Seminar report on wire drawing
#1

PRODUCTION PROCESS

WIRE DRAWING

The wire rod to be drawn is pointed in the Wire Pointing Machine. This pointed wire is inserted through the die of the first Wire Drawing Machine and fastened to a locking device on the drum. The drum is then started, as the drum rotates, the wire fastened to the drum gets pulled and coiled around the drum. Since the wire getting pulled is passed through the die having a higher inlet diameter and lower outlet diameter, the drawn wire diameter gets reduced.
• The starting end of the drawn wire is released from the lock of the first drum and then it's passed trough the overhead loop and pulley provided. It is brought down and is inserted through the die of the second drum and drawn through this die for further reduction. Thus, the wire is drawn through all the wire drawing drums of the set in a continuous manner to get the required finished diameter of the wire.
• When the drum of the last wire drawing machine gets fully loaded with the drawn wire, the machine will be stopped to unload the finished material and then restarted. If one opts for the continuous coiling machine, then the drawing process will not have to be stopped for this purpose.
• When the bundle of the input rod finishes, the machine should be stopped. The end of this bundle is welded to the end of a new bundle rod using the butt welding machine. Then the process is to be continued.
• Also, in case of an accidental snapping of wire in between drums, the snapped ends are welded with the help of the butt welding machine and the process is continued.

This process of wire drawing is done in two stages. In first stage the diameter of wire is reduced from 6 mm to 3-2.8 mm. In second stage the diameter of wire is reduced from 3-2.8 mm to 0.9mm. The end product from first stage is used for making wire nails & the end product from second stage is used as binding wire after it is exposed to heat treatment technically called Annealing. After annealing process is over the binding wire is stocked for marketing. Usually 10-15 Kg bundles are made for marketing.

Process of Annealing

Annealing is used to treat work-hardened parts made out of low-Carbon steels (< 0.25% Carbon). This allows the parts to be soft enough to undergo further cold working without fracturing. Process of annealing is done by raising the temperature to just below the Ferrite-Austenite region. This temperature is about 727 ºC (1341 ºF) so heating it to about 700 ºC (1292 ºF) should suffice. This is held long enough to allow recrystallization of the ferrite phase, and then cooled in still air. Since the material stays in the same phase through out the process, the only change that occurs is the size, shape and distribution of the grain structure. This process is cheaper since the material is not heated to a very high temperature or cooled in a furnace.




Wire Nail Manufacturing
The wire end from coil passes through rollers and fed intermittently in the gripping dies, which close firmly allowing heading punch to press the head of the nails, then grip loosened and required length of the nail is fed constantly, where it is cut by cutting tools leaving ample stock for the head of the next nail. Thus ready nail is ejected by the ejector. The operations are repeated in each revolution.
Grinding
The cutters of Wire Nails Making Machines on continuous working, its cutters become blunt and require regrinding. The grinding machine is specially designed to sharpen all the profiles of cutters. It is fitted with four grinding wheels of different shapes and special attachments. The Motor of 1 H.P X 2800 R.P.M is fitted in it.

