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    Jorge Fernandez
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    Method and apparatus for producing a wire

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    Method and apparatus for producing a wire

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    © All Rights Reserved
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    2 Ansichten22 Seiten

    Us 3934446

    Hochgeladen von

    Jorge Fernandez
    Method and apparatus for producing a wire

    Copyright:

    © All Rights Reserved
    Als PDF herunterladen oder online auf Scribd lesen
    Markieren Sie unangemessene Inhalte
    von 22
    United States Patent 1% Avitzur tn 3,934,446 (45) Jan. 27, 1976 [54] METHODS OF AND APPARATUS FOR PRODUCTION OF WIRE [76] Inventor: Betzalel Avitzur, 817 N. 31st St Allentown, Pa. 18104 [22] Filed: Apr. 16, 1974 [21] Appl. No. 461,307 [52] US. Ch. 72/206; 72/262 (51) Int. cL B21B 21/00 [38] Field of Search . 72/206, 256, 262, 263, 72/92, 93, 64, 65, 233, 231 186] References Cited UNITED STATES PATENTS 3,143,786 8/1964 Jones 72/206 3.186.943 5/1965 Ware 72/206 3,525,096 8/1970 Klenz. 72/206 765,216 10/1973 Green 727262 Primary Examiner—C. W. Lanham Assistant Examiner—Robert M. Rogers Atorney, Agent, or Firm—Seidel, Gonda & Goldhammer [57] ABSTRACT Methods of and apparatus for the production of wire are presented. Previously, the most economic and popular process was drawing. In each pass, a small re- duction was obtained and normally several dies in tan- dem were mounted on a single wire drawing machine The process was continuous ahd precision wire was made. Also in the prior art, traditional rolling was a continuous process, but was limited to heavy and me- dium gauge, to small reductions per pass, and to poor dimensional and surface control. In comparison, tradi- tional extrusion and hydrostatic extrusion are capable of large reductions, good dimensional control and sur- face finish, but are limited to finite wire or rod length. The more’ recent concepts of: continuous extrusion with viscous drag, continuous chamber extrusion, con- tinuous extrusion forming, combined hydrostatic ex- trusion and drawing for fine wire and helical extrusion are compared and their advantages and shortcomings are discussed, A family of new processes of and apparatus for combining extrusion and rolling, utilizing the friction drag provided by rolling with open chamber extrusion is described. A continuous process, with large reductions and good dimensional control, can be achieved. 22 Claims, 17 Drawing Figures 0 |. 5 fe “f 3,934,446 U.S. Patent Jan. 27, 1976 Sheet 1 of 10 U.S. Patent Jan. 27,1976 Sheet 20f 10 3,934,446 FIG. 2 U.S. Patent Jan. 27,1976 Sheet 3010 3,934,446 FIG. 3 FIG. 5 FIG. 4 FIG. 6 U.S. Patent Jan. 27, 1976 Sheet 4 of 10 NG FIG. 7 3,934,446 U.S. Patent Jan. 27,1976 Sheet 5 of 10 3,934,446 I | | | x 3 fl i li 59 Oe FIG. 8 U.S. Patent Jan. 27,1976 Sheet 6 of 10 33,934,446 U.S. Patent Jan. 27,1976 Sheet 70f 10 3,934,446 U.S. Patent Jan. 27,1976 Sheet 80f 10 3,934,446 an 1 MN ! | | | | HAW ANAT | Z-| 4 5, Hi ( ¢ ] \ | 1 iii N Z : LAMM MI idl, Til, FIG. 1 U.S. Patent Jan. 27,1976 Sheet 90f 10: 3,934,446 U.S. Patent Jan. 27, 1976 Sheet 10 of 10 FIG. /4a FIG. 146 3,934,446 3,934,446 1 METHODS OF AND APPARATUS FOR PRODUCTION OF WIRE BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates methods of and apparatus for the production of wire. Accordingly, it is a general “object of this invention to provide new and improved ‘methods and apparatus of such character. 2. Description of the Prior Art a. Forward In the production of wire and rod of all shapes and cross sections, the processes of wire drawing, rod roll: ing and extrusion are the conventional production methods. One or the other of the following two limiting. factors plagues each of these processes. By the pro- cesses of wire or rod drawing or rolling one can accom- plish only small reductions per pass. For larger redue- tions, successive passes must be followed. The process, however, can then be done as a steady state continuous process with little interruptions. In the process of extru- sion, larger reductions can be made in a single pass, but only finite lengths can be extruded and the process is intermittent, In the search for a truly continuous process, with large reductions per pass, the following four recent processes were proposed and developed: I. Continuous Extrusion with Viscous Drag by Fuchs — See: Fuchs, F. J., Wire Jr, 105 October, (1970) 2. Continuous Chamber Extrusion by Fuchs — See: Fuchs, F. J., and Schmebl, G. L., “Continuous Hydrostatic Extrusion”, presented and published, NEL/AIRAPT International Conference on Hydro: static Extrusion, University of Sterling, Scotland, June 13-15, 1973. 3. Continuous Extrusion Forming by Green — See: Green, D., “Continuous Extrusion - Forming of Wire Sections”, Jr. of the Inst. of Metals, Vol. 100, 1972 4. Combined Extrusion Drawing for Fine Wire. Eash process is described briefly, its concept ex- plained and its shortcomings pointed out. . Continuous Extrusion with Viscous Drag The development by Dr. Fuchs of Western Electric, as reported in Wire Jr., 105 (1970), utilizes viscous drag as the motivating force for the extrusion of contin- ‘uous rod of aluminum or copper. In principle, the liq- uid passing through a narrow gap between a chamber and a rod drags the rod forward by viscous drag. To maintain flow, a pressure drop prevails between the pressure at an'entrance on the back side of the cham- ber and an exit at the front. Only a small differential pressure can be maintained in each chamber. The dif- Terence in pressure between entrance and exit must be below the flow strength of the workpiece material to prevent pinch off. Thus, only low drag and small reduc- tions can be made by the use of a single chamber. In fone embodiment, the chambers are piggybacked in tandem to effect large reductions. The highest-pressure chamber is in front, discharging through a passage into a lower-pressure chamber behind it. The discharge from chamber to chamber proceeds, until at the last chamber, the exit pressure is atmospheric. Thus, if the entrance pressure to the first chamber is (say) 200,000 psi, a gradual drop prevails toward the entrance to the chamber at the back. Because of the forward motion of the rod, a small gap around the rod at the walls between 5 1s 20 25 30 35 40 45 50 55 60 65 chambers does not leak. A rolled or extruded rod could, be reduced to final telephone wire size in a single die by a single pass, This process was apparently abandoned due to poor efficiency. The applicant has calculated the expected power consumed by shear in the liquid itself and has determined that maximum efficiency expected theoret- ically is in the vicinity of 30%. This 30% efficiency could only be achieved when pressure approaches in- finity and the gap between the rod and the chamber approaches zero. Such conditions can not exist in prac- tice. Furthermore, approaching such conditions, the process becomes very unstable and any change in pres sure oF size of the rod throws the process out of bal- ‘Thus, due to inefficiency, such process becomes un- acceptable for economical production application. ¢. Continuous Chamber Extrusion To avert the shortcomings of the continuous viscous drag extrusion, a continuous segmented chamber ex- truder, has been developed, as reported by Fuchs, F.J., and Schmehl, G. L., “Continuous Hydrostatic Extru” sion”, presented and published, NEL/AIRAPT Interna- tional Conference on Hydrostatic Extrusion, University of Sterling, Scotland, June 13-15, 1973. The continu- ‘ous chamber is made from matching segments moving in a chainlike manner. Four circumferentially seg- mented parts form together a short length of the cham- ber. Longitudinally, many segments form the length of the chamber which is open on both ends. The segments move together parallel to the axis of symmetry of the chamber. They separate at the exit in order to get away from the chamber they formed and then return to the entrance side where they meet again to form the cham- ber with their matching counter-parts. A die is set at the exit and a rod is fed at the entrance. The rod is squeezed and dragged by the segmented chamber, moving with it towards the die. To enhance the drag, the rod is coated with plastic material before entering the machine. The rod is machined to close tolerances before coating to fit snugly in the chamber. As the rod reaches the die, the drag produces enough pressure to force extrusion through the die, Very little relative motion is expected between the moving chamber and the rod, so that friction losses are minimized ‘The motivation mechanism to mobilize the chamber components and the matching of the components re- quires a high degree of precision. Cleanliness must be maintained to avoid gaps between the matching seg- ments, through which fins from the deforming work- piece might squeeze. Besides being precision made, the mechanism must be highly rigid to produce and with- stand the high operating pressures and forces, Preparation of the raw material to enter the machine (dimensioning and coating) and the watchmakers’ pre cision, combined with massivity demands from the production machine parts and assembly, are the major shortcomings of such machines. d. Continuous Extrusion Forming ‘A development by D. Green of the British Atomic Energy Agency, reported at “Continuous Extrusion- Forming of Wire Sections”, Jr. of the Inst. of Metals, Vol 100, 1972, employs friction between a workpiece and a tool as the motivating force for continuous extru- sion. There, in an explanatory model which describes the principles, a die with a hole is attached to a station ary platen. A top platen with a square groove is mounted over the bottom stationary platen. Together, 3,934, 3 they form a square