Analysis and treatment of abnormal causes in wire drawing process
Analysis and treatment of abnormal causes in wire drawing process
1、Disconnection
1.Loose joint:adjust the current,power on time and pressure of butt welder to improve welding quality.
2.Wire has impurities:strengthen the acceptance of raw materials.
3.Unreasonable die matching:adjust the die to eliminate the phenomenon of large and small deformation process.
4.Incorrect or unsmooth die hole shape:the die shall be repaired in strict accordance with the standard,and the sizing area shall not be too long to ensure the smoothness of the die hole.
5.Excessive back pull:adjust the number of winding turns on the drum.
6.Drum thread pressing:adjust the number of winding turns on the drum to correct the worn drum.
7.Poor lubrication:check the lubrication system and determine the composition and temperature of the lubricant.
8.Aluminum rod is wet:prevent the aluminum rod from being wet,and the wet aluminum rod will not be used temporarily.
2、Incorrect size and shape
1.Wear of die hole:measure the wire diameter frequently,and replace the die when it is found that it is out of tolerance.
2.Wire drawing:adjust the die to improve the lubrication effect.
3.Using the wrong mold:measure the wire diameter after threading.
4.Wire scratch:check the quality and lubrication of die hole.
5.Dies skew:pay attention to straighten the mold and repair the dies base.
3、Abrasions,bumps,scratches
1.There is jumper phenomenon on the conical drum:the surface of the drum is polished and the angle is correct.
2.There are grooves on the drum:remove the drum to repair and polish it.
3.Places with broken line on the equipment:the drum interface is uneven,and the guide wheel does not rotate flexibly.
4.The reels collide with each other:the reels should be placed in "t" shape and separated from each other during transportation.
5.Uneven ground:repair the ground and lay steel plate.
6.Over full take-up:stick to the post and concentrate on setting down according to the regulations.
4、Peeling,pockmarking,triangle mouth and burr
1.The wire rod has flash,inclusion and shrinkage cavity:the inspection shall be strengthened,and the unqualified ones shall not be put into production.
2.The Dies hole is not smooth,deformation,etc.:strict inspection,unqualified dies is not on the machine.
3.Poor lubrication:improve the lubrication effect.
4.The drum is not smooth and the sliding rate is too high:polish the drum surface and adjust the die matching.
5、Wavy,serpentine
1.Improper die matching:adjust the die matching,and the deformation degree of the finished die should not be too small.
2.Serious vibration of wire drawing machine:repair and reinforce equipment to eliminate vibration.
3.Severe wire jitter:adjust the tension and keep the take-up speed stable.
4.The shape of die hole is not suitable:the length of sizing area should be suitable,not too short,or even none.
5.Uneven and unclean lubrication supply:ensure uniform lubricant supply and filter lubricant for use.
6、There are continuous scratches on the wire
1.Wire scratch:check all parts contacting with wire,such as guide wheel and wire rod.
2.The temperature of lubricating fluid is too high:strengthen the cooling,and use the forced cooling method when necessary.
3.High alkali content and uncleanness of lubricant:Test regularly to keep the composition of lubricant and ensure its cleanness.
4.The die hole is not smooth and has defects:strengthen the repair and management of the die,and the unqualified die can not be used on the machine.
5.The lubrication area of the die hole is blocked:the lubricating fluid should be filtered to eliminate the metal chips and various impurities in the lubricating fluid.
7、Oxidation,water and oil stains
1.Insufficient lubrication and high temperature of lubricating fluid:ensure sufficient supply of lubricating fluid and strengthen cooling of lubricating fluid.
2.Splash of lubricating fluid:block the splash part,and wipe the line with felt at the outlet of finished product line.
3.The storage site is not clean and the greasy gloves contaminate the wire rod:adhere to 6S management to ensure the cleanness of the work site.
8、Full,partial,disordered,tight and loose take up and lay down lines
1.Improper alignment:adjust the alignment width and position according to the take-up reel specification.
2.Improper take-up tension:adjust take-up tension and take-up speed.
3.Wiring mechanism failure:careful observation,timely troubleshooting.
4.Irregularity of take-up reel:select qualified reel to operate.
5.Over full take-up:strengthen the monitoring,and reset the number of lower coil or repair the equipment in case of automatic disc change.
Analysis and treatment of abnormal causes in wire drawing process
1、Disconnection
1.Loose joint:adjust the current,power on time and pressure of butt welder to improve welding quality.
2.Wire has impurities:strengthen the acceptance of raw materials.
3.Unreasonable die matching:adjust the die to eliminate the phenomenon of large and small deformation process.
4.Incorrect or unsmooth die hole shape:the die shall be repaired in strict accordance with the standard,and the sizing area shall not be too long to ensure the smoothness of the die hole.
5.Excessive back pull:adjust the number of winding turns on the drum.
6.Drum thread pressing:adjust the number of winding turns on the drum to correct the worn drum.
7.Poor lubrication:check the lubrication system and determine the composition and temperature of the lubricant.
8.Aluminum rod is wet:prevent the aluminum rod from being wet,and the wet aluminum rod will not be used temporarily.
2、Incorrect size and shape
1.Wear of die hole:measure the wire diameter frequently,and replace the die when it is found that it is out of tolerance.
2.Wire drawing:adjust the die to improve the lubrication effect.
3.Using the wrong mold:measure the wire diameter after threading.
4.Wire scratch:check the quality and lubrication of die hole.
5.Dies skew:pay attention to straighten the mold and repair the dies base.
3、Abrasions,bumps,scratches
1.There is jumper phenomenon on the conical drum:the surface of the drum is polished and the angle is correct.
2.There are grooves on the drum:remove the drum to repair and polish it.
3.Places with broken line on the equipment:the drum interface is uneven,and the guide wheel does not rotate flexibly.
4.The reels collide with each other:the reels should be placed in "t" shape and separated from each other during transportation.
5.Uneven ground:repair the ground and lay steel plate.
6.Over full take-up:stick to the post and concentrate on setting down according to the regulations.
4、Peeling,pockmarking,triangle mouth and burr
1.The wire rod has flash,inclusion and shrinkage cavity:the inspection shall be strengthened,and the unqualified ones shall not be put into production.
2.The Dies hole is not smooth,deformation,etc.:strict inspection,unqualified dies is not on the machine.
3.Poor lubrication:improve the lubrication effect.
4.The drum is not smooth and the sliding rate is too high:polish the drum surface and adjust the die matching.
5、Wavy,serpentine
1.Improper die matching:adjust the die matching,and the deformation degree of the finished die should not be too small.
2.Serious vibration of wire drawing machine:repair and reinforce equipment to eliminate vibration.
3.Severe wire jitter:adjust the tension and keep the take-up speed stable.
4.The shape of die hole is not suitable:the length of sizing area should be suitable,not too short,or even none.
5.Uneven and unclean lubrication supply:ensure uniform lubricant supply and filter lubricant for use.
6、There are continuous scratches on the wire
1.Wire scratch:check all parts contacting with wire,such as guide wheel and wire rod.
2.The temperature of lubricating fluid is too high:strengthen the cooling,and use the forced cooling method when necessary.
3.High alkali content and uncleanness of lubricant:Test regularly to keep the composition of lubricant and ensure its cleanness.
4.The die hole is not smooth and has defects:strengthen the repair and management of the die,and the unqualified die can not be used on the machine.
5.The lubrication area of the die hole is blocked:the lubricating fluid should be filtered to eliminate the metal chips and various impurities in the lubricating fluid.
7、Oxidation,water and oil stains
1.Insufficient lubrication and high temperature of lubricating fluid:ensure sufficient supply of lubricating fluid and strengthen cooling of lubricating fluid.
2.Splash of lubricating fluid:block the splash part,and wipe the line with felt at the outlet of finished product line.
3.The storage site is not clean and the greasy gloves contaminate the wire rod:adhere to 6S management to ensure the cleanness of the work site.
8、Full,partial,disordered,tight and loose take up and lay down lines
1.Improper alignment:adjust the alignment width and position according to the take-up reel specification.
2.Improper take-up tension:adjust take-up tension and take-up speed.
3.Wiring mechanism failure:careful observation,timely troubleshooting.
4.Irregularity of take-up reel:select qualified reel to operate.
5.Over full take-up:strengthen the monitoring,and reset the number of lower coil or repair the equipment in case of automatic disc change.
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