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Textbook Wire Technology Second Edition Process Engineering and Metallurgy Roger N Wright Ebook All Chapter PDF
Textbook Wire Technology Second Edition Process Engineering and Metallurgy Roger N Wright Ebook All Chapter PDF
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WIRE
TECHNOLOGY
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WIRE
TECHNOLOGY
Process Engineering and
Metallurgy
Second Edition
By
ROGER N. WRIGHT
To my wife, Patricia, who has learned that every room is an office, and every
table a desk.
v
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CONTENTS
Preface xiii
About the Author xv
vii
viii Contents
6. Drawing Temperature 45
6.1 Contributions to the Drawing Temperature 45
6.2 Temperature Measurement 50
6.3 Interpass Cooling 52
6.4 Practical Examples of Drawing Temperature Effects 52
6.5 Questions and Problems 58
7. Drawing Speed 59
7.1 Definition and Basic Formulas 59
7.2 The Role of Drawing Speed in Analysis 60
7.3 The Effect of Drawing Speed on Lubrication 62
7.4 Some Practical Issues 63
7.5 Questions and Problems 64
References 297
List of Symbols 305
Selected Formulae 311
Index 315
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PREFACE
xiii
xiv Preface
that one is not likely to find such a course on wire processing, except perhaps
in Eastern Europe. This approach has allowed me to use directly much of my
experience in technology-focused short courses, as well as my experience in
teaching undergraduates and graduate students at Rensselaer. I have written
it with the hope that it will be useful for self-study and continuing education
offerings, as well as serving as a desk reference. At this point in time, I believe
that it occupies a unique position in the engineering literature.
This second edition differs from its predecessor primarily in its summary
and citation of relevant research of the 2009-2015 time frame.
Finally, I would like to thank the most helpful staff at Elsevier Inc., par-
ticularly Jeffrey Freeland, for their patient handling of this second edition of
my book.
xv
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CHAPTER 1
Contents
1.1 Concepts 1
1.1.1 Drawing 1
1.1.2 Wire, Rod, and Bar 1
1.1.3 Materials 2
1.2 How Does Drawing Work? 2
1.2.1 Why Not Simply Stretch the Wire, Rod, or Bar? 2
1.2.2 A Simple Explanation of the Drawing Process 3
1.2.3 Comparison to Other Processes 4
1.2.4 Overall Process Hardware 5
1.3 Questions and Problems 6
1.1 CONCEPTS
1.1.1 Drawing
The concept of drawing addressed in this book involves pulling wire, rod, or
bar through a die or converging channel to decrease cross-sectional area and
increase length. In the majority of cases, the cross section is circular, although
noncircular cross sections may be drawn and/or created by drawing. In
comparison to rolling, drawing offers much better dimensional control,
lower capital equipment cost, and extension to small cross sections. In com-
parison to extrusion, drawing offers continuous processing, lower capital
equipment cost, and extension to small cross sections.
to drawing, bar stock may have been cast, rolled, extruded, or swaged (rotary
cold forged). Rod drawing involves stock that may be coiled, and hence
may be delivered to the die from a coil, and taken up as a coil, on a block
or capstan. Round rod stock will often have a 0.3-1-cm diameter and will
often have been cast and/or rolled prior to drawing. Wire drawing involves
stock that can be easily coiled and subjected to sequential or tandem drawing
operations with as many as a dozen or more draws occurring with a given
drawing machine. Each drawing operation or “pass” will involve delivery
of the wire to the die from a coil on a capstan, passage through the die,
and take-up on a capstan that pulls the wire through the die. Fine wire
drawing typically refers to round wire with a diameter of less than
0.1 mm, and ultra-fine wire drawing typically refers to round wire as fine
as 0.01 mm in diameter.
1.1.3 Materials
Essentially any reasonably deformable material can be drawn, and the general
analysis is the same regardless of the wire, rod, or bar material. The individual
technologies for the major commercial materials, however, involve many
nuances. The drawing technologies are often divided into ferrous (steel)
and nonferrous and electrical (usually copper and aluminum), although
there is specialty production and research and development interest in such
high-value-added products as thermocouple wire, precious metal wire, bio-
medical wire, wire for high temperature service, superconducting wire, and
so on.
Apart from the material drawn, drawing technology depends substan-
tially on the materials used for dies (“carbide,” diamond, tool steel) and
on the materials or formulations used for lubricants and coatings.
(a) (b)
(c)
Figure 1.2 Schematic illustration of (a) forces in forging or upsetting, (b) some of the
forces in extrusion, and (c) roll motion and roll force in rolling. (From Dieter GE.
Mechanical metallurgy, 3rd ed. Boston, MA: McGraw-Hill; 1986. p. 504. Copyright held
by McGraw-Hill Education, New York, USA.)