Nail Polishing
The nail polishing drum is used for polishing the wire nails. It revolves at 40 to 45 R. P. M and having capacity 200 kg per hour. It requires 2H.P electric motor. The nails with nipping are loaded into the drum above the half filled level and suitable quantity approx 80% of saw dust and leather cutting is added. There after they are tumbled for approximately 20 to 40 minutes depending on the dirt accumulation on the nails. The nipping and scouring can be drawn off together at the end of the process, if the machine is ordered with a dust filter unit with an exhauster. Otherwise the nails can be separated through a sieve also.
NOW THE NAILS ARE READY FOR DISPATCH.
INTRODUCTION
In engineering, woodworking and construction, a nail is a pin-shaped, sharp object of hard metal, typically steel, used as a fastener. Nails for specialized purposes may also be made of stainless steel, brass or aluminium.
Nails are typically driven into the workpiece by a hammer or by a nail gun driven by compressed air or a small explosive charge. A nail holds materials together by friction in the axial direction and shear strength in lateral directions. The point of the nail is also sometimes bent over or clinched to prevent it from pulling out.
Nails are made in a great variety of forms for specialized purposes. The most common type of nail is a "wire nail". Other types of nails include "pins", "tacks", "brads", and "spikes."
Today, nails are usually made of steel. Formerly they were usually of wrought iron, but for some purposes nails are made of copper or rather brass.
Commonly nails are designated as 50 x 3.0 indicates a nail 50 mm long (not including the head) and 3 mm in diameter. Lengths are rounded to the nearest millimeter.
Nails are divided into three broad categories based on their length. In general nails less than 1 inch (2.5 cm) in length are called tacks or brads. Nails 1-4 inches (2.5-10.2 cm) in length are called nails, while those over 4 inches (10.2 cm) are some-times called spikes. These categories are roughly defined, and there is considerable crossover between them.
The most typical nail point is a four-sided tapered cut called a diamond point. Other nails may have a blunter point to prevent splitting certain woods. Chisel points, barbed points, needle points, and many others are sometimes used on specialty nails.
Collated coil nails are used in the industries of wood furniture, architecture, board package and fitment.
Types of nail include:
• Box - a wire nail with a head; box nails have a smaller shank than common nails of the same size
• Bright - no surface coating; not recommended for weather exposure or acidic or treated lumber
• Casing - a wire nail with a slightly larger head than finish nails; often used for flooring
• Cement coated- nail coated with adhesive (cement) for greater holding power; also resin- or vinyl-coated; coating melts from friction when driven to help lubricate then hardens when cool; color varies by manufacturer (tan, pink, are common)
• Common - a common construction wire nail with a head: common nails have larger shanks than box nails of the same size
• Duplex - a common nail with a second head, allowing for easy extraction
• Finish - a wire nail that does not have a "head"; can be easily concealed
• Galvanized - treated for resistance to corrosion and/or weather exposure
• Electrogalvanized - provides a smooth finish with some corrosion resistance

• Mechanically galvanized - deposits more zinc than electrogalvanizing for increased corrosion resistance
• Hot-dip galvanized - provides a rough finish that deposits more zinc than other methods, resulting in very high corrosion resistance that is suitable for some acidic and treated lumber; often easier to bend than other types of nails
• Head - round flat metal piece affixed to the top of the nail; for increased holding power
• Helix - the nail has a square shank that has been twisted this makes the nail very difficult to pull out; often used in decking
• Phosphate-coated - a dark grey to black finish providing a surface that binds well with paint and joint compound and minimal corrosion resistance
• Point - sharpened end opposite the "head" for greater ease in driving
• Ring Shank - small rings on the shank to prevent the nail from being worked back out often used in flooring
• Shank - the body the length of the nail between the head and the point; may be smooth, or may have rings or spirals for greater holding power
• Sinker - Same thin diameter as a box nail, cement coated the funnel shaped head is easier to nail flat and the head has a grid on the strike surface to keep the hammer strike from slipping; these are the common nails used in framing today
• Spike - a large nail (usually over 4" - 100 mm)



Quality Control
Raw materials must meet certain standards for chemical composition, yield strength, hardness, corrosion resistance and other properties. These are usually certified by the company supplying the wire, and may be independently checked by the nail manufacturer.
During manufacture, nails must also meet certain specifications regarding dimensions and properties. These are achieved using a method known as statistical process control, which periodically samples the dimensions and properties of the nails being produced and evaluates any changes through statistical analysis techniques.
The Future
The demand for mass-produced commodity nails is dependent on the fluctuations in the housing market, which varies with the economy. Demand for these nails is also subject to competition from local manufacturers.
The demand for specialty nails, on the other hand, is expected to continue to grow and be profitable. New building materials, such as composite wood-fiber and cement-based siding and roofing, require new specialty nails. New corrosion-resistant coatings for nails are also being developed.
One unique new nail market is the result of the increase in building restoration and preservation efforts throughout the country.

Different types of wire nails


Types of nails













PROCESS FLOW CHART


PRODUCTS : Wire Nails & Binding Wire

RAW MATERIAL
(6 mm Diameter wire)

WIRE DRAWING (Stage - I)
(Diameter reduces from 6mm to 3-2.8mm)

___ WIRE NAIL MAKING

WIRE DRAWING (Stage - II)
(Diameter reduces from 3-2.8mm to 0.90mm)



ANNEALING PROCESS



FINAL PRODUCT : BINDING WIRE




PACKING & MARKETING



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