Manufacturing method of plated special shaped wire

Abstract

The present disclosure aims to provide a method for manufacturing a plated deformed wire that can effectively suppress peeling of the plating layer. The method for manufacturing a plated deformed wire of the present disclosure includes a plastic processing step of passing a metallic material wire 30 having a circular cross section through an opening 20 of a die 2 that rotates around a central axis and performing wire drawing and twisting on the material wire 30 to form a deformed wire 31, and a plating step of passing the deformed wire 31 through a tank 14 that stores a plating solution containing at least molten zinc and immersing the deformed wire 31 in the plating solution to form a zinc-containing plating layer 32 on the surface of the deformed wire 31.

Description

[Technical field]

[0001] The present disclosure relates to a method for manufacturing a plated shaped wire. [Background technology]

[0002] The deformed wire rod is a metal wire rod having a polygonal cross section such as a square shape and having both ends twisted. The deformed wire rod is also called a twist bar or a screw bar, for example.

[0003] Wire mesh made with deformed wire is lighter than wire mesh made with metal wire (round bar) with a circular cross section, and the addition of a twist improves its tensile strength. Therefore, wire mesh made with deformed wire has the advantages of being inexpensive, durable, and easy to install when used for fences and barriers. Another advantage of wire mesh made with deformed wire is that it has a high adhesion rate to concrete and can be used well for reinforcing bars, etc.

[0004] When wire mesh using deformed wire is used for, for example, a fence or railing to prevent damage from animals, the wire mesh is left outdoors and is therefore required to have rust resistance. The applicant has previously proposed a method for producing a plated deformed wire having rust resistance by passing a plated material wire having a circular cross section through a die and subjecting the material wire to wire drawing and twisting (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2018-094560 A Summary of the Invention [Problem to be solved by the invention]

[0006] The method described in Patent Document 1 makes it possible to manufacture a plated deformed wire in which peeling of the plating layer during and after processing is suppressed. In response to this, the applicant conducted intensive research in order to manufacture a plated deformed wire in which peeling of the plating layer can be further suppressed compared to conventional plated deformed wires, and as a result, has completed the manufacturing method of the plated deformed wire disclosed herein.

[0007] An object of the present disclosure is to provide a method for manufacturing a plated deformed wire that can effectively suppress peeling of a plating layer. [Means for solving the problem]

[0008] A method for manufacturing plated deformed wire according to the present disclosure includes a plastic processing step in which a metal material wire having a circular cross section is passed through an opening of a die rotating around a central axis and subjected to wire drawing and twisting processes to convert the material wire into a deformed wire, and a plating step in which the deformed wire is passed through a tank containing a plating liquid containing at least molten zinc and immersed in the plating liquid to form a zinc-containing plating layer on the surface of the deformed wire. Effect of the Invention

[0009] The method for manufacturing a plated irregular wire according to the present disclosure can manufacture a plated irregular wire that can effectively prevent peeling of the plating layer. [Brief description of the drawings]

[0010] [Figure 1] FIG. 1 is a diagram showing the steps of a method for manufacturing a plated shaped wire according to the present disclosure. [Diagram 2] FIG. 2 is a schematic diagram of a wire drawing machine. [Diagram 3] FIG. 3 is a schematic diagram of a plating apparatus. [Figure 4] FIG. 4 is a perspective view of the die. [Figure 5A] FIG. 5A is an enlarged front view showing openings in the approach portion and the bearing portion of the die. [Figure 5B] FIG. 5B is an enlarged view of a portion of FIG. 5A. [Figure 6] FIG. 6 is a side view of a portion of the plated profile wire. [Figure 7] FIG. 7 is a cross-sectional view of a plated deformed wire. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] [Outline of the manufacturing method of plated profile wire disclosed herein] A method for manufacturing plated deformed wire according to the present disclosure includes, in this order, a plastic processing step in which a metal material wire having a circular cross section is passed through an opening of a die rotating around a central axis and subjected to wire drawing and twisting processes to convert the material wire into a deformed wire, and a plating step in which the deformed wire is passed through a tank containing a plating liquid containing at least molten zinc and immersed in the plating liquid to form a zinc-containing plating layer on the surface of the deformed wire.