chamber with a block closing the left end; the hole in the block is the die opening. The right end of the chamber is open. A round rod is placed in the chamber, touching at the four surfaces. Then, the top platen is made to slide towards the die, Friction 5 from the three sides of the moving platen drags the rod toward the die, where the rod is blocked, Please note that friction from the top platen exceeds and over- comes resistance by friction from the bottom platen. The friction effect on the rod is to upset the rod. The more the rod is upset, the more effective the friction drag becomes. As it comes closer and closer to the die, more contact prevails between the workpiece and the four walls. At the die, the round original rod has al- ready deformed into a square rod. Pressure is high enough to effect an extrusion through the die. As a bonus, the design is made so as to leave a small gap between the die block and the moving platen, Through this gap, a thin chip is discarded, removing the unde sired surface of the rod. Standard extruded or rolled stock serves as the workpiece When the stationary platen is replaced by a station- ary semi-circular member, and the moving platen by a rotating cylindrical tool, a continuous process is estab- lished. The two major factors restricting the efficiency of such process are the redundant work of upsetting the incoming wire and friction losses. The redundant work is due to an upsetting of the original round wire to a square (and then starting from a square rather than a round — through the die). This work is independent of the attempted reduction. The friction losses in the square channel depend both on friction values and on reduction e. Combined Extrusion Drawing for Fine Wire ‘One of the shortcomings of the process of hydrostatic extrusion is the finite length of an extruded billet. Since the process of wire drawing has the advantage of being a continuous process, the problem of overcoming the batch-interrupted nature of hydrostatic extrusion has long been with us. When a spool of wire is inserted into a cylindrical chamber, longer runs can be made. Simple spools can 20 2s 30 35 40 446 4 be used, and spinning reels and standing reels have been explored at Battelle, as set forth in U.S. Pat. No. 3,328,998, “High Reduction Drawing”, By Sabroff, A. M., and Fiorentino, R. J. — July, 1967, and by Pugh of the National Engineering Laboratories in Scotland, in “The Mechanical Behavior of Materials Under Pres- sure”, FIG. 41 of Chapter 9, “Hydrostatic Extrusion”, Elsevier Materials Science Series, 1970, Pugh, H. Ll. D., (Editor). When the extrusion pressure is aug- mented by a pull, a Robertson process is provided, as described by J. Robertson at “Method of and Appara. tus for Forming Metal Articles”, British Pat. No. 19,356, October 14, 1893; U.S. Pat. No. 524,504, Au: gust 14, 1894, Hundreds of thousands of feet of fine wire, (<0,001 inch), used in the solid state industries, can be spooled and inserted into a % inch bore cham: ber to provide very long runs between loadings. Deli- instrumentation to relate chamber pressure to augmenting tension controls is essential for such equip- ment. Development work along these lines is followed internationally. With present day limited chamber size, only very fine wire production is expected to be eco- nomically competitive for this process. It should be noted that very long wire can be made, but the process is not a truly continuous process. £. Helical Extrusion Another process by Green is called Helical Extru. sion. There, hydrostatic extrusion is combined with a chip forming process to produce a small gauge wire (of all shapes) directly from an ingot. Reductions of thou- sands to one are obtained. Because of the involved concept, this prior-art process is not described herein. Very long wire can be made, but the process is not truly continuous. Each ingot is loaded separately. g. Comparisons of Alternate Processes In Table I, the alternate possible processes for the production of wire and rod are tabulated vertically, Criteria for the comparison of major characteristics of those processes are listed horizontally, thus obviating the necessity for deliberation. The process of “extroll- ing” the newly proposed process of this invention, in included, TABL ‘COMPARISONS OF ALTERNATE PROCESSES Power” Design Dimensional, Property Product Reduction oth charac surtuce ia Other Process engi possible” Speed _clency _terisics femal damage comments Roig Un Small High High Simpl, fow mov Poor limited ing pars. rugged Conventional ‘Short Large Moderate Moderate Simple, few tow aie ‘extrusion ing pars rugged Wire Ue Sell gh oigh Sa Goo Graing Vimitod Contintous Un Large Very Excess: Complicated, but Good “Limite only by ability fxtrsion with Dito Right ely few moving ports to collect product Sissons drag oor Continuovt Un. Larger” Moderate Esimed Complicated, many —

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