WCA November 2014

Technology news

Changing the way of wire drawing

Ajex & Turner is using vitrified nanocrystalline technology that has changed the traditional way of wire drawing. The prospects of this technology will, the company believes, have a huge impact in the future and will save material and manufacturing costs for cable companies. Its research and development team has developed diamond coated dies and extrusion tooling for bunching and compacting copper and aluminium multi-wire strands for electric cables. These dies are made with multi-layer coatings of nanocrystalline diamond composites on tungsten carbide nibs, which provide a smooth surface with low friction.  This technology provides a much harder and compact surface in comparison to PCD, and the company is developing a process to re-size and re-polishing from 29mm to 42mm. There are numerous advantages over PCD. The layer of diamond is 100 per cent diamond and resistant to wear, unlike PCD which is a mixture of cobalt and other hard materials. This gives a cost-saving on repolishing, with tolerance remaining the same. The cost of the new dies is

also four to five times less than PCD, and can be recut in microns. Ajex and Turner’s R and D is working to increase the layers of coatings, which may also help coating profile dies and increase the working life of the die by a further 30 to 50 per cent. The size range is 2.5mm to 42mm, while the reduction angle is generally 18 to 24 degrees with 20 to 30 per cent bearing length. The model TCD-10 will help die polishing and grinding as it does both ❍ A range of dies from Ajex and Turner

of these in one operation, saving time and energy, and increasing cost effectiveness. The machine operates at high speed and can recondition dies in a short period of time. It is also possible to achieve a mirror polish using diamond suspension and steel pins. The company has also started manufacturing wire drawing lubricants for copper and aluminium for fine wire and RBD, in association with a UK-based company. Ajex and Turner – India Website : www.ajexturner.com

Mechanical cleaning systems

system for the removal of residual scales, swarf and dust, to reduce excess drawing agent or to extend tool life of metal forming machines. To optimise surface condition both pre-process and post-process the material passes through a rotating spiral brush. Depending on the application and material the brushes can have nylon, brass or steel filaments. The rotary movement of the brush supports the wiping effect of this well-proven tool. Further contamination removed from the wire does not clog-up the brush because centrifugal force throws a major part of the removed contamination into the base of the unit. Inside a lidded working box two separate compartments include a rotating unit to fix a cut-to-length spiral brush and an air wipe. Removed dirt is caught in the trough and collected in a removable draw-type container. Following the spiral brush the air jet nozzle blows off any remaining loose particles. GEO-Reinigungstechnik GmbH – Germany Website : www.geo-reinigungstechnik.de

GEO-Reinigungstechnik specialises in the production of wet chemical cleaning systems for wire, strip, tube, cable, rod and similar longitudinal configurations. Almost all of the demands on the cleaning processes can be realised with proven GEO components, such as high performance ultrasonic tube reactors and high pressure or steam jets. GEO in-line cleaning systems can be complemented by state-of-the-art systems for continuous bath monitoring and much more, according to individual requirements. For less demanding cleaning tasks, mechanical methods are suitable. The ‘Primary Wire Wipe’ system (PWW) enjoys popularity in this field. The wire to be cleaned passes between two strips of absorbing tape material that move in opposite directions. In this way a clean tape surface is continuously presented to the wire or strip material. Equipped with one of the most popular and universal tools for surface treatment of wires, cables and rods the DRB brush cleaning system for wires, cables, rod and small pipes is a compact, eco-friendly and cost-effective

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Wire & Cable ASIA – November/December 2014