Rent 9780123820921 | Wire Technology : Process Engineering and Metallurgy

Summary Table of Contents

Wire drawing is a metalworking process used to reduce the diameter of a wire by pulling the wire through a single, or series of, drawing die(s). The engineering applications of wire drawing are broad and far-reaching, including electrical wiring, cables, tension-loaded structural components, springs, paper clips and spokes for wheels.This all-new, classical text is the first to explain the complex theory and sophisticated engineering concepts with relation to wire drawing in an accessible and universal way for practicing engineers.Designed to facilitate the entry and training of new engineers and upgrade the professional practice of those already in the field in the face of increased product demands and tightening specifications, this essential resource by industry expert Roger Wright provides: A technical overview and introduction of engineering concepts related to wire drawing, suitable for beginners and practiced engineers looking to brush up on the theory behind the process An interface with basic engineering education so as to provide an accessible introduction for engineers new to the field Real-world worked examples, problems and protocols based on true life engineering scenarios and challenges Unique coverage of the author's own pass design and risk prediction calculations, developed through decades of research and wire industry consultingWhilst most competing titles are less practical in their approach and focus on either ferrous, non-ferrous or electrical, our book takes a universal approach more suited to the practicing engineer who needs knowledge of wire drawing across the board. Ideal for use as a complete insight into the process from start to finish or a dip-in resource for practical problem-solving, this versatile work-a-day guide, training tool and desk reference will help readers train their staff and adapt and improve processes at minimal cost for maximum performance. Provides a unique universal approach, covering ferrous and non-ferrous metals Authored by an internationally-recognized specialist in wire drawing with extensive academic and industry experience Real-world worked examples, problems and protocols based on true life engineering scenarios and challenges allow engineers to easily apply the theory to their workplace to improve processes, productivity and efficiency Compact, concise and practical in comparison to the large, competing handbook tomes that are overwhelming for beginners and impractical for day-to-day work use Ideal for use as a complete insight into the process from start to finish or as a dip-in resource for practical problem-solving, analysis and trouble-shooting

