WCA September 2012

Dies, lubricants and drawing

Whole range available Compacting dies are always used in bunched and stranded conductors. The multiple wires drawn in wire drawing machines, a process before stranding, are formed into circular/shaped conductors by passing and compressing wires to the desired shape and sizes. The conductor sizes are mostly referred in sq, mm and AWG.

The type machines, whether double or single twist, are called bunchers with the take-up reel inside the machine and wire twisting at very high speed, usually at 5,000tpm or above. The dies are located at the entrance of the machine to gather the incoming wires for the bunched conductors and bow

sometimes these dies are located before the take-up reel inside the machine to shape the wire that goes onto the reel to make the conductor compacted, reducing the bow loading effect. Based on the conductor construction, material and application type, the stranding dies can be classified in the following types: • Bunched or gathering dies ❍ ❍ Dies from Ajex & Turner The bunched or gathering and semi-compacting dies are basically used in low voltage conductor making to reduce the over-all conductor diameter meeting the specified conductor size in sq and mm. These dies are made in tungsten carbide material. For high voltage cables the conductor demands a high compactness level, better shape and ridge-free formation. This is achieved using poly crystalline dies. These dies are useful to get the exact the CR value and metal, polymer and other accessories savings. These dies are available for 16, 25, 35, 50, 70, 95, 120, 150, 185, 240, 300, 400, 500, 630, 800 and 1,000mm conductor. New developments There are two new developements in the wide range of tungsten carbide die reworking machines from Bremer GmbH, Germany. Bremer has developed the new machine KSPM1 Microcontrol. The machine can work with very small diameter (range 0.07-0.5mm) and is specially developed for repairing the conical section of tungsten carbide drawing dies (0.08mm saw wire). With automatic computer settings, the roundness can be reached with very narrow tolerance. Furthermore, Bremer has developed grinding and polishing equipment for the repair and production of tungsten carbide drawing dies with a full automatic process (range 0.5-10mm). • Semi-compacting dies • Highly compacting dies Ajex & Turner Wire Dies Co – India Website : www.ajexturner.com

Bremer GmbH – Germany Website : www.bremer-willi.de

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Wire & Cable ASIA – September/October 2012