DRAWING PROCESS AND DRAWING PROCESS AND DRAWING MACHINESDRAWING MACHINES

1.1. NIEHOFF ENDEXNIEHOFF ENDEX2.2. NIEHOFF MM85 NIEHOFF MM85

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DRAWING PROCESSDRAWING PROCESS

STEPS IN DRAWING PROCESSSTEPS IN DRAWING PROCESS

• Pay-offPay-off• DrawingDrawing• AnnealingAnnealing• Take-upTake-up

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INTRODUCTION:INTRODUCTION:DRAWING PROCESS:

• Drawing is the process of elongating thick wires or rods of metal to thin wires of required diameter.

• In this process, the diameter of the initial rod or specimen reduces and the length of the initial specimen increases.

• The principle behind this phenomenon is The principle behind this phenomenon is thethe “ “LAW OF CONSERVATION OF LAW OF CONSERVATION OF MASS”.MASS”.

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STEPS IN DRAWING STEPS IN DRAWING PROCESS:PROCESS:

PAY-OFF:PAY-OFF:• Pay-off is the step or process of providing feed to the drawing Pay-off is the step or process of providing feed to the drawing

machine. machine. • In this step, the material to be drawn is brought in the form of large In this step, the material to be drawn is brought in the form of large

coils called Ips (inputs).coils called Ips (inputs).

DRAWING:DRAWING:• In drawing section, we employ a machine named W.D.M to which, In drawing section, we employ a machine named W.D.M to which,

the coil is fed and is drawn through certain number of dies with the the coil is fed and is drawn through certain number of dies with the help of capstans to obtain the final required diameter. help of capstans to obtain the final required diameter. COOLING:COOLING:

– cooling is employed in order to prevent the breakage and cooling is employed in order to prevent the breakage and oxidation of the wire so as to attain good quality conductor. oxidation of the wire so as to attain good quality conductor.

– The cooling process is carried out either by The cooling process is carried out either by spray typespray type or or immersed type immersed type cooling. cooling.

– The coolant used for this purpose depends upon the material to The coolant used for this purpose depends upon the material to be drawn.be drawn.

STEPS IN DRAWING STEPS IN DRAWING PROCESS:PROCESS:

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ANNEALING:ANNEALING:

• Annealing is the process of heating and quick or rapid Annealing is the process of heating and quick or rapid cooling of metal in order to make them soft, ductile and cooling of metal in order to make them soft, ductile and easily machineable. easily machineable.

• All metals do not require annealing. All metals do not require annealing. • The metals which upon slow cooling becomes hard, The metals which upon slow cooling becomes hard,

requires annealing so that the softness attained during requires annealing so that the softness attained during heating can be retained by the metal. For example, heating can be retained by the metal. For example, Copper.Copper.

TAKE-UP:TAKE-UP:• Take-up is the process or step of taking the finished wire Take-up is the process or step of taking the finished wire

from the machine in the form of small wires.from the machine in the form of small wires.• At take-up, we employ either COILER or SPOOLER, for At take-up, we employ either COILER or SPOOLER, for

baskets or small bobbins respectively, depending upon baskets or small bobbins respectively, depending upon the requirement for the stranding process.the requirement for the stranding process.

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NIEHOFF ENDEX:NIEHOFF ENDEX:TECHNICAL DATA:TECHNICAL DATA:

• MAKEMAKE : AMERICAN – 2008: AMERICAN – 2008• PURPOSEPURPOSE : COPPER DRAWING.: COPPER DRAWING.• MACHINE TYPEMACHINE TYPE : SLIP TYPE, SINGLE LINE: SLIP TYPE, SINGLE LINE• TYPE OF COOLINGTYPE OF COOLING : SPRAY TYPE.: SPRAY TYPE.• MATERIAL DRAWNMATERIAL DRAWN : EC Grade copper coil, 8mm : EC Grade copper coil, 8mm

diameter, weight: 3.5 to diameter, weight: 3.5 to 5 5 tons.tons.

• LINE SPEEDLINE SPEED : 34.5m/s max. (Speed : 34.5m/s max. (Speed depends on required wire depends on required wire

diameter).diameter).