Preface	p. xiii
About the Author	p. xv
The General Idea	p. 1
Concepts	p. 1
How Does Drawing Work?	p. 2
Questions and Problems	p. 5
A Brief History of Technology	p. 7
Ancient and Early Technology	p. 7
The Nineteenth Century	p. 9
The Twentieth Century	p. 10
Further Reading	p. 11... MORE
Questions and Problems	p. 11
Twentieth Century Equipment Concepts	p. 13
Overview	p. 13
Benches	p. 13
Blocks	p. 14
Multiple-die Machines	p. 15
Other in-line Processes	p. 17
Questions and Problems	p. 17
Basic Engineering Variables Pertinent to Drawing	p. 19
General Quantities	p. 19
Quantities Describing the Workpiece and Die During Drawing	p. 23
Questions and Problems	p. 26
Basic Drawing Mechanics	p. 29
A Simple Drawing Stress Model	p. 29
Drawing Limits	p. 33
An Illustrative Calculation	p. 34
The Issue of Optimum Die Angles and � Values	p. 34
Die Pressure	p. 35
Centerline Tension	p. 37
Plastic Flow Outside the Drawing Cone	p. 38
Effects of Back Tension	p. 40
Questions and Problems	p. 41
Drawing Temperature	p. 43
Contributions to the Drawing Temperature	p. 43
Temperature Measurement	p. 49
Interpass Cooling	p. 50
Practical Examples of Drawing Temperature Effects	p. 50
Questions and Problems	p. 56
Drawing Speed	p. 57
Definition and Basic Formulas	p. 57
The Role of Drawing Speed in Analysis	p. 58
The Effect of Drawing Speed on Lubrication	p. 60
Some Practical Issues	p. 61
Questions and Problems	p. 62
Friction, Lubrication, and Surface Quality	p. 65
Modes of Lubrication and Related Friction Response	p. 65
Physical Conditions in the Lubricant Layer	p. 71
Quantifying the Friction Stress	p. 74
Drawing With High Friction	p. 75
Redraw Stock Surface Conditioning Issues	p. 75
Characterization With Microscopy	p. 76
Illustrations of Microscopic Characterization and Analysis	p. 77
The Development of Chevrons (Crow's Feet)	p. 82
Questions and Problems	p. 88
Drawing Die and Pass Schedule Design	p. 89
General Aspects and The Role Of �	p. 90
Common Die Materials	p. 94
Other Elements of Die Design	p. 99
Pressure Dies	p. 101
Die Wear and Die Life	p. 102
Pass Schedule Concepts	p. 104
Drawing Practice and Cast and Pitch Control	p. 109
Questions and Problems	p. 110
Shaped Dies and Roller Dies	p. 113
Drawing Shapes with One-Piece Dies	p. 113
Drawing with Unpowered Roller Die Systems	p. 118
�Drawing� with Powered Roller Die Systems	p. 121
Roll Gap Issues	p. 123
Questions and Problems	p. 124
Mechanical Properties of Wire and Related Testing	p. 127
The Flow Stress of the Wire	p. 128
The Tensile Test	p. 130
The Crystal Plasticity Basis for the Flow Curve	p. 138
Other Mechanical Tests	p. 144
Hardness Tests	p. 144
Compression Tests	p. 145
Bending Tests	p. 148
Torsion Tests	p. 149
Creep Testing	p. 151
Fatigue Testing	p. 153
Springback Testing	p. 153
Questions and Problems	p. 154
Drawability and Breaks	p. 157
Practical Definitions	p. 157
Measuring and Estimating Drawability	p. 158
Categorizing Drawing Breaks	p. 164
Mechanics of Drawing Breaks	p. 167
The Generation of �Fines�	p. 171
Questions and Problems	p. 173
Relevant Aspects of Copper and Copper Alloy Metallurgy	p. 175
Important Properties of Copper	p. 176
Primary Processing	p. 176
Crystal Structure, Grains, Texture, Anisotropy, and Springback	p. 180
Flow Stress, Cold Working, and Annealing	p. 182
Solid Solutions and Phases	p. 185
Factors Affecting Conductivity/Resistivity	p. 187
Dilute Copper Alloys	p. 188
High Alloy Systems	p. 192
Beryllium Copper, A Precipitation Strengthening (Hardening) Alloy	p. 195
Questions and Problems	p. 197
Relevant Aspects of Carbon and Low Alloy Steel Metallurgy	p. 199
Important Properties of Steel	p. 200
Primary Processing	p. 200
The Iron-Iron Carbide Phase Diagram	p. 204
Austenite Decomposition	p. 207
Structure-Mechanical Property Relations	p. 209
Transformation Diagrams	p. 210
Flow Stress, Cold Working, and Annealing	p. 215
Aging in Steel	p. 217
Carbon Steel Compositions	p. 225
Low Alloy Steel Compositions	p. 226
Questions and Problems	p. 227
Other Metallurgical Systems for Wire Technology	p. 229
Aluminum and its alloys	p. 229
Austenitic Stainless Steels	p. 234
Tool Steels	p. 237
Nickel and Nickel Alloys	p. 240
Questions and Problems	p. 242
Wire Coatings	p. 245
Reasons for Coating Wire	p. 245
Coating Types and Coating Processes	p. 245
Enamels and Enameling	p. 246
Extrusion	p. 247
Hot Dipping	p. 249
Electro-Coating	p. 249
Other Coating Technologies	p. 251
Zinc Alloy Coating of Steel - A Detailed Illustration and Analysis	p. 251
Composite Mechanical Properties of Coated Wire	p. 253
Questions and Problems	p. 256
Redraw Rod Production	p. 257
The Rod Rolling Process	p. 257
The Oval/Round Sequence	p. 259
Other Geometrical Sequences	p. 263
Some Process Correction Contexts	p. 264
Questions and Problems	p. 265
Wire Forming	p. 267
Scope	p. 267
Bending	p. 267
Twisting	p. 269
Stretching	p. 271
Upsetting	p. 271
Swaging	p. 272
Cold Extrusion	p. 276
Questions and Problems	p. 278
Physical Properties	p. 279
Scope	p. 279
Density	p. 279
Melting Points and Ranges	p. 280
Specific Heat	p. 281
Thermal Conductivity	p. 281
Electrical Resistivity	p. 282
Current and Near-Term Developments	p. 285
Scope	p. 285
Drawing Machines	p. 286
Long-Life Dies For Ferrous Drawing	p. 288
Measurement and Instrumentation	p. 289
Annealing
Payoff and Take-Up Systems	p. 292
List of Symbols	p. 297
References	p. 303
Selected Formulas	p. 309
Index	p. 311
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