The General Idea 5
Drum
Die
holder
Soap
box
Figure 1.3 Illustration of a single die wire drawing system with a lubrication application
box, a die (in a die holder), and a rotating drum to apply tension and take up the wire.
(From Avitzur B. Handbook of metal-forming processes. New York: John Wiley & Sons;
1985. p. 195. Copyright held by B. Avitzur, Allentown, PA, USA.)
6 Wire Technology
Contents
2.1 Ancient and Early Technology 7
2.2 The Nineteenth Century 9
2.3 The Twentieth Century 10
2.4 Further Reading 11
2.5 Questions and Problems 11
3. The wire drawer need pay no taxes on anything relating to his trade
which he buys or sells in Paris.
4. Apprentices to wire drawers will serve ten years without pay and then be
paid a premium of 20 sous.
Nuremberg was apparently a major center for Middle Ages and Renaissance
wire technology, with documentation from the fourteenth-to-middle-
sixteenth centuries found in the Hausbuch der Mendelschen Zw€olfbruderstiftung
zu Nürnberg. Major developments are attributed to Rudolph von Nurem-
berg. In the early fourteenth century, he utilized water power and
camshaft-driven draw benches. Previous to this, the only practical sources
of power were manual, which involved such expedients as hand-lever
devices called “brakes” and swinging body motion utilized by harnessed
“girdlemen.” The rather effective dies prepared from hard stone by the
Egyptians were followed in later millennia by easily worked but rapidly
wearing iron and steel plates. An illustration of a swing-assisted medieval
rod drawer with tongs and drawing plate is shown in Figure 2.1.
Figure 2.1 Illustration of medieval wire drawing, as presented in the Hausbuch der
Mendelschen Zwo €lfbruderstiftung zu Nürnberg.
A Brief History of Technology 9
Figure 2.2 Albrecht Durer’s 1489 painting, The Wire Drawing Mill (Staatliche Museen,
Berlin.)
10 Wire Technology
The use of natural diamond dies for fine gages persisted, however, and
natural diamond dies and modern carbides were joined in 1974 by synthetic
diamond dies, first introduced by the General Electric Company under the
name Compax. This product, and subsequent variations and competing
products, utilized synthetic diamond powder first developed by General
Electric in 1954.
Twentieth century lubrication developments involved the use of a num-
ber of chemically engineered soaps, gels, and emulsions, including synthetic
as well as natural products. Major attention was devoted to lubricant removal
and disposal, as well as to environmental impact.
2.5.3. Examine Figure 2.1 carefully. What drawing speed and production
rate do you think the craftsman is capable of?
Answers: Routine hand labor is generally at speeds of 1 m/s, and this
would be a good guess for the worker in Figure 2.1. The rod appears to have
a diameter of roughly 2 cm. Thus the volume drawn in 1 s would be near
300 cm3, and the volume for an hour of actual drawing would be somewhat
over 1 m3. If the product were iron base, the mass for an hour of actual draw-
ing would be under 10,000 kg or a rate of roughly ten tons per hour. This
does not factor in the down time between pulls and time for rest. The drawer
would probably be doing well to draw a ton or two per hour.
2.5.4. The development of the American “heartland” involved numerous
expanded markets for wire, and there is even a pertinent citation at the
Alamo in San Antonio, Texas. Similar observations can be made for central
Europe. Cited in Section 2.2 are examples of wire products and applications
such as telegraph and telephone wire, bale ties and barbed wire, and woven
fence wire. Moreover, the ubiquitous availability of wire led to many
secondary products often made at home or by traveling “tinkers.” Think
of some possible home implements that could have been made of wire.
Answers: The interested reader is directed to Everyday Things Wire by
Slesin et al.16 Examples of cages, traps, baskets, wine caddies, condiment sets,
grills, toasters, bottle carriers, egg holders, and platters are shown, as well as
illustrations of whisks, beaters, whips, griddles, forks, mashers, strainers,
hangers, light and lamp protectors, weeders, pickers, and endless toys and
“gifts.”
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la Galicie, tandis que Dedko promettait de ne pas attaquer la
Pologne.
Les choses s’arrangèrent ainsi ; Lubarte continua de régner sur
le pays, qui était sorti si heureusement de la crise. Mais Casimir
n’oubliait pas ses projets. Il se fit délier d’avance par le pape du
serment prêté à Dedko, s’assura de la neutralité des Tartares, et,
profitant de ce que les princes lithuaniens étaient engagés à
combattre les Allemands et ne pouvaient secourir Lubarte, il
s’empara inopinément, en 1349, de la Galicie et de la Volhynie
occidentale.
XI.
La lutte pour s’emparer de la Galicie
et de la Volhynie. — L’union de 1385.