A turntable for drawing tungsten alloy thick wire and a tungsten alloy thick wire drawing method using the same

Abstract

The present invention relates to the technical field of tungsten wire drawing, specifically a turntable for drawing tungsten alloy coarse wires and a method for drawing tungsten alloy coarse wires using the same. The invention provides a turntable with a specific structure that guides the tungsten wires into orderly arrangement through transition arcs and wire-supporting tapers, thereby eliminating overlap of the tungsten wires and effectively reducing the wire breakage rate. Furthermore, the present invention coordinates the relationship between wire diameter, speed, and temperature, perfectly balancing the plasticity and toughness of the tungsten wires, significantly reducing the wire breakage rate and improving the wire drawing success rate. No wire breakage occurs during the drawing process, and the overlap rate is zero. At the same time, waste graphite ash is converted into waste, which not only increases the value of graphite emulsion but also improves production efficiency.

Description

Technical Field

[0001] The invention relates to the technical field of tungsten wire drawing, in particular to a turntable for drawing tungsten alloy thick wires and a tungsten alloy thick wire drawing method using the turntable. Background Art

[0002] Tungsten alloy wire, due to its outstanding properties such as high strength, high hardness, and high-temperature resistance, has been widely used in the photovoltaic industry in recent years, particularly in busbars used in silicon wafer cutting consumables, where it has gradually replaced some traditional high-carbon steel wires. Tungsten alloy wire not only meets the photovoltaic industry's high demands for cutting materials but also brings significant commercial value and economic benefits. However, despite its outstanding performance in applications, its production process still faces technical challenges, particularly in the drawing process, which urgently need to be addressed.

[0003] Tungsten alloy wire production requires multiple drawing passes, with the drawing of thick wire (thick wire with a diameter greater than 0.355mm) being essential for producing fine wire. This drawing process typically utilizes gases such as natural gas, propane, or hydrogen to heat the thick wire. The rotating winding turntable drives the tungsten alloy wire through a die, drawing the thick wire into a thinner tungsten alloy wire that is then wound onto the turntable. Traditional winding turntables are typically made of pig iron. Due to its tendency to react with water vapor in the air, the turntable surface is often covered with rust, which increases friction during the winding process and may contaminate the tungsten alloy wire surface. Furthermore, the cylindrical winding tube in traditional winding turntables is vertically connected to the bottom support plate, subjecting the tungsten alloy wire to significant upward compressive forces during winding. Consequently, poor lubrication and inappropriate design of the traditional winding turntable can lead to varying degrees of wire overlap and even wire breakage during the winding process. Especially when drawing tungsten alloy wire with a diameter greater than 1.9mm, the high drawing force required increases the extrusion pressure generated during the wire reeling process. When the combined extrusion pressure from the reel and the drawing force exceeds the yield strength of the tungsten alloy wire, the wire is prone to breakage. Wire breakage not only affects continuous drawing production but also severely impacts product quality and production efficiency. Summary of the Invention

[0004] In view of the technical problems existing in the prior art, the present invention provides a turntable for drawing tungsten alloy thick wire and a tungsten alloy thick wire drawing method using the turntable.

[0005] According to one aspect of the present invention, the present invention provides the following technical solutions:

[0006] A turntable for drawing tungsten alloy thick wires, comprising a cylinder and a screw taper block, wherein the cylinder and the screw taper block are connected by a transition arc;

[0007] And the diameter D1 of the cylinder is (624+100ø 2 ) mm, the height H1 of the cylinder is (210-10×ø) mm; the axial length L1 of the transition arc is (D1 / (120-185)) mm, and the radial length L2 of the transition arc is ((0.4-0.6)×L1) mm; the bottom cross-sectional diameter D2 of the taper block is (2×(L2+L3)+D1) mm, where L3=((0.9-1.05)×L1+(0.6-0.85)×L2) mm; the R of the transition arc is (20×ø) mm; where ø is the diameter of the wire drawing die aperture, in mm.

