practice)
(1.00 1.098 1.204 1.319 1.446 1.585 1.737 1.903 2.086 2.286 2.506 2.746 2.800)
2. Traditional theoretical mold matching method (C-method mold matching)
Symbol Definition and Related Formulas
In the past, symbols were defined starting from the inlet line, but for the convenience of computer calculation (using an Excel spreadsheet), the opposite is true, starting from the outlet mold.
1. Aperture of each mold: (outlet mold) d1, d2, d3... dn
2. Extension coefficient of each track: (starting from the constant speed roller) μ 1, μ 2, μ 3 μ N
3. Speed increase ratio of each tower wheel: (starting from the constant speed roller) ν one ν two ν 3 ν N
4. Sliding coefficient of each track: τ one τ two τ 3 τ N
5. Absolute (cumulative) sliding coefficient of the nth tower wheel: τ N=vn/un
6. Linear speed of the nth tower wheel: vn
7. Speed of copper wire on the nth tower wheel: un
eight μ N= ν N* τ N
9. dn=dn-1 * √ μ N
The following is an example of the lh-280/17 wire drawing machine to illustrate the calculation method of mold configuration:
a. Determine the mechanical parameters of the wire drawing machine:
Each type of wire drawing machine manual has equipment parameters, mechanical elongation (or different names), which is the ratio of adjacent tower wheel growth of the wire drawing machine. Some manuals have instructions for calculation. The growth rate ratio of the lh-280/17 wire drawing machine is:
1.20:1, (last line: 1.15:1), i.e.: ν N=1.2
b. Sliding coefficient τ N:
Generally, the pulling machine is taken from 1.02 to 1.04, taking τ N=1.03
c. Calculate the elongation coefficient of the wire: μ N= ν N* τ N=1.2 * 1.03=1.236
d. Determine the specifications of the incoming and outgoing lines: incoming line: 2.80; Outgoing line: 1.00
e. Mold matching calculation
1.0-1.112-1.236-1.374-1.528-1.698-1.888-2.099-2.334-2.595-2.800
3. New theoretical mold matching method (x method mold matching)
The foundation of low sliding cable is to ensure safe (continuous) and smooth (continuous) cable laying, while also minimizing sliding. Therefore, the minimum specification requirement for sliding coefficient is:
one τ 3- τ Requirements for n range from 1.0 to 1.01, with an average value of 1.005 in the calculation of mold configuration
2. Safety sliding coefficient τ two
Here is an introduction to determining the safe sliding coefficient τ The method of 2, lh-280/17 wire drawing machine, has a structure that meets the performance of low sliding wire, and the safety sliding coefficient is achieved by reducing the speed increase ratio of the last tower wheel. Therefore, the safe sliding coefficient τ 2=(1.2/1.15) * 1.005=1.049
For example, the safety sliding coefficient of lh-200/17 wire drawing machine τ 2=(1.2/1.15) * 1.005=1.049;
B22 wire drawing machine, designed with a safe sliding coefficient τ 2=(1.175/1.15) * 1.005=1.027;
Safety sliding coefficient of b32 wire drawing machine τ 2=(1.15/1.12) * 1.005=1.032;
Safety sliding coefficient of s20 wire drawing machine τ 2=(1.12/1.08) * 1.005=1.042;
Safety sliding coefficient of s24 wire drawing machine τ 2=(1.1/1.08) * 1.005=1.024.
a. Determine the mechanical parameters of the wire drawing machine:
Each type of wire drawing machine manual has equipment parameters, mechanical elongation (or different names), which is the ratio of adjacent tower wheel growth of the wire drawing machine. Some manuals have instructions for calculation. The growth rate ratio of the lh-280/17 wire drawing machine is:
1.20:1, (last line: 1.15:1), i.e.: ν N=1.2
b. Sliding coefficient:
one τ 3- τ Take 1.005 as n
2. Safety sliding coefficient τ 2=(1.2/1.15) * 1.005=1.049
c. Calculate the elongation coefficient of the wire: μ 1= ν 1* τ 2=1.15 * 1.049=1.206
μ N=1.2 * 1.005=1.206
d. Determine the specifications of the incoming and outgoing lines: incoming line: 2.80; Outgoing line: 1.00
e. Model calculation: dn=dn-1 * √ μ N (1.00-1.098-1.206-1.325-1.455-1.597-1.754-1.927-2.116-2.323-2.552-2.800)
Summary: Through the comparison of the three mold matching methods mentioned above, the low sliding cable has a significant advantage in terms of energy conservation. And the loss of wire drawing oil is reduced, the service life of the tower wheel is extended, and the comprehensive benefits are obvious. Three mold matching methods are tailored to local conditions and selected reasonably based on technical and management levels.
The three mold matching methods each have their own characteristics. Method C does not have strict requirements for equipment and molds; The x and j methods require high equipment accuracy, strict mold tolerance, and high operator proficiency. The combination of x method and series mold (see "Improving Mold Utilization by Using Series Mold for Medium Drawing Machines") yields better results. It is also important to use molds and lubrication systems in order to achieve good energy-saving results with low sliding cables. Only by improving in multiple aspects can we improve production and technical levels, and the company as a whole can reach a higher level, ultimately achieving energy-saving goals.
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