Cold wire drawing process and improved soap chamber

Abstract

The invention relates to a cold wire drawing process and an improved soap chamber which, by forming a soap chamber system rotating at the same radial speed as the rotary rolling system in the cold wire drawing process, ensures that the entire surface of the wire is better coated with soap.

Description

[0001] DESCRIPTION

[0002] COLD WIRE DRAWING PROCESS AND IMPROVED SOAP CHAMBER

[0003] Technical Field of the Invention

[0004] The invention relates to a cold wire drawing process and an improved soap chamber which, by forming a soap chamber system rotating at the same radial speed as the rotary rolling system in the cold wire drawing process, ensures that the entire surface of the wire is completely covered with soap.

[0005] State of the Art

[0006] Cold drawing is a chipless forming method applied by passing hot-rolled steel rod products through a smaller die in order to obtain a more precise surface quality, thereby reducing the cross-section and elongating the material length.

[0007] The cold wire drawing process is applied to reduce the diameter and increase the strength of metal wires, and is commonly used for processing metals such as steel, copper, and aluminium in wire form. The wire is drawn under high tensile forces at room temperature to achieve the desired dimension and shape. This method plays a critical role in the production of thin and long wires. Today, wire drawing processes supported by environmentally friendly technologies are capable of meeting the specific needs of various industrial fields.

[0008] Cold wire drawing is performed by means of special wire drawing machines. These machines enable the wire to pass through dies, thereby reducing its diameter and increasing its length. Soap chambers located in the drawing machines are of great importance during the process. The soap chamber applies a lubricant to the surface of the wire, reducing friction, improving process efficiency, and preventing wear of the dies. The correct selection and concentration of lubricants directly affect the surface quality and the quality of the drawing process.

[0009] Soap chambers play a critical role in terms of efficiency and cost-effectiveness of the wire drawing process. By reducing friction, soap minimises die wear, improves wire surface quality, reduces energy consumption, and shortens process time. This ensures a more efficient and sustainable production process.

[0010] Although various proposals and applications have been developed in the state of the art for the soap chamber used in the cold wire drawing process, these developments remain insufficient. Some patent applications developed for this purpose are given below.

[0011] The invention disclosed in the application numbered “CN218310068U” in the state of the art relates to a lubrication box for drawing bolts and wires, which solves the lubrication box problem in the drawing of bolts and wires. It describes a helical arrangement positioned parallel to the rod drawing process in order to ensure that the surfaces of rods which do not receive soap during the drawing process are covered with soap.

[0012] The invention disclosed in the application numbered “CN202741032U” in the state of the art belongs to the technical field of wire drawing process units of a dry-type wire drawing machine and generally relates to a type of wire drawing lubricant mixing device. It forms a capsule system to prevent soap burning and includes equipment within the capsule performing a deceleration function. It is described that the system comprises a mixing mechanism designed to prevent soap burning and clumping, and a specific deceleration mechanism for this purpose.

[0013] In the state of the art, soap / lubricant chambers are present in cold wire drawing processes. The wire drawing soap chamber located before the rolling stage, which is a step of the existing wire drawing process, is used in square or rectangular forms. These systems are used in wire drawing machines in a fixed and immobile manner. The main soap-related defects occurring in the state of the art are as follows:

[0014] - Clumping: When there is insufficient soap between the rolling die and the wire, the heat generated as a result of the high frictional force causes black, hard clumps to form due to the deterioration of the polymeric solid lubricants under the effect of the heated wire, the inadequate cooling of the coolant fluids present in the rotary rolling systems, and the natural heating of the wire as its diameter decreases. T unnelling: The formation of tunnels inside the soap box prevents the wire from adequately contacting the soap and reduces soap pickup resulting inefficient lubricant film on wire surface.

[0015] - Irregular lubrication on the wire surface: The soap used must uniformly cover the entire surface of the wire. In areas where the amount of soap is low, scratches and corrosion that develop over time may appear on the wire, while in areas with excess soap, the excessive pressure and heat generated during rolling cause the soap to bum and adhere to the wire surface.

[0016] However, in the state of the art, there is no soap / lubricant chamber capable of eliminating soap-related defects in cold wire drawing, reducing soap chamber dusting by 90%, providing both insulation and soap level control, preventing clumping by means of the groove and breaker path design, breaking up clumped and burnt / degraded soaps into small particles for reuse, being installable in a manner compatible with wire drawing machines of different planar angles, and operating without requiring cooling or consuming water.

[0017] As a result, due to the drawbacks mentioned above and the inadequacy of current solutions regarding the subject matter, a development in the relevant technical field has become necessary.

[0018] The Aim of the Invention

[0019] The most important aim of the invention is to increase the amount of soap adhered by the wire by maintaining the initial form of the soap within the chamber. In this way, soap-related defects are eliminated and complete covering of the surface of the wire is achieved.

[0020] Another aim of the invention is to enable more efficient use of soap by controlling soap- related defects. In this way, soap consumption is reduced.

[0021] Another aim of the invention is to ensure that the soap is evenly distributed over the wire. In this way, the service life of the rolling die is increased.

[0022] Another aim of the invention is the presence of the groove and the breaker path. In this way, soaps that have clumped due to moisture or that have become compressed and enlarged in size within the package are brought to the same size and burnt or clumped soap formed during production is broken down into powder form.

[0023] Another aim of the invention is to ensure the homogeneous mixing of soap particles of different sizes.

[0024] Another aim of the invention is to reduce the soap chamber dusting problem by 90%.

[0025] Another aim of the invention is the presence of a mica window providing both insulation and control of the soap level.

[0026] Description of Drawings

[0027] Figure 1 is the drawing showing the general view of the cold wire drawing system that is the subject of the invention.

[0028] Figure 2 is the drawing showing the general view of the soap chamber in the cold wire drawing system that is the subject of the invention.

[0029] Figure 3 is the drawing showing the sectional detailed view of the soap chamber in the cold wire drawing system that is the subject of the invention.

[0030] Figure 4 is the drawing showing the upper isometric detailed view of the soap chamber in the cold wire drawing system that is the subject of the invention.

[0031] Reference Numbers

[0032] 1. Wire

[0033] 2. Wire Drawing Head

[0034] 3. Soap Chamber

[0035] 4. Rolling Die

[0036] 5. Reducer and Motor

[0037] 6. Belt Pulley System

[0038] 7. Groove

[0039] 8. Breaker Path

[0040] 9. Machine Fixing Plate

[0041] 10. Bearing 11. Front and Rear Flange

[0042] 12. Inlet-Outlet Nozzle

[0043] 13. Bearing Housing Component

[0044] 14. Mechanical Reinforcement Bar

[0045] 15. Locking Clamp

[0046] 16. Soap Compression Region

[0047] 17. Soap Chamber Adjusting Component

[0048] 18. Mica

[0049] Description of the Invention

[0050] The invention relates to a cold wire drawing process and an improved soap chamber which, by forming a soap chamber system rotating at the same radial speed as the rotary rolling system in the cold wire drawing process, ensures that the entire surface of the wire is covered with soap.

[0051] The invention contains the soap, which is the lubricant required for enabling the wire (1 ) to enter the cross-sectional reduction process performed in the rolling die (4) made of tungsten carbide material, carried out by a mechanical method for reducing the diameter of the wire (1 ). The invention operates with solid lubricants. The soap adheres to the surface of the wire (1 ) through the roughness present on the wire (1 ) passing through these solid lubricants. While the wire (1 ) continues to be processed inside the rolling die (4), it undergoes cold deformation, and in order to facilitate this process, the soap coating present on the wire (1 ) is distributed over the surface of the wire (1 ) by means of the high pressure formed and the heat generated as a result of the reduction in the diameter of the wire (1 ). Since the soap used also contains corrosion-preventive components, it helps protect the processed wire (1 ) from corrosion both during and after the operations.

[0052] The invention is a cold wire drawing process and an improved soap chamber that comprise at least one wire drawing head (2), which includes a water flow path, around which the wire (1 ) whose diameter is reduced is coiled, and which allows the temperature of the coiled wire (1 ) to decrease during the period until the coiled wire (1 ) enters the next rolling die (4), and which rotates at different speeds according to the diameter-reduction ratio; a rotary soap chamber (3) which contains soap, through which the wire (1 ) passes and becomes covered with soap, and which rotates at the same radial speed as the rolling die (4); a rolling die (4) which is driven by a reducer and motor (5) and which, by means of the cold deformation method, shapes the wire (1 ) and provides the reduction of its diameter; a reducer and motor (5) which, together with the belt pulley system (6), enable the rotation of the rolling die (4) and the rotary soap chamber (3); a belt pulley system (6) which, with the movement of the reducer and motor (5), enables the rotation of the rotary soap chamber (3); a groove (breaker) (7) formed by welding plates onto the inner surface of the soap chamber (3), having a width of 2-3 mm and a spacing of 12-16 mm coiled in a helical form, the distance between the plates decreasing as they approach the rolling die (4); a breaker path (8) which is a machined region where the soap conveyed by the groove (7) towards the rolling die (4) is collected and which allows the soap to move smoothly towards the mouth of the rolling die (4); a machine fixing plate (9) which is a plate mounted to fix the rotary-drum-type soap chamber (3) onto the wire drawing bench; front and rear bearings (10) which, by the mechanical movement received from the reducer and motor (5), allow the rotary soap chamber (3) to rotate around its own axis; front and rear flanges (11 ) which fix the front and rear bearings (10) and the soap chamber (3) on the axis of the