[0008] According to another aspect of the present invention, the present invention provides the following technical solutions:

[0009] A method for drawing a tungsten alloy thick wire, using the above-mentioned turntable for drawing a tungsten alloy thick wire, comprises the following steps:

[0010] S1. Pour graphite ash produced by tungsten wire drawing, pure water, and a binder into a stirring barrel in a weight ratio of 7:(9-10):(3-4), and stir for 30-70 minutes until the viscosity reaches 4.3-6.5 cP to prepare a graphite emulsion;

[0011] S2. Apply the graphite emulsion evenly to the surface of the turntable, and repeat the application 3 to 5 times to ensure that the surface is fully covered;

[0012] S3. Place the mother wire end in a heating furnace and heat for 3-5 minutes. After high temperature treatment, place the wire end in a sodium nitrite bath for sintering. Use a cleaning cloth to remove excess sodium nitrite from the surface of the tungsten wire.

[0013] S4. Place the mother wire in a three-stage heating furnace for heating. The temperatures of the heating furnace are: T1 = (380 + 150 × ø) ° C, T2 = (T1 + 50 × (5-ø)) ° C, T3 = (T2 + 40 × (6-ø)) ° C. The heated tungsten wire passes through the drawing die for drawing.

[0014] S5. Use wire clamps to pull the tungsten wire from the die outlet to the turntable and fix the wire clamps on the turntable. The compression ratio (i.e., the ratio of the reduction in the diameter of the tungsten wire after drawing to the original diameter of the tungsten wire) is 15-30%, the die temperature is (480+15×ø)℃, and the wire drawing speed is (8-2×ø)m / min.

[0015] S6. Turn on the wire-collecting motor and the turntable rotates to drive the drawing and collection of the wire.

[0016] The beneficial effects of the present invention are as follows:

[0017] The present invention provides a turntable for drawing tungsten alloy coarse wire and a method for drawing tungsten alloy coarse wire using the same. The turntable has a specific structure that uses a transition arc and a taper block to guide the tungsten wires into orderly arrangement, eliminating overlap and effectively reducing the wire breakage rate. Furthermore, the present invention coordinates the relationship between wire diameter, speed, and temperature to perfectly balance the plasticity and toughness of the tungsten wire, significantly reducing the wire breakage rate and improving the wire drawing success rate. No wire breakage occurs during the drawing process, and the overlap rate is zero. Furthermore, waste graphite ash is converted into recycled material, which not only increases the value of graphite emulsion but also improves production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the structures shown in these drawings without paying any creative work.

[0019] Figure 1 Schematic diagram of the overall structure of the turntable of the present invention;

[0020] Figure 2 This is a front view of the turntable of the present invention;

[0021] Figure 3 for Figure 2 Enlarged view of point A in the middle.

[0022] Among them, 1-cylinder; 2-screw taper block; 3-transition arc.

[0023] The purpose, features and advantages of the present invention will be further described with reference to the accompanying drawings and in conjunction with the embodiments. DETAILED DESCRIPTION

[0024] The following will be a clear and complete description of the technical solutions in the embodiments. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts are within the scope of protection of the present invention.

[0025] According to one aspect of the present invention, the present invention provides the following technical solutions:

[0026] like Figure 1-3 As shown, a turntable for drawing tungsten alloy thick wire includes a cylinder 1 and a screw taper block 2, and the cylinder 1 and the screw taper block 2 are connected by a transition arc 3;

[0027] And the diameter D1 of cylinder 1 is (624+100ø 2) mm, the height H1 of the cylinder 1 is (210-10×ø) mm; the axial length L1 of the transition arc 3 is (D1 / (120-185)) mm, and the radial length L2 of the transition arc 3 is ((0.4-0.6)×L1) mm; the bottom cross-sectional diameter D2 of the supporting taper block 2 is (2×(L2+L3)+D1) mm, where L3=((0.9-1.05)×L1+(0.6-0.85)×L2) mm; the R of the transition arc 3 is (20×ø) mm; where ø is the diameter of the wire drawing die aperture, in mm.

