Method for manufacturing plated deformed wire

Abstract

The objective of the present disclosure is to provide a method for manufacturing a plated deformed wire capable of favorably suppressing peeling of the plating layer. A method for manufacturing a plated deformed wire according to the present disclosure includes: a plastic processing step of subjecting a metal material wire 30 having a circular lateral cross-section to wire drawing processing and twisting processing by having the metal material wire 30 passed through an opening 20 of a die 2 rotating around a central axis, thereby making the material wire 30 into a deformed wire 31; and a plating processing step of forming a plating layer 32 containing zinc on the surface of the deformed wire 31 by passing the deformed wire 31 through a tank 14 in which a plating liquid containing at least molten zinc is stored, and immersing same in the plating liquid.

Description

Manufacturing method of plated special shaped wire

[0001] The present disclosure relates to a method for manufacturing a plated profile wire.

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

[0003] Wire mesh made with deformed wire rods is lighter than wire mesh made with metal wire rods (round bars) with a circular cross section, and the addition of a twist improves tensile strength. Therefore, wire mesh made with deformed wire rods 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 rods 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 therefore is 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).

[0005] Japanese Patent Application Publication No. 2018-094560

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

[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 that rotates around a central axis and subjected to wire drawing and twisting processing to convert the material wire into a deformed wire, and a plating step in which the deformed wire is passed through a tank that stores 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.

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

[0010] FIG. 1 is a diagram showing the steps of a method for manufacturing a plated deformed wire according to the present disclosure. FIG. 2 is a schematic diagram of a wire drawing machine. FIG. 3 is a schematic diagram of a plating device. FIG. 4 is a perspective view of a die. FIG. 5A is an enlarged front view of openings in the approach section and bearing section of the die. FIG. 5B is an enlarged view of a portion of FIG. 5A. FIG. 6 is a side view of a portion of a plated deformed wire. FIG. 7 is a cross-sectional view of a plated deformed wire.

[0011] [Overview of the manufacturing method for plated deformed wire according to the present disclosure] The manufacturing method for 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 that rotates around a central axis and subjected to wire drawing and twisting processing to turn the material wire into a deformed wire, and a plating step in which the deformed wire is passed through a tank that stores 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] The method for manufacturing a plated deformed wire of the present disclosure involves plastically processing a material wire to form a deformed wire, and then plating the deformed wire to produce a plated deformed wire. If plastic processing such as twisting is performed on the plated material wire after plating, there is a risk that the surface of the plated material wire may be scratched during the plastic processing. In harsh outdoor environments, scratches on the surface of the processed plated deformed wire may cause the plating layer to peel off due to these scratches. According to the method for manufacturing a plated deformed wire of the present disclosure, the surface of the plated deformed wire is less likely to be scratched during plastic processing, so the plated deformed wire after production is less likely to peel off the plating layer and exhibits good rust prevention effects.

[0013] The method for manufacturing a plated deformed wire according to the present disclosure can preferably be configured so that 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, and in the plastic working step, the speed at which the deformed wire is drawn through the opening in 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 in the die through which the material wire passes is a substantially polygonal shape with rounded corners having a radius of curvature of 0.7 mm or more, the material wire can be plastically worked into a deformed wire at a high drawing speed. This improves the manufacturing efficiency of plated deformed wire and enables plated deformed wire to be produced inexpensively.

[0014] The method for manufacturing a plated deformed wire according to the present disclosure can preferably be configured such that, in the plastic working 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 working step is 100 mm or more and 200 mm or less. According to the method for manufacturing a plated deformed wire of the present disclosure, the axial length required for one twist in the plated deformed wire after production (twist interval) is short and the twists are densely present in the plated deformed wire, thereby favorably improving the tensile strength of the plated deformed wire.

[0015] The method for manufacturing a plated deformed wire according to the present disclosure can preferably be configured so 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 Manufacturing Method of Plated Deformed Wire of the Present Disclosure] A specific embodiment of the manufacturing method of plated deformed wire of 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 their description will not be repeated.

[0017] The method for manufacturing 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 a shape that appears to be twisted by gripping both ends; a plating step in which a zinc-containing plating layer 32 is formed on the surface of deformed wire 31 to form plated deformed wire 33; and a coiling step in which plated deformed wire 33 is wound up and coiled. The plating process includes a first step of passing the deformed wire 31 through a first tank 11 storing hot water and immersing it in hot water; a second step of passing the deformed wire 31 after the first step through a second tank 12 storing cold water and immersing it in cold water; a third step of passing the deformed wire 31 after the second step through a third tank 13 storing acid and immersing it in acid; a fourth step of passing the deformed wire 31 after the third step through a fourth tank 14 storing flux and immersing it in flux; and a fifth step of passing the deformed wire 31 after the fourth step through a fifth tank 15 storing a plating solution containing at least molten zinc (referred to as "molten zinc" in the present disclosure) and immersing it in the plating solution.

[0018] The metallic material wire 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 material wire 30 is not particularly limited, but is, for example, 5.5 mm or more and 7.0 mm or less. The material wire 30 is wound into a coil on 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 that thins 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 that twists the material wire 30 around its axis along the axial direction, and as shown in Figure 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] The material wire 30 is subjected to wire drawing and twisting, for example, by passing it through a die 2 installed in a wire drawing machine 1. Fig. 2 is a schematic diagram of the wire drawing machine 1 for producing a deformed wire 31.

[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 unwinder 4 and the winder 5 include, for example, cylindrical bodies 41 and 51 that can rotate around central axes 40 and 50, respectively. The winder 5 is configured so that the cylindrical body 51 rotates by a rotational driving force from a motor and winds up the deformed wire 31 after plastic working. The unwinder 4 is configured so 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 winder 5, and unwinds the material wire 30 from the cylindrical body 41.

[0023] The die 2 is placed in the die holder 3 to perform wire drawing and twisting on the material wire 30. As shown in Fig. 4, the die 2 has a cylindrical shape with a circular outer shape in cross section, for example, and has an opening 20 that passes through 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 undergoes plastic deformation while being drawn out of the opening 20, becoming 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 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 can be exemplified by various shapes such as a triangle, a rectangle, a pentagon, and a hexagon, but a rectangle is preferred. A substantially polygonal shape 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 that occurs when wire-cut electric discharge machining is used to form the opening 20 with a polygonal cross-section in the die 2, as the corners of the polygon are not perfectly rounded and inevitably have a curvature radius of approximately 0.1 mm to 0.3 mm. However, rounding the corners does not refer to the inevitable rounding, but rather refers to a process in which the corners of the polygon are rounded to a curvature radius of 0.7 mm or more, preferably 0.8 mm or more, and more preferably 1.0 mm or more. In other words, a substantially polygonal shape 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 curvature radius 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 along the central axis, in the order in which the material wire 30 passes through. The approach section 21 is a section of the die 2 for gradually reducing the diameter of the material wire 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, which has a substantially rectangular cross section, the dimension S of the opening 20a at the bearing section, where the cross section is narrowest, 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 to 6 mm. The back-relief section is a section of the die 2 that is tapered away from the deformed wire 31 to prevent damage to the surface of the deformed wire 31 being drawn through the opening 20 of the die 2.

[0027] As shown in Figure 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, and 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 die 2 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 it. 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, it is also preferable that the speed at which the winder 5 pulls out the deformed wire 31 from the opening 20 of the die 2 (the winding speed of the winder 5) is constant.

[0031] The speed at which the deformed wire 31 is drawn through the opening 20 of the die 2 when the wire material 30 is drawn and twisted 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 the wire material 30 is drawn and twisted through the die 2, if the cross section of the opening 20 of the die 2 (particularly the opening 20 a in the bearing portion) is polygonal and the corners of the polygon are not rounded (including when unavoidable rounding is present), 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 can cause 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 inexpensively.

[0032] The rotation speed of the die 2 during the wire drawing and twisting of the material wire 30 is not particularly limited, but is preferably 556 rpm to 834 rpm when the drawing speed is 50 m / min or higher. Rotating the die 2 at a high speed within the above-mentioned range increases the amount of twist per unit length of the deformed wire 31. For example, as shown in FIG. 6 , the axial length L required for one twist of the deformed wire 31 can be set to 100 mm to 200 mm, preferably 120 mm to 180 mm, and most preferably 150 mm. In other words, it is preferable to rotate the material wire 30 one revolution per length of 120 mm to 180 mm. By keeping the spacing of the "twists" formed in the deformed wire 31 within the above-mentioned range, the final plated deformed wire 33 will have dense twists, thereby improving the tensile strength of the plated deformed wire 33.

[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 fed to the die 2, and a box that contains a lubricant to be applied to the material wire 30 before it is fed to the die 2.

[0034] The deformed wire 31 plastically worked by the wire drawing machine 1 described above is plated by being immersed in molten zinc in the plating device 10. By plating the deformed wire 31, a plated deformed wire 33 is manufactured. Figure 3 is a schematic diagram of the plating device 10. The deformed wire 31 is wound around a payout machine 16. The plated deformed wire 33 is wound around a winder 17.

[0035] The plating apparatus 10 is an apparatus for immersing a deformed wire 31 in molten zinc by passing it through a fifth tank 15, which is a tank that stores at least molten zinc, to form a zinc-containing plating layer 32 on the surface of the deformed wire 31. 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 to the first to fourth layers 11 to 14 in 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 deformed wire 31. The acid is not particularly limited, but examples of the acid include hydrochloric acid, sulfuric acid, and nitric acid. 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 deformed 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 deformed wire 31 are removed, making it easier to form a plating layer 32 (described later) on the surface of the deformed 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 flux-treated deformed wire 31 is then dried, for example, in a drying oven, and then transferred to the fifth tank 15.

[0039] The fifth tank 15 stores a plating solution containing at least molten zinc. The plating solution may contain small amounts of other molten metals, such as molten iron or molten aluminum, in addition to molten zinc. The temperature of the plating solution is not particularly limited, but is, for example, 450°C to 480°C. The plating solution stored in the fifth tank 15 is heated by a heater to adjust the temperature to a predetermined level. The deformed wire 31 is immersed in the plating solution through the fifth tank 15, and the plating solution is applied to the surface of the deformed wire 31. The time for which the deformed wire 31 is immersed in the plating solution is not particularly limited, but is, for example, 1 second or less. Immersing the deformed wire 31 in the plating solution at the above-described temperature and for the above-described time allows sufficient plating solution to be applied to the surface of the deformed wire 31, and a plated deformed wire 33 having a sufficiently thick plating layer 32 can be produced.

[0040] The plating solution 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 amount of plating solution adhered to the surface of the deformed wire 31. As a result, as shown in Fig. 7, a plating layer 32 with a predetermined amount of plating solution adhered to the surface of the deformed wire 31 is formed almost uniformly. The amount of plating solution adhered to the surface of the deformed wire 31 is not particularly limited, but may be, for example, 40 g / m ２ or more, and 155 g / m ２ It is preferable that this 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 into a coil by the winder 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 include, for example, cylindrical bodies 161, 171 that can rotate around central axes 160 and 170, respectively. The winder 17 is configured so that the cylindrical body 171 rotates due to 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 straps, and then packaged. The unwinder 16 is configured so that the cylindrical body 161 rotates due to the force of the rotation of the cylindrical body 171 of the winder 17 winding up the plated deformed wire 33, and unwinds the deformed wire 31 from the cylindrical body 161. Various rolls of 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-described method for manufacturing a 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 produce 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 harsh outdoor environments, scratches on the surface of the plated deformed wire after processing could potentially cause the plating layer to peel off. According to the above-described method for manufacturing a plated deformed wire, the plastic processing of the material wire 30 during the manufacturing process does not scratch the surface of the plated deformed wire 33, which is the finished product. Therefore, the plated deformed wire 33 is less likely to peel off the plating layer 32, resulting in a good appearance and excellent rust prevention. Furthermore, the plating layer 32 can be uniformly formed on the surface of the deformed wire 31.

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

[0046] The above describes in detail the method for manufacturing plated shaped wire according to the present disclosure based on an embodiment, but the method for manufacturing plated shaped wire according to the present disclosure is not limited to the above-described embodiment, and various modifications are possible within the scope that does not deviate from the gist thereof.

[0047] REFERENCE SIGNS LIST 1 wire drawing machine 2 die 3 die holder 10 plating device 11 first tank 12 second tank 13 third tank 14 fourth tank 15 fifth tank 20 die opening 30 wire material 31 deformed wire 32 plating layer 33 plated deformed wire

Claims

1. A method for manufacturing plated deformed wire, comprising: a plastic processing step of passing a metallic material wire having a circular cross section through an opening of a die that rotates around a central axis and performing wire drawing and twisting on the material wire to turn the material wire into a deformed wire; and a plating step of passing the deformed wire through a tank that stores a plating solution containing at least molten zinc and immersing the deformed wire in the plating solution to form a zinc-containing plating layer on the surface of the deformed wire.

2. A method for manufacturing plated deformed wire as set forth in claim 1, wherein the cross-sectional shape of the opening in the die is a roughly polygonal shape with the corners of the polygon rounded with a radius of curvature of 0.7 mm or more, and in the plastic working process, the speed at which the deformed wire is pulled out of the opening in the die is 50 m / min or more.

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

4. A method for manufacturing plated deformed wire as described in claim 2, wherein the axial length required for twisting one turn of the deformed wire obtained in the plastic processing step is 100 mm or more and 200 mm or less.

5. A method for manufacturing a plated deformed wire according to any one of claims 1 to 4, wherein the plating process includes: a first step of passing the deformed wire through a tank storing hot water and immersing it in the hot water; a second step of passing the deformed wire after the first step through a tank storing cold water and immersing it in the cold water; a third step of passing the deformed wire after the second step through a tank storing acid and immersing it in the acid; a fourth step of passing the deformed wire after the third step through a tank storing flux and immersing it in the flux; and a fifth step of immersing the deformed wire after the fourth step in the plating solution.

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