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ENDEX:ENDEX:

• ENDEXENDEX is a wire drawing machine, which is is a wire drawing machine, which is employed to draw copper wires only.employed to draw copper wires only.

• In RC – C plant, the Endex using is American In RC – C plant, the Endex using is American made, 2008 model. made, 2008 model.

• It is a single line drawing machine which uses It is a single line drawing machine which uses spray type cooling. spray type cooling.

• Endex needs approximately 800V to operate and it Endex needs approximately 800V to operate and it employs 2 motors of 400 HP and 200 HP to run the employs 2 motors of 400 HP and 200 HP to run the W.D.M and Annealer respectively and 2 motors of W.D.M and Annealer respectively and 2 motors of 40 HP to run the coolant pump and coiler.40 HP to run the coolant pump and coiler.

• The main parts of the Endex are as follows:The main parts of the Endex are as follows:

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PARTS OF ENDEX:PARTS OF ENDEX:

PAYPAY – – OFFOFF:: • During pay – off, the copper coil from the During pay – off, the copper coil from the

copper plant is brought in the form of IPs copper plant is brought in the form of IPs i.e. large coils, with 8mm wire diameter i.e. large coils, with 8mm wire diameter weighing approximately from 3.5 tons to 5 weighing approximately from 3.5 tons to 5 tons. tons.

• This copper is then straightened and fed to This copper is then straightened and fed to the W.D.M with the help of a horizontal the W.D.M with the help of a horizontal cylindrical roller and wire guider. cylindrical roller and wire guider.

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W.D.M: Wire Drawing W.D.M: Wire Drawing Machine:Machine:• In this, a certain number of In this, a certain number of

dies, based on the final dies, based on the final diameter required, is placed diameter required, is placed in the drawing line and the in the drawing line and the copper is drawn through copper is drawn through these dies to obtain the these dies to obtain the required diameter. required diameter.

• There is provision for 15 There is provision for 15 dies at a time in the dies at a time in the machine. machine.

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The number of dies required and the die The number of dies required and the die sequence is calculated from the elongation % sequence is calculated from the elongation % obtained, i.e.obtained, i.e.

• Elongation,Elongation, EL = [D2 / D1] ² - 1EL = [D2 / D1] ² - 1

Where,Where, D1 – starting diameter and D2 D1 – starting diameter and D2

is final is final diameterdiameter• Factor, Y = √ (EL + 1)Factor, Y = √ (EL + 1)• Next die = Y × Final dieNext die = Y × Final die

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ANNEALERANNEALER::• Annealing is the process of making Annealing is the process of making

the metal soft by heating it and the metal soft by heating it and then cooling suddenly.then cooling suddenly.

• In Endex, annealing is carried out In Endex, annealing is carried out in annealer with the help of in annealer with the help of coolant, which is a mixture of coolant, which is a mixture of oil(22G metalube) and water.oil(22G metalube) and water.

• The copper wire is passed through The copper wire is passed through many rollers and cooling chamber many rollers and cooling chamber and the coolant is sprayed over it and the coolant is sprayed over it inside the roller cabin and cooling inside the roller cabin and cooling cabin.cabin.

• After annealing, the copper wire is After annealing, the copper wire is passed to the Dancerpassed to the Dancer

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DANCERDANCER::• Dancer is used mainly to maintain Dancer is used mainly to maintain

uniform diameter throughout the length uniform diameter throughout the length of the drawn copper wire. In dancer, of the drawn copper wire. In dancer, there are two rollers, which are there are two rollers, which are maintained at a particular distance maintained at a particular distance vertically and the copper wire is wound vertically and the copper wire is wound over them.over them.

• These rollers maintained at a distance These rollers maintained at a distance ensure uniform tension on the copper ensure uniform tension on the copper wires, which in turn results in uniform wires, which in turn results in uniform diameter throughout the length of the diameter throughout the length of the drawn copper wire.drawn copper wire.

• The dancer is also used to maintain The dancer is also used to maintain balance over the copper wires when they balance over the copper wires when they pass through the annealer to the coiler. pass through the annealer to the coiler.

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COILER:COILER:• Coiler is used to coil the drawn Coiler is used to coil the drawn

wires into a basket.wires into a basket.• It consists of a rotating capstan It consists of a rotating capstan

around which the drawn wires are around which the drawn wires are wound to form the coils.wound to form the coils.