[0028] According to another aspect of the present invention, the present invention provides the following technical solutions:

[0029] A method for drawing a tungsten alloy thick wire, using the above-mentioned turntable for drawing a tungsten alloy thick wire, comprises the following steps:

[0030] S1. Pour graphite ash produced by tungsten wire drawing, pure water, and a binder into a stirring barrel in a weight ratio of 7:(9-10):(3-4), and stir for 30-70 minutes until the viscosity reaches 4.3-6.5 cP to prepare a graphite emulsion;

[0031] S2. Apply the graphite emulsion evenly to the surface of the turntable, and repeat the application 3 to 5 times to ensure that the surface is fully covered;

[0032] S3. Place the mother wire end in a heating furnace and heat for 3-5 minutes. After high temperature treatment, place the wire end in a sodium nitrite bath for sintering. Use a cleaning cloth to remove excess sodium nitrite from the surface of the tungsten wire.

[0033] S4. Place the mother wire in a three-stage heating furnace for heating. The temperatures of the heating furnace are: T1 = (380 + 150 × ø) ° C, T2 = (T1 + 50 × (5-ø)) ° C, T3 = (T2 + 40 × (6-ø)) ° C. The heated tungsten wire passes through the drawing die for drawing.

[0034] S5. Use wire clamps to pull the tungsten wire from the die outlet to the turntable, and fix the wire clamps on the turntable. The compression ratio is 15-30%, the mold temperature is (480+15×ø)℃, and the wire drawing speed is (8-2×ø)m / min.

[0035] S6. Turn on the wire-collecting motor and the turntable rotates to drive the drawing and collection of the wire.

[0036] The technical solution of the present invention is further described below with reference to specific embodiments.

[0037] Example 1

[0038] A method for drawing a tungsten alloy thick wire comprises the following steps:

[0039] S1. Pour graphite ash produced by tungsten wire drawing, pure water, and a binder into a stirring barrel in a weight ratio of 7:10:3, and stir for 50 minutes until the viscosity reaches 4.8 cP to prepare a graphite emulsion;

[0040] S2. Apply the graphite emulsion evenly to the surface of the turntable, repeating the application 4 times to ensure full coverage of the surface;

[0041] S3. Select a tungsten wire with a diameter of 2.4 mm and a mass of 5.3 kg as the mother wire. Place the mother wire head in a heating furnace and heat it for 4 minutes. After high-temperature treatment, place the wire head in a sodium nitrite bath for sintering. Use a cleaning cloth to remove excess sodium nitrite from the surface of the tungsten wire.

[0042] S4. Use a drawing die with an aperture of 1.9 mm for drawing. Place the mother wire in a three-stage heating furnace for heating. The temperatures of the heating furnace are: T1 = 665°C, T2 = 820°C, and T3 = 984°C. The heated tungsten wire passes through the drawing die for drawing.

[0043] S5. Use wire pliers to pull the tungsten wire from the die outlet to the turntable and secure the pliers to the turntable. The diameter D1 of the turntable cylinder is 985 mm, and the height H1 of the cylinder is 191 mm. The axial length L1 of the transition arc is 6.4 mm, and the radial length L2 of the transition arc is 2.6 mm. The bottom cross-sectional diameter D2 of the taper block is 1004.8 mm, where L3 is 7.3 mm. The R of the transition arc is 38 mm. The compression ratio is 20.83%, the mold temperature is 508.5°C, and the drawing speed is 4.2 m / min.

[0044] S6. Turn on the wire-collecting motor and rotate the turntable to drive the wire drawing and collection. Under this condition, the wire is drawn 10 times without wire breakage and the wire overlap rate is zero.

[0045] Example 2

[0046] A method for drawing a tungsten alloy thick wire comprises the following steps:

[0047] S1. Pour graphite ash produced by tungsten wire drawing, pure water, and a binder into a stirring barrel in a weight ratio of 7:10:4, and stir for 60 minutes until the viscosity reaches 5.6 cP to prepare a graphite emulsion;

[0048] S2. Apply the graphite emulsion evenly to the surface of the turntable, repeating the application 5 times to ensure full coverage of the surface;

[0049] S3. Select a tungsten wire with a diameter of 2.9 mm and a mass of 5.5 kg as the mother wire. Place the mother wire head in a heating furnace and heat it for 5 minutes. After high-temperature treatment, place the wire head in a sodium nitrite bath for sintering. Use a cleaning cloth to remove excess sodium nitrite from the surface of the tungsten wire.