[0012] In the method for manufacturing plated deformed wire of the present disclosure, a material wire is plastically processed to form a deformed wire, and then the deformed wire is plated to manufacture a plated deformed wire. If plastic processing such as twisting is performed on the plated material wire after plating, the surface of the plated material wire may be scratched during the plastic processing. In harsh outdoor environments, if the surface of the plated deformed wire after processing is scratched, the scratch may cause the plating layer to peel off. According to the method for manufacturing plated deformed wire of the present disclosure, the surface of the plated deformed wire is less likely to be scratched during plastic processing, so that the plated deformed wire after production is less likely to have the plating layer peel off and can exhibit good rust prevention effects.

[0013] The method for manufacturing a plated deformed wire according to the present disclosure can be preferably configured such that the cross-sectional shape of the opening in the die is an approximately polygonal shape with corners of the polygon rounded with a radius of curvature of 0.7 mm or more, and in the plastic processing step, the speed at which the deformed wire is drawn from the opening of the die is 50 M / min or more. According to the method for manufacturing a plated deformed wire of the present disclosure, since the cross-sectional shape of the opening of the die through which the material wire passes is an approximately polygonal shape with corners rounded with a radius of curvature of 0.7 mm or more, the material wire can be plastically processed to produce a deformed wire at a high drawing speed. Therefore, the manufacturing efficiency of plated deformed wire can be improved, and plated deformed wire can be manufactured at low cost.

[0014] The method for manufacturing a plated deformed wire according to the present disclosure can be preferably configured such that, in the plastic processing step, when the speed at which the deformed wire is drawn out of the opening of the die is 50 M / min or more, the rotation speed of the die is 556 rpm or more, or the axial length required for one twist in the deformed wire obtained in the plastic processing step is 100 mm or more and 200 mm or less. According to the method for manufacturing a plated deformed wire according to the present disclosure, in the plated deformed wire after production, the axial length required for one twist (twist interval) is short and the twists are densely present in the plated deformed wire, so that the tensile strength of the plated deformed wire can be favorably improved.

[0015] A method for manufacturing a plated deformed wire according to the present disclosure can preferably be configured such that the plating process includes a first step of passing the deformed wire through a tank containing hot water and immersing it in the hot water, a second step of passing the deformed wire after the first step through a tank containing cold water and immersing it in the cold water, a third step of passing the deformed wire after the second step through a tank containing acid and immersing it in the acid, a fourth step of passing the deformed wire after the third step through a tank containing flux and immersing it in the flux, and a fifth step of immersing the deformed wire after the fourth step in the plating solution.

[0016] [Embodiment of the manufacturing method of plated profile wire of the present disclosure] A specific embodiment of the method for manufacturing a plated profile wire according to the present disclosure will be described with reference to Figures 1 to 3. In the drawings, the same or corresponding parts are denoted by the same reference characters, and descriptions thereof will not be repeated.

[0017] The manufacturing method for plated deformed wire includes at least a plastic processing step in which a metal material wire 30 having a circular cross section is plastically processed into deformed wire 31 having a polygonal or nearly polygonal cross section and having a shape as if both ends are gripped and twisted; a plating step in which a zinc-containing plating layer 32 is formed on the surface of deformed wire 31 to produce plated deformed wire 33; and a coiling step in which plated deformed wire 33 is wound and coiled. The plating process includes a first step of passing the deformed wire 31 through a first tank 11 in which hot water is stored and immersing it in hot water; a second step of passing the deformed wire 31 after the first step through a second tank 12 in which cold water is stored and immersing it in cold water; a third step of passing the deformed wire 31 after the second step through a third tank 13 in which acid is stored and immersing it in acid; a fourth step of passing the deformed wire 31 after the third step through a fourth tank 14 in which flux is stored and immersing it in flux; and a fifth step of passing the deformed wire 31 after the fourth step through a fifth tank 15 in which a plating solution containing at least molten zinc (referred to as "molten zinc" in this disclosure) is stored and immersed in the plating solution.

[0018] The metal wire material 30 that is the raw material for the plated deformed wire 33 is preferably an iron wire or a steel wire. The diameter of the wire material 30 is not particularly limited, but is, for example, 5.5 mm or more and 7.0 mm or less. The wire material 30 is wound into a coil shape by a payout machine 4.