• The basket is placed on an The basket is placed on an escalator under the coiler which escalator under the coiler which changes the basket automatically changes the basket automatically when the basket is filled.when the basket is filled.

• The finished baskets are taken The finished baskets are taken away to the next process with the away to the next process with the help of fork – lifts.help of fork – lifts.

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MAIN TYPES OF BEARINGS USED IN MAIN TYPES OF BEARINGS USED IN ENDEX:ENDEX:

• 6308-2RS6308-2RS• 6304-2Z6304-2Z• 6310-2RS6310-2RS• 62096209• 22317-CW3322317-CW33• 23220-CC/W3323220-CC/W33• 23220-CCW323220-CCW3• 24122-CC24122-CC• 22213-E22213-E• SKF-202SKF-202

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WATER AND COOLANT QUALITY WATER AND COOLANT QUALITY DOCUMENT:DOCUMENT:

DRAWING SECTIONDRAWING SECTION

• PH value of medium PH value of medium : 8.5 to 9.3: 8.5 to 9.3• Concentration of oil in medium Concentration of oil in medium : 10 % to 12%: 10 % to 12%• Conductivity of the medium Conductivity of the medium : 4500µS/cm to 6000µS/cm: 4500µS/cm to 6000µS/cm

ANNEALERANNEALER• PH value of medium PH value of medium : 8.5 to 9.3: 8.5 to 9.3• Concentration of oil in medium Concentration of oil in medium : 4% to 5%: 4% to 5%• Conductivity of the medium Conductivity of the medium : 4500µS/cm to 6000µS/cm: 4500µS/cm to 6000µS/cm

NB:NB: The water used in ENDEX should be distilled or demineralized water only.The water used in ENDEX should be distilled or demineralized water only.In case of cooling of the live parts, the distilled or demineralized water may be In case of cooling of the live parts, the distilled or demineralized water may be very aggressive (or corrosive). very aggressive (or corrosive). To reduce this corrosiveness, we add small amount of glycol to it and in that To reduce this corrosiveness, we add small amount of glycol to it and in that case, the conductivity of the glycol added water solution should be of maximum case, the conductivity of the glycol added water solution should be of maximum 80µS/cm.80µS/cm.

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BREAKDOWNS AND SOLUTIONS:BREAKDOWNS AND SOLUTIONS:Drawing section:Drawing section:

Wire breakage:Wire breakage:

• The main causes for wire breakage in the drawing sections are as follows:The main causes for wire breakage in the drawing sections are as follows:– The key stuck in capstan hub is loose or damaged.The key stuck in capstan hub is loose or damaged.– The bearings of capstans are damaged.The bearings of capstans are damaged.– The capstan ceramic ring is broke or grooved.The capstan ceramic ring is broke or grooved.– The driving belt is loose.The driving belt is loose.– Bad IP or bad welding of wiresBad IP or bad welding of wires. .

Front door stuck up:Front door stuck up:

• The main reasons for front door stuck up are:The main reasons for front door stuck up are:– The line beading of the door is misaligned.The line beading of the door is misaligned.– The drive motor chain pulley damaged.The drive motor chain pulley damaged.

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Annealer:Annealer:

Wire breakage:Wire breakage:

• The reasons for wire breakage in annealer are:The reasons for wire breakage in annealer are:– The annealer ring or contact ring is worn out.The annealer ring or contact ring is worn out.– The final capstan surface is grooved.The final capstan surface is grooved.– Guider pulley bearing is damagedGuider pulley bearing is damaged– Contact pulley bearing damagedContact pulley bearing damaged..

Drive belt slip or cut:Drive belt slip or cut:• The reasons for belt slip are:The reasons for belt slip are:

– Bad condition of belt due to prolonged use.Bad condition of belt due to prolonged use.– Belt driven pulleys worn out.Belt driven pulleys worn out.– Driving motor shaft damaged.Driving motor shaft damaged.coolant leakage:coolant leakage:The leakages in slip rings are mainly due to damaged o-rings.The leakages in slip rings are mainly due to damaged o-rings.– The cooling bay leakage is due to damaged counter ring or seal ring The cooling bay leakage is due to damaged counter ring or seal ring – The leakages in cooling devices are due to damaged seals.The leakages in cooling devices are due to damaged seals.

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Dancer:Dancer:Wire breakage:Wire breakage:• The wire breakage in dancer is mainly due to the The wire breakage in dancer is mainly due to the

drive belt slip and low pressure of pneumatics drive belt slip and low pressure of pneumatics due to leakagesdue to leakages..

Coiler:Coiler:

Wire breakage:Wire breakage:– The bearing of guider pulleys and sheaves are damaged.The bearing of guider pulleys and sheaves are damaged.– The deflector roller stuck up or misaligned due to The deflector roller stuck up or misaligned due to

damaged bearing.damaged bearing.

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NIEHOFF MM85/ NIEHOFF-NIEHOFF MM85/ NIEHOFF-II:II:

TECHNICAL DATA:TECHNICAL DATA:

• MAKE MAKE : GERMAN- 2008: GERMAN- 2008• LUBRICATIONLUBRICATION : IMMERSED TYPE, 100% oil : IMMERSED TYPE, 100% oil

for aluminum, Oil – water for aluminum, Oil – water mixture for mixture for coppercopper

• MATERIAL USED MATERIAL USED : EC Grade Aluminum : EC Grade Aluminum COIL, COIL, 9.5mm diameter,9.5mm diameter, Weight: 2 tonsWeight: 2 tons

• LINE SPEEDLINE SPEED : 20m/s to 22m/s: 20m/s to 22m/s• PURPOSE PURPOSE : ALUMINUM AND COPPER : ALUMINUM AND COPPER

DRAWINGDRAWING• TYPETYPE : SLIP, DOUBLE LINE: SLIP, DOUBLE LINE

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NIEHOFF MM85/NIEHOFF-II:NIEHOFF MM85/NIEHOFF-II:

• MM85 or NIEHOFF – II is a wire drawing MM85 or NIEHOFF – II is a wire drawing machine used to draw both copper and machine used to draw both copper and aluminum. aluminum.

• It employs immersed type of cooling system. It employs immersed type of cooling system. • It is a two line drawing machine i.e. two It is a two line drawing machine i.e. two

baskets of finished wires can be made at a baskets of finished wires can be made at a time.time.

• It can also be used to make small bobbins of It can also be used to make small bobbins of drawn wires. drawn wires.

• The main parts of MM85 are: The main parts of MM85 are:

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PARTS OF MM85:PARTS OF MM85:

PAYPAY – – OFFOFF / / INTAKEINTAKE:: • During pay – off, the aluminum coil is brought in During pay – off, the aluminum coil is brought in

the form of IPs i.e. large coils, with 9.5mm wire the form of IPs i.e. large coils, with 9.5mm wire diameter, weighing approximately from 4 tons to diameter, weighing approximately from 4 tons to 4.5 tons. 4.5 tons.

• This aluminum is then straightened and fed to the This aluminum is then straightened and fed to the W.D.M with the help of horizontal cylindrical rollers. W.D.M with the help of horizontal cylindrical rollers.

• In MM85, since it is a two line drawing machine, In MM85, since it is a two line drawing machine, two IPs are drawn at a time.two IPs are drawn at a time.

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W.D.M: Wire Drawing Machine:W.D.M: Wire Drawing Machine:• The process of drawing is carried The process of drawing is carried

out in this unit of the machine. out in this unit of the machine. • In this, there is a provision to put In this, there is a provision to put

13 dies. 13 dies. • Based on the final diameter Based on the final diameter

required, the number of dies required, the number of dies required is calculated and is placed required is calculated and is placed in the drawing line according to its in the drawing line according to its sequence. sequence.

• Both the aluminum and copper is Both the aluminum and copper is drawn through these dies to obtain drawn through these dies to obtain the required diameter. the required diameter.

• The number of dies required is The number of dies required is calculated from the elongation % calculated from the elongation % obtainedobtained; ;

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The number of dies required and the die The number of dies required and the die sequence is calculated from the elongation % sequence is calculated from the elongation % obtained, i.e.obtained, i.e.

• Elongation,Elongation, EL = [D2 / D1] ² - 1EL = [D2 / D1] ² - 1 Where,Where, D1 - starting diameter and,D1 - starting diameter and, D2 - is final diameterD2 - is final diameter

• Factor, Y = √ (EL + 1)Factor, Y = √ (EL + 1)• Next die = Y × Final dieNext die = Y × Final die

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ANNEALERANNEALER::

• Annealing is the process of making the metal soft Annealing is the process of making the metal soft by heating it and then cooling suddenly. by heating it and then cooling suddenly.

• By doing so the softness attained by the material By doing so the softness attained by the material due to heating is contained in it. due to heating is contained in it.

• Thus, annealing is done to soften the metal.Thus, annealing is done to soften the metal.• After annealing, the copper wires are passed to After annealing, the copper wires are passed to

the Dancer.the Dancer.

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DANCERDANCER::

• Dancer is used mainly to maintain uniform diameter Dancer is used mainly to maintain uniform diameter throughout the length of the drawn copper and aluminum throughout the length of the drawn copper and aluminum wires. wires.

• In dancer, there are two rollers, which are maintained at a In dancer, there are two rollers, which are maintained at a particular distance vertically and the drawn metal wire is particular distance vertically and the drawn metal wire is wound over them. wound over them.

• The wire takes 3 complete rounds on these rollers and the The wire takes 3 complete rounds on these rollers and the fourth turn goes out of the dancer. fourth turn goes out of the dancer.

• These rollers maintained at a distance ensure uniform These rollers maintained at a distance ensure uniform tension on the copper wires, which in turn results in uniform tension on the copper wires, which in turn results in uniform diameter throughout the length of the drawn wires.diameter throughout the length of the drawn wires.

• The dancer is also used to maintain balance over the The dancer is also used to maintain balance over the drawn wires when they pass through the annealer to the drawn wires when they pass through the annealer to the coiler.coiler.

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COILER:COILER: • Coiler is used to coil the Coiler is used to coil the drawn wires into a basket. drawn wires into a basket.

• It consists of a rotating It consists of a rotating capstan around which the capstan around which the drawn wires are wound to drawn wires are wound to form the coils. form the coils.

• The basket is placed on an The basket is placed on an escalator under the coiler escalator under the coiler which changes the basket which changes the basket automatically when the automatically when the basket is filled.basket is filled.

• The finished baskets are The finished baskets are taken away to the next taken away to the next process with the help of fork process with the help of fork – lifts– lifts

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SPOOLER:SPOOLER:

• Spooler serves the same purpose as Spooler serves the same purpose as that of the coiler i.e. (Coiling and take-that of the coiler i.e. (Coiling and take-up). up).

• The main difference is that, that coiler The main difference is that, that coiler is used to fill baskets while spooler is is used to fill baskets while spooler is used to make small bobbins. used to make small bobbins.

• The size of bobbins may vary from The size of bobbins may vary from 300mm to 500mm. 300mm to 500mm.

• The spooler is run with the help of a The spooler is run with the help of a motor and its main systems are motor and its main systems are operated with the help of hydraulic operated with the help of hydraulic equipments.equipments.

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WATER AND COOLANT QUALITY WATER AND COOLANT QUALITY DOCUMENT:DOCUMENT:

• In Niehoff MM85, we use water for In Niehoff MM85, we use water for drawing and annealing section, only in drawing and annealing section, only in the case of copper drawing. the case of copper drawing.

• So it is same as that of the water and So it is same as that of the water and coolant quality requirement as in Endex.coolant quality requirement as in Endex.

• For further details refer water and For further details refer water and coolant quality document for coolant quality document for ENDEX.ENDEX.

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BREAKDOWNS AND SOLUTIONS:BREAKDOWNS AND SOLUTIONS:• In MM85, we have the same breakdowns and In MM85, we have the same breakdowns and

almost the same reasons for break downs as almost the same reasons for break downs as that of Endex. The different case is, in that of that of Endex. The different case is, in that of the spooler.the spooler.

Spooler:Spooler:

• In spooler the main problems are:In spooler the main problems are:• Hydraulic system malfunction due to hydraulic Hydraulic system malfunction due to hydraulic

oil leakagesoil leakages• Wire traverse stuck up due to damaged lead Wire traverse stuck up due to damaged lead

screwscrew• Too much vibration in pintels, due to worn out Too much vibration in pintels, due to worn out

shaft.shaft.

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MAINTENANCE PROCEDURESMAINTENANCE PROCEDURES

Procedure for changing Procedure for changing capstan ceramic capstan ceramic rings inrings indrawing section:drawing section:

• In Endex, we have In Endex, we have ceramic rings of 3 sizes, ceramic rings of 3 sizes, namely small, medium namely small, medium and large. To change and large. To change these rings, follow the these rings, follow the below steps:below steps:

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Remove the capstan cap or flange Remove the capstan cap or flange and then remove the key from and then remove the key from the key stuck.the key stuck.

• After removing After removing the key, remove the key, remove the ceramic ring the ceramic ring using a using a hydraulic jack or hydraulic jack or a similar puller.a similar puller.

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Replace the Replace the old or old or damaged damaged ring with a ring with a new ring.new ring.

• Put back the keys in Put back the keys in the key stuck and the key stuck and check for its check for its tightness.tightness.

• Put back the capstan Put back the capstan cap; check the cap; check the correct fitting of the correct fitting of the ring and then tight ring and then tight the bolts. the bolts.

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Procedure for changing annealer Procedure for changing annealer rings or contact bands:rings or contact bands:

• Annealer ring made of nickelAnnealer ring made of nickel

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We use nickel or copper bands as annealer We use nickel or copper bands as annealer ring in Endex. To change the ring, follow the ring in Endex. To change the ring, follow the steps given below:steps given below:

– Loosen the screws on the thrust collar and Loosen the screws on the thrust collar and remove the thrust collar.remove the thrust collar.

– Remove the damaged band and clean the Remove the damaged band and clean the contacting surface with greaseless agents to contacting surface with greaseless agents to ensure good transmission of current.ensure good transmission of current.

– Adjust the band and make sure that it fits Adjust the band and make sure that it fits around the complete circumference.around the complete circumference.

– A clearance of 0.03mm to 0.05mm is A clearance of 0.03mm to 0.05mm is acceptable.acceptable.

– After putting on the new band, tighten the thrust After putting on the new band, tighten the thrust collar with screws evenly. (Tightening torque – collar with screws evenly. (Tightening torque – 18Nm).18Nm).

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Procedure for changing Procedure for changing bearings and pulleysbearings and pulleys

For changing the bearings or For changing the bearings or pulleys, follow the steps pulleys, follow the steps given below:given below:

• Remove the lock head bolt Remove the lock head bolt or screw.or screw.

• Using the adequate puller, Using the adequate puller, pull out the bearing or pull out the bearing or pulley from the shaft.pulley from the shaft.

• Replace the bearing or Replace the bearing or pulley with new ones and pulley with new ones and put them back on the shaft.put them back on the shaft.

• In case of bearings, heat the In case of bearings, heat the bearing using the heating bearing using the heating device and then put the device and then put the bearing on the shaft instead bearing on the shaft instead of employing mechanical of employing mechanical ways of hammering etc.ways of hammering etc.

• After cooling, check the tightness After cooling, check the tightness of the bearing on the shaft; put of the bearing on the shaft; put back the lock head bolt and check back the lock head bolt and check for the correct fitting of the pulley for the correct fitting of the pulley and bearingand bearing

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Procedure for changing flat belts:Procedure for changing flat belts:• For changing flat belt, we For changing flat belt, we

employ the following employ the following procedures:procedures:

• Loosen the tension rollers and Loosen the tension rollers and driven pulleys.driven pulleys.

• Remove the damaged belt and Remove the damaged belt and put new one.put new one.

• The new belt should be The new belt should be tensioned enough to get an tensioned enough to get an elongation of 2.5%. For that,elongation of 2.5%. For that,

• Mark two lines on the belt Mark two lines on the belt exactly 1m apart from each exactly 1m apart from each other.other.

• Now, tight the belt and check Now, tight the belt and check the distance between these two the distance between these two lines.lines.

• Tight the belt until the distance Tight the belt until the distance between the two lines is exactly between the two lines is exactly 1.025m i.e. 2.5% elongation.1.025m i.e. 2.5% elongation.