[0050] S4. Use a drawing die with an aperture of 2.4 mm for drawing. Place the mother wire in a three-stage heating furnace for heating. The temperatures of the heating furnace are: T = 740°C, T2 = 870°C, and T3 = 1014°C. The heated tungsten wire is drawn through the drawing die.

[0051] S5. Use wire clamps to pull the tungsten wire from the die outlet to the turntable and secure the clamps to the turntable. The diameter D1 of the turntable cylinder is 1200 mm, and the height H1 of the cylinder is 186 mm. The axial length L1 of the transition arc is 7.7 mm, and the radial length L2 of the transition arc is 3.9 mm. The bottom cross-sectional diameter D2 of the taper block is 1230.6 mm, where L3 = 11.4 mm. The R of the transition arc is 48 mm. The compression ratio is 17.24%, the mold temperature is 516°C, and the drawing speed is 3.2 m / min.

[0052] S6. Turn on the wire-collecting motor and rotate the turntable to drive the wire drawing and collection. Under this condition, the wire is drawn 10 times without wire breakage and the wire overlap rate is zero.

[0053] Example 3

[0054] A method for drawing a tungsten alloy thick wire comprises the following steps:

[0055] S1. Pour graphite ash produced by tungsten wire drawing, pure water, and a binder into a stirring barrel in a weight ratio of 7:9:4, and stir for 70 minutes until the viscosity reaches 6.3 cP to prepare a graphite emulsion;

[0056] S2. Apply the graphite emulsion evenly to the surface of the turntable, repeating the application three times to ensure full coverage of the surface;

[0057] S3. Select a tungsten wire with a diameter of 3.5 mm and a mass of 5.8 kg as the mother wire. Place the mother wire head in a heating furnace and heat it for 3 minutes. After high-temperature treatment, place the wire head in a sodium nitrite bath for sintering. Use a cleaning cloth to remove excess sodium nitrite from the surface of the tungsten wire.

[0058] S4. Use a drawing die with an aperture of 2.9 mm for drawing. Place the mother wire in a three-stage heating furnace for heating. The temperatures of the heating furnace are: T = 815°C, T2 = 920°C, T3 = 1044°C. The heated tungsten wire passes through the drawing die for drawing.

[0059] S5. Use wire pliers to pull the tungsten wire from the die outlet to the turntable and secure the pliers to the turntable. The diameter D1 of the turntable cylinder is 1465 mm, and the height H1 of the cylinder is 181 mm. The axial length L1 of the transition arc is 9.4 mm, and the radial length L2 of the transition arc is 5.6 mm. The bottom cross-sectional diameter D2 of the taper block is 1505.4 mm, where L3 is 14.6 mm. The R of the transition arc is 58 mm. The compression ratio is 17.14%, the mold temperature is 523.5°C, and the drawing speed is 2.2 m / min.

[0060] S6. Turn on the wire-collecting motor and rotate the turntable to drive the wire drawing and collection. Under this condition, the wire is drawn 10 times without wire breakage and the wire overlap rate is zero.

[0061] Comparative Example 1

[0062] The difference from Example 1 is that the length L1 of the transition arc along the axial direction is 4.3 mm.

[0063] After drawing and collecting the wire, the wire was broken 15 times in total, and the wire overlap rate was 5%.

[0064] Comparative Example 2

[0065] The difference from Example 1 is that the length L2 of the transition arc along the radial direction is 6.3 mm.

[0066] After drawing and collecting the wire, the wire was broken 10 times in total, and the wire overlap rate was 2%.

[0067] Comparative Example 3

[0068] The difference from Example 1 is that the R of the transition arc is 3.7 mm.

[0069] After drawing and collecting the wire, the wire was broken 23 times and the wire overlap rate was 0%.

[0070] Comparative Example 4

[0071] The difference from Example 1 is that the mold temperature is 470°C.

[0072] After drawing and collecting, the wire was broken 18 times and the wire overlap rate was 0%.

[0073] Comparative Example 5

[0074] The difference from Example 1 is that the drawing speed is 5.5 m / min.

[0075] After drawing and collecting the wire, the wire was broken 8 times in total, and the wire overlap rate was 0%.

[0076] Comparative Example 6

[0077] The difference from Example 1 is that a traditional turntable is used in which a cylinder and a bottom support plate are vertically connected.

[0078] After drawing and collecting, the wire was broken 27 times and the wire overlap rate was 0%.

[0079] Comparative Example 7

[0080] The difference from Example 1 is that the surface of the turntable is not coated with graphite emulsion.

[0081] After drawing and collecting the wire, the wire was broken 23 times and the wire overlap rate was 10%.

[0082] Comparative Example 8

[0083] The difference from Example 1 is that a single-stage heating furnace is used instead of a three-stage heating furnace, and the temperature is 980°C.

[0084] After drawing and collecting, the wire was broken 18 times and the wire overlap rate was 0%.

[0085] The above description is only a preferred embodiment of the present invention and does not limit the patent scope of the present invention. All equivalent structural transformations made by using the contents of the present invention specification under the inventive concept of the present invention, or direct / indirect application in other related technical fields are included in the patent protection scope of the present invention.

Claims

1. A method for drawing tungsten alloy thick wire, characterized in that: The tungsten alloy thick wire drawing turntable includes a cylinder and a screw taper block, which are connected by a transition arc; and the diameter D1 of the cylinder is (624+100ø 2 ) mm, the height H1 of the cylinder is (210-10×ø) mm; the length L1 of the transition arc along the axial direction is (D1 / (120-185)) mm, and the length L2 of the transition arc along the radial direction is ((0.4-0.6)×L1) mm; the bottom cross-sectional diameter D2 of the supporting taper block is (2×(L2+L3)+D1) mm, where L3=((0.9-1.05)×L1+(0.6-0.85)×L2) mm; the R of the transition arc is (20×ø) mm; where ø is the diameter of the wire drawing die hole, in mm; the method comprises the following steps: S1. stirring graphite ash produced by tungsten wire drawing with pure water and a binder to obtain a graphite emulsion; S2. Apply the graphite emulsion evenly to the surface of the turntable to ensure full coverage; S3. Place the mother wire head in a heating furnace and heat it. After high temperature treatment, place the wire head in a sodium nitrite bath for sintering. Use a cleaning cloth to remove excess sodium nitrite from the surface of the tungsten wire. S4. Place the mother wire in a three-stage heating furnace for heating. The heated tungsten wire passes through a drawing die for drawing. The temperatures of the heating furnace are: T1 = (380 + 150 × ø) ° C, T2 = (T1 + 50 × (5-ø)) ° C, and T3 = (T2 + 40 × (6-ø)) ° C. S5. Use wire clamps to pull the tungsten wire from the die outlet to the turntable and fix the wire clamps on the turntable; the mold temperature is (480+15×ø)℃, and the wire drawing speed is (8-2×ø)m / min; S6. Turn on the wire-collecting motor, and the turntable rotates to drive the drawing and collection of the wire. After 10 drawing operations, no wire breakage occurs and the wire overlap rate is zero.

2. The tungsten alloy thick wire drawing method according to claim 1, wherein: In step S1, the weight ratio of graphite ash, pure water, and binder is 7:(9-10):(3-4).

3. The tungsten alloy thick wire drawing method according to claim 1, wherein: In step S1, the stirring time is 30 to 70 minutes.

4. The tungsten alloy thick wire drawing method according to claim 1, wherein: In step S1, the viscosity of the graphite emulsion is 4.3-6.5 cP.

5. The tungsten alloy thick wire drawing method according to claim 1, wherein: In step S5, the compression ratio is 15-30%.

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