EoW September 2010

technology news

More wizardry for dies

CPA Wire Technologies GmbH has developed a furnace technology for the heat treatment of steel goods and high carbon wires and bands. The project was partnered by the Austrian research funding agency. Under the brand name CPA–AEOX Industrial Furnaces the company has launched a patented furnace series which is aimed in particular at the perceived weaknesses of the products currently available in the market. Apart from energy savings, said to be up to 40%, and low emission combustion of gases, the series offers a part-load capacity of 25% to 115% of the nominal load for flexible production. The temperature profile in the furnace and the furnace atmosphere are graphically parameterised via the integrated control and visualisation system. Core of the new technology for austenitisation, patenting, tempering and diffusion is a combination of radiant and convection heat by recirculation and appropriate guiding of the flue gases at multi-phase pre-heating of the combustion air while cooling the exhaust gases as well as recuperation of the heat drag-out by the material to be treated. In contrast to conventional industrial furnaces for the mentioned purpose the furnace pressure and the exhaust gas stream in the furnace are not reached via the instreaming gas/air mixture but via the high circulation of the flue gases generated by a special fan. The challenge of the furnaces currently offered on the market of an inadmissible change in the furnace atmosphere by a reduction of the furnace pressure and the flue gas flow under part-load is thereby prevented, as well as a reduction of the convection heat ratio that results in a significantly better controllability at varying furnace loads and different product mixes. By increasing the convection heat transfer to the material to be treated, a reduction of the furnace length of around 20% is possible, and a reduction of the heat emission via the outer casing can be achieved. Special fans, designed for temperatures of over 1,000°C and integrated into the furnaces, are provided in addition to the monitoring function of all electrical parameters and the lubricant supply with a flow, pressure and oscillation sensor technology. The process is continuously monitored and diagnosed by the process control and diagnosis system IMPERIO by CPA. All furnaces can be heated with gas as well as electrically. As an option, gas-heated furnaces can also be equipped with aWobbe-index measuring unit and a corresponding combustion air control. A new CPA Do-It-Yourself (DIY) Plug & Play concept simplifies the installation and commissioning of the modularly designed furnaces. CPAWire Technologies GmbH – Austria Email : wiretec@cpa.at Website : www.cpa.at Energy efficient, super heat treatment furnaces With over 100 years of experience the Esteves Group produces a comprehensive range of standard and custom diamond and carbide tools and dies for drawing, stranding, bunching, compacting, tube calibration and extrusion; also split and shaped dies in both diamond and carbide. Esteves Group – Brazil Email : sales@estevesgroup.com Website : www.estevesgroup.com The Esteves Group is releasing a major update to its Drawing Die Wizard computer program, a free to download design tool for wire dies. The Esteves Group believes it is the only wire die manufacturer to enable its customers to understand the logic behind the design of the ideal die for each application, and the selection of the most cost-effective die blank. Highlights of the new version include: Real-time 3D view of the inner profile of the designed die • Computer generated microscope view with realistic light reflections that simulates • looking at an actual die with a real microscope. This makes it easy to view and discuss various profile shapes before the die is manufactured Animated simulation of wire drawn through the die makes it possible to see the • location and growth of a wear ring for the particular profile Supports ten languages • Improved reduction cone angle and blank suggestions •

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EuroWire – September 2010