[0019] The material wire 30 is subjected to plastic processing such as wire drawing and twisting to form a deformed wire 31. Wire drawing is a plastic processing to thin the material wire 30, and the material wire 30 is gradually thinned to a predetermined wire diameter by the wire drawing. Twisting is a plastic processing to twist the material wire 30 around its axis along the axial direction, and as shown in Fig. 6, twisting forms twists at predetermined intervals in the deformed wire 31 and plated deformed wire 33 that are plastically deformed from the material wire 30.

[0020] A material wire 30 is subjected to a wire drawing process and a twisting process, for example, by passing it through a die 2 installed in a wire drawing machine 1. FIG.

[0021] The wire drawing machine 1 includes at least a die 2 , a die holder 3 , a payout machine 4 , a winding machine 5 , a motor 6 , a power transmission mechanism 7 , and a box 8 .

[0022] The unwinding machine 4 and the winding machine 5 include, for example, cylindrical bodies 41, 51 that can rotate around central axes 40 and 50, respectively. The winding machine 5 is configured such that the cylindrical body 51 rotates by a rotational driving force from a motor, and the cylindrical body 51 winds up the deformed wire 31 after plastic working. The unwinding machine 4 is configured such that the cylindrical body 41 rotates by a force of winding up the deformed wire 31 due to the rotation of the cylindrical body 51 of the winding machine 5, and pays out the material wire 30 from the cylindrical body 41.

[0023] The die 2 is placed in a die holder 3 in order to perform drawing and twisting on a material wire 30. As shown in Fig. 4, the die 2 has, for example, a cylindrical shape with a circular outer shape in cross section, and has an opening 20 penetrating the die 2 in the direction of the central axis of the die 2. After being passed through the opening 20 of the die 2, the material wire 30 is plastically deformed while being pulled out from the opening 20, to become a deformed wire 31.

[0024] 4, 5A, and 5B, the opening 20 is formed in the die 2 so as to extend along the central axial direction centered on the central axis of the die 2. The cross-sectional shape of the opening 20 in the die 2 determines the cross-sectional shape of the deformed wire 31. The cross-sectional shape of the opening 20 is polygonal or approximately polygonal.

[0025] The polygon may be exemplified by various shapes such as a triangle, a rectangle, a pentagon, and a hexagon, but is preferably a rectangle. The term "approximately polygonal" refers to a shape in which at least one corner of the polygonal cross-sectional shape of the opening 20 is rounded. Here, rounding the corners does not refer to the inevitable rounding of the corners of the polygon, which is not a perfect corner when wire-cut electric discharge machining is used to form the opening 20 having a polygonal cross-sectional shape in the die 2, but refers to performing a process to round the corners of the polygon, for example, with a radius of curvature of 0.7 mm or more, preferably 0.8 mm or more, and more preferably 1.0 mm or more. In other words, the term "approximately polygonal" refers to a shape in which at least one corner of the polygonal cross-sectional shape of the opening 20 is replaced with an arc with a radius of curvature R of 0.7 mm or more. The substantially polygonal shape is preferably a shape in which all corners of the polygon are rounded, that is, a shape in which all corners of the polygon are replaced with arcs having a curvature radius R of 0.7 mm or more. In this embodiment, the cross-sectional shape of the opening 20 of the die 2 is a substantially quadrilateral shape in which all corners of the quadrilateral are rounded.

[0026] The die 2 includes an approach section 21, a bearing section 22, and a back relief section in the order that the wire material 30 passes through along the central axis. The approach section 21 is a section of the die 2 for gradually reducing the wire diameter of the wire material 30. The bearing section 22 is a section of the die 2 for determining the dimensions of the deformed wire 31. In the opening 20 of the die 2 having a substantially rectangular cross section, the dimension S of the opening 20a at the bearing section having the narrowest cross section is expressed as the distance between two opposing sides of the substantially rectangular cross section (opposite side dimension S) as shown in FIG. 5A. The opposite side dimension S of the opening 20a is not particularly limited, but is, for example, 4 mm or more and 6 mm or less. The back relief section is a section of the die 2 that is tapered away from the deformed wire 31 in order not to damage the surface of the deformed wire 31 drawn through the opening 20 of the die 2.

[0027] As shown in Fig. 2, the die 2 is fixed in the die holder 3. In order to twist the material wire 30, the material wire 30 is passed through the rotating die 2. Since the die 2 is integrated with the die holder 3, the die 2 rotates together with the die holder 3.

[0028] The die holder 3 is rotatably attached to the box 8. The die holder 3 is a member for holding the die 2 in the box 8 without succumbing to the force of the winder 5 pulling out the deformed wire 31 from the die 2. The die holder 3 is also a member for rotating the die 2 together with the material wire 30 to impart a twist to the material wire 30. The die holder 3 is cylindrical, and the die 2 can be inserted into the die holder 3. The die 2 is inserted into the die holder 3 and fixed in the die holder 3 using a plurality of die fixing bolts or the like.

[0029] The die 2 rotates together with the die holder 3 around the central axis of the die 2 by transmitting a rotational driving force from the motor 6 to the die holder 3 via a power transmission mechanism 7. The mechanism of the power transmission mechanism 7 is not particularly limited and various conventionally known configurations can be adopted as long as the rotational driving force from the motor 6 can be transmitted to the die holder 3 to rotate the die holder 3. The power transmission mechanism 7 can be, for example, a combination of a timing belt and a sprocket.

[0030] The die 2 preferably rotates at a constant speed in a fixed direction during the plastic working of the material wire 30. At that time, the speed at which the winder 5 pulls out the irregularly shaped wire 31 from the opening 20 of the die 2 (the winding speed of the winder 5) is also preferably constant.

[0031] The speed at which the deformed wire 31 is drawn through the opening 20 of the die 2 when drawing and twisting the material wire 30 is not particularly limited, but is, for example, 50 M / min to 200 M / min, preferably 80 M / min or more, more preferably 90 M / min or more, and more preferably 100 M / min or more. When drawing and twisting the material wire 30 with the die 2, if the cross-sectional shape of the opening 20 of the die 2 (particularly the opening 20a in the bearing portion) is polygonal and the corners of the polygon are not rounded (including the case where unavoidable roundness exists), it is difficult to draw the deformed wire 31 at a high speed of 80 M / min or more, and drawing the deformed wire 31 at a high speed causes problems such as wire breakage. On the other hand, if the cross-sectional shape of the opening 20 of the die 2 (particularly the opening 20a in the bearing portion) is approximately polygonal and the corners of the polygon are rounded, it is possible to draw out the deformed wire 31 at a high speed of 80 M / min or more, thereby improving the manufacturing efficiency of the final plated deformed wire 33 and enabling the plated deformed wire 33 to be manufactured at low cost.

[0032] The number of rotations of the die 2 when drawing and twisting the material wire 30 is not particularly limited, but is preferably 556 rpm or more and 834 rpm or less when the above-mentioned drawing speed is 50 M / min or more. By rotating the die 2 at a high speed within the above-mentioned range, the amount of twist per unit length of the deformed wire 31 can be increased. For example, as shown in FIG. 6, the axial length L required for twisting the deformed wire 31 one turn can be set to 100 mm or more and 200 mm or less, preferably 120 mm or more and 180 mm or less, and most preferably 150 mm. In other words, it is preferable to rotate the material wire 30 one turn at a length of 120 mm or more and 180 mm or less. When the interval of the "twists" formed in the deformed wire 31 is within the above-mentioned range, the twists are densely present in the final plated deformed wire 33, and the tensile strength of the plated deformed wire 33 can be improved satisfactorily.

[0033] In addition, the wire drawing machine 1 also includes a removal device that physically or chemically removes scale and other particles adhering to the material wire 30 before it is sent to the die 2, and a box that contains a lubricant to be applied to the material wire 30 before it is sent to the die 2.

[0034] The deformed wire 31 plastically processed by the wire drawing machine 1 described above is plated by being immersed in molten zinc in the plating device 10. The deformed wire 31 is plated to produce a plated deformed wire 33. FIG. 3 is a schematic diagram of the plating device 10. The deformed wire 31 is wound around the unwinding machine 16. The plated deformed wire 33 is wound around the winding machine 17.

[0035] The plating apparatus 10 is an apparatus for forming a zinc-containing plating layer 32 on the surface of the deformed wire 31 by passing the deformed wire 31 through a fifth tank 15, which is a tank that stores at least molten zinc, and immersing the deformed wire 31 in the molten zinc. The plating apparatus 10 includes a first tank 11 that stores hot water, a second tank 12 that stores cold water, a third tank 13 that stores acid, a fourth tank 14 that stores flux, a fifth tank 15 that stores at least molten zinc, and a conveying device that conveys the deformed wire 31 from the first to fourth layers 11-14 in that order.

[0036] The first layer 11 stores hot water. The hot water is high-temperature water heated to 60°C or higher. The second layer 12 stores cold water, for example, at about 20°C. The deformed wire 31 is passed through the first tank 11 and immersed in hot water to raise the temperature of the deformed wire 31, and then passed through the second tank 12 and immersed in cold water to rapidly cool the deformed wire 31, thereby quenching the deformed wire 31.

[0037] The third tank 13 stores acid. The acid is a surface cleaner that removes rust, oil, and the like adhering to the surface of the irregular wire 31. The acid is not particularly limited, but hydrochloric acid, sulfuric acid, nitric acid, and the like are used. The temperature of the acid is not particularly limited, but is, for example, 50°C or higher and 70°C or lower. By passing the irregular wire 31 through the fourth tank 14 and immersing it in the acid, the rust, oil, and the like adhering to the surface of the irregular wire 31 are removed, making it easier to form a plating layer 32, which will be described later, on the surface of the irregular wire 31.

[0038] The fourth tank 14 stores flux. The flux is a surface cleaning agent that removes oxides and the like adhering to the surface of the deformed wire 31. An appropriate flux is used depending on the material of the deformed wire 31. The temperature of the flux is not particularly limited, but is, for example, 50°C or higher and 70°C or lower. By passing the deformed wire 31 through the fourth tank 14 and immersing it in the flux, oxides and the like adhering to the surface of the deformed wire 31 are removed, making it easier to form a plating layer 32 (described later) on the surface of the deformed wire 31. The deformed wire 31 that has been treated with the flux is transported to the fifth tank 15 after being dried, for example, in a drying furnace.

[0039] The fifth tank 15 stores a plating liquid containing at least molten zinc. The plating liquid may contain a small amount of other molten metals such as molten iron and molten aluminum in addition to the molten zinc. The temperature of the plating liquid is not particularly limited, but is, for example, 450°C to 480°C. The plating liquid stored in the fifth tank 15 is heated by a heater to adjust to a predetermined temperature. The deformed wire 31 is passed through the fifth tank 15 and immersed in the plating liquid, so that the plating liquid is attached to the surface of the deformed wire 31. The time for which the deformed wire 31 is immersed in the plating liquid is not particularly limited, but is, for example, 1 second or less. By immersing the deformed wire 31 in the plating liquid at the above-mentioned temperature and time, a sufficient plating liquid can be attached to the surface of the deformed wire 31, and a plated deformed wire 33 having a plating layer 32 with a sufficient thickness can be manufactured.

[0040] The plating liquid adhered to the surface of the deformed wire 31 is wiped off by a wiping device disposed above the fifth tank 15, for example, to control the adhesion of the plating liquid. As a result, as shown in Fig. 7, a plating layer 32 with a predetermined amount of plating liquid adhered to the surface of the deformed wire 31 is formed almost uniformly. The amount of plating layer 32 adhered to the surface of the deformed wire 31 is not particularly limited, but may be, for example, 40 g / m 2 More than 155g / m 2 More preferably, it is equal to or greater than this.

[0041] The deformed wire 31 on which the plating layer 32 is formed, that is, the plated deformed wire 33, is cooled to room temperature and then wound up into a coil by the winding machine 17.

[0042] The conveying device is not particularly limited, but for example, conveys the deformed wire 31 to the plating device 10 by roll conveyance, and includes at least a payout machine 16, a winding machine 17, and a plurality of rollers 18.

[0043] The unwinder 16 and the winder 17 are provided with, for example, cylindrical bodies 161, 171 that can rotate around a central axis 160 and a central axis 170, respectively. The winder 17 is configured such that the cylindrical body 171 rotates by a rotational driving force from a motor, and the cylindrical body 171 winds up the plated deformed wire 33. The plated deformed wire 33 is coiled by the winder 17. The coiled plated deformed wire 33 is compressed, bound with a strap, and then packaged. The unwinder 16 is configured such that the cylindrical body 161 rotates by a force of winding up the plated deformed wire 33 by the rotation of the cylindrical body 171 of the winder 17, and the deformed wire 31 is unwound from the cylindrical body 161. The multiple rollers 18 are arranged at appropriate positions along the running direction of the deformed wire 31 and the plated deformed wire 33.

[0044] According to the above-mentioned manufacturing method of plated deformed wire, the material wire 30 is plastically processed to form the deformed wire 31, and then the deformed wire 31 is plated to manufacture the plated deformed wire 33. If the plated material wire is subjected to plastic processing such as twisting, the surface of the plated material wire may be scratched during the plastic processing. In a harsh outdoor environment, if the surface of the plated deformed wire is scratched after processing, the scratch may cause the plating layer to peel off. According to the above-mentioned manufacturing method of plated deformed wire, the surface of the plated deformed wire 33, which is the finished product after production, is not scratched by the plastic processing of the material wire 30 in the manufacturing process, so the plated deformed wire 33 is less likely to have the plating layer 32 peeled off, and can exhibit a good appearance and good rust prevention effect. In addition, the plating layer 32 can be formed uniformly on the surface of the deformed wire 31.

[0045] Thus, there is a difference in appearance and rust resistance between the conventional case in which a plated deformed wire is manufactured by plastically processing a material wire that has been plated in advance, and the case of the present disclosure in which a material wire is plastically processed and then plated to manufacture the plated deformed wire 33. Therefore, by focusing on this difference, it is possible to distinguish between the plated deformed wire manufactured by the conventional manufacturing method and the plated deformed wire 33 manufactured by the manufacturing method of the present disclosure.

[0046] The above describes in detail the manufacturing method for plated deformed wire according to the present disclosure based on an embodiment, but the manufacturing method for plated deformed wire according to the present disclosure is not limited to the above-described embodiment and various modifications are possible without departing from the gist of the method. [Explanation of symbols]

[0047] 1. Wire drawing machine 2 Dice 3 Dice Holder 10 Plating Equipment 11 Tank 1 12 Second tank 13 Third tank 14 Fourth tank 15 Tank 5 20 Dice opening 30 Material wire rod 31 Deformed wire rod 32 Plating layer 33 Plated special shaped wire

Claims

1. a plastic processing step of drawing and twisting a metal wire material having a circular cross section through an opening of a die rotating around a central axis to convert the metal wire material into a deformed wire material; a plating process step of passing the irregular-shaped wire through a tank in which a plating solution containing at least molten zinc is stored and immersing the irregular-shaped wire in the plating solution to form a zinc-containing plating layer on a surface of the irregular-shaped wire; A method for manufacturing a plated profile wire, comprising:

2. The cross-sectional shape of the opening in the die is a substantially polygonal shape with rounded corners having a radius of curvature of 0.7 mm or more, 2. The method for producing a plated deformed wire according to claim 1, wherein in the plastic working step, the deformed wire is drawn out from the opening of the die at a speed of 50 M / min or more.

3. 3. The method for producing a plated deformed wire according to claim 2, wherein in the plastic working step, a rotation speed of the die is 556 rpm or more.

4. 3. The method for producing a plated deformed wire according to claim 2, wherein an axial length of the deformed wire obtained in the plastic working step required for twisting it one turn is 100 mm or more and 200 mm or less.

5. The plating process includes: a first step of passing the deformed wire through a tank containing hot water and immersing the deformed wire in the hot water; a second step of passing the deformed wire after the first step through a tank containing cold water and immersing the deformed wire in the cold water; a third step of passing the deformed wire after the second step through a tank containing an acid and immersing the deformed wire in the acid; A fourth step of passing the deformed wire after the third step through a tank containing flux and immersing the deformed wire in the flux; a fifth step of immersing the irregular shaped wire after the fourth step in the plating solution; A method for producing a plated profile wire according to claim 1 , comprising: