Copper Wire Drawing Machines Production Defects & Solutions

Shrink Line

It means that the diameter of the product drawn by the copper wire drawing machines is smaller than the die hole diameter under the condition that the die hole diameter of the copper wire drawing machine meets the size requirements.

Defect Analysis

1. The working area of the mold is too long;
2. The mold holes of the finished mold or the front pad mold are blocked by copper mud and copper powder, which increases the resistance when the copper wire passes through and causes wire shrinkage;
3. The mold reduction rate is too large, causing the tensile force to be too large;
4. The thread tension is too high.

Solution

1. Adjust the qualified finished product mold and cushion mold;
2. Clean the copper mud and copper powder in the mold hole in time;
3. Adjust the mold;
4. Adjust the take-up tension of the copper wire drawing machine.

Disconnected

Refers to the problem of interruptions in the production process.

Defect Analysis

1. The quality of copper material is too poor;
2. Improper take-up tension;
3. The mold reduction rate is too high the mold sizing area is too long or the hole diameter exceeds the standard;
4. The cone wheel of the copper wire drawing machine is grooved or has too many windings, causing wire pressure;
5. The joint is not firm.

Solution

1. Replace with qualified copper material or appropriately reduce the wire take-up speed;
2. Adjust the take-up tension;
3. Adjust mold matching and replace molds;
4. Pay attention to the operation method and replace the cone wheel;
5. Ensure joint quality.

Flash

A more pronounced yin and yang surface caused by out-of-roundness (flatness).

Defect Analysis

1. The finished mold of the copper wire drawing machine or the pad mold close to the finished mold is too flat;
2. The mold is not placed correctly.

Solution

1. Replace the mold;
2. Check the mold placement of the copper wire drawing machines.

Oxidation

The surface of the copper material is corroded by the atmosphere, water, or dirt to produce copper oxide and cuprous oxide, resulting in dark red, gray, and black colors.

Defect Analysis

1. The outlet mold was not placed properly, causing drawing oil to leak and contaminate the copper wire;
2. The temperature of the drawing oil is too high, the water volume is insufficient, and the cooling is insufficient; there is not enough steam when the annealing line is opened, steam leakage, or insufficient annealing cooling water.
3. The iron shaft is not wiped clean of oil and water stains when putting it on the machine, or there are oil stains and water stains on the operator’s hands when putting the iron shaft on;
4. Use oily gloves to touch bare wires during transportation;
5. The storage time is too long, the copper wire is not wrapped in time, and the storage location is too hot or humid.

Solution

1. Before starting the copper wire drawing machines, check whether the outlet mold is placed correctly;
2. Check whether the liquid and gas supply is sufficient and whether the temperature of the copper wire outlet is too high.
3. Wipe your hands with a clean rag when getting on the machine and pay attention to protecting the copper wire when transporting the iron shaft;
4. The copper wire storage location should be clean and dry, should not be left for too long, and should be well-wrapped.

Black Spots

There are spots and dots on the surface of the copper wire.

Defect Analysis

1. The oil stains on the blank itself or the residual stains on the oxide layer after drawing form spots;
2. The drawing oil has been used for a long time and contains more oil stains and chloride ions that adhere to the surface of the copper wire to form spots;
3. The mold holes are worn, which can easily bring out oil stains and cause black spots.

Solution

1. Replace qualified bad materials or pull copper wires of smaller specifications when the copper wire drawing machines process requirements can be met;
2. Strengthen the storage of drawing oil and replace it with new drawing oil when necessary;
3. Replace worn molds.

The Cable is Uneven

Refers to the unevenness of the copper wire drawing machine.

Defect Analysis

1. The cable arrangement stroke is not adjusted to the correct distance;
2. The cable arrangement stroke should be long on both sides or long on one side and short on the other.
3. The cable arrangement system is faulty and the traveling speed of the cable arrangement rod is inconsistent.

Solution

1. Frequently adjust and arrange the wiring during the production process.
2. Troubleshoot the wiring fault.

Clamp Line

It means that the outer copper wire of the copper wire drawing machines is caught by the inner layer, and the copper wire cannot be laid out normally.

Defect Analysis

1. The take-up tension is unstable, resulting in inconsistent cable tightness;;
2. The cable arrangement is uneven.

Solution

1. Adjust the equipment tension;
2. Frequently adjust and arrange the wiring.

Loose Line

It means that the wiring of the copper wire drawing machine is not tight, and obvious dents will appear when you press it with your fingers.

Defect Analysis

1. The equipment tension is too loose.
2. “Water leakage” contaminates the cone wheel or booster wheel, and the sliding rate of the copper wire will be reduced. If the take-up speed is not increased accordingly, the wire will loosen;

Solution

1. Properly adjust the take-up tension, and promptly eliminate any problems with the tension system.
2. Pay attention to the cleaning of the cone wheel and power-assisted wheel or adjust the take-up speed

Clip Edge

The copper wires at both ends of the take-up shaft of the copper wire drawing machines are clamped by the sides of the shaft and cannot be paid out.

Defect Analysis

1. The take-up shaft is severely deformed
2. Slight deformation of the take-up shaft and too tight take-up tension will also cause edge clamping

Solution

1. The take-up spool cannot be used if it is severely deformed.
2. When using a slightly deformed take-up spool, adjust the tension as low as possible to reduce edge clamping while ensuring that the cable arrangement is flat.

Copper Wire Feels Burrs

The copper wire is not smooth when you touch it with your hands, and may scratch your hands in severe cases.

Defect Analysis

1. The copper material is of poor quality and produces burrs during the drawing process;
2. The exit mold or several molds close to the exit mold are broken;
3. The grooves of the cone wheel, fixed speed wheel, line guide wheel, etc. are too deep;
4. The take-up tension is unstable and the copper wire jumps sharply.

Solution

1. Replace qualified copper materials;
2. Replace qualified molds;
3. Replace cone wheels, fixed speed wheels, etc. with too-deep grooves in time;
4. Properly adjust the take-up tension of the copper wire drawing machines, and promptly eliminate any problems with the tension system.

Abrasions

The surface of the copper wire is hairy or has continuous scars on one side.

Defect Analysis

1. The copper wires themselves are pressed against each other due to reasons such as too many windings or grooves on the cut wheels;
2. The surface of the cone wheel, fixed speed wheel, three-groove guide wheel, cable guide wheel, etc. is not smooth, causing scratches on the copper wire;

Solution

1. Correct the operation method;
2. Do a good job in maintaining the copper wire drawing machines, and replace parts on time when they need to be replaced.

Bending

Refers to the situation where the copper wire has a certain pitch of twists and is not straight.

Defect Analysis

1. The shrinkage rate of the mold is too small, the center of the mold is not straight or flat, and the copper wire is unevenly stressed;
2. The take-up speed is too fast, the groove of the power-assisted wheel or guide wheel is deep, or there is copper powder and oil agglomeration in the felt, which affects the line speed;
3. Caused by loose winding on the cone wheel and power-assisted wheel or vibration of the equipment.
4. The exit mold cleaning felt pad is placed too high

Solution

1. Adjust the mold matching and place the mold in a straight position;
2. Adjust the take-up speed, and operation method and pay attention to equipment maintenance.
3. Ensure that the copper wire is still in a horizontal position after passing through the felt during the operation of the copper wire drawing machines.

Adela

See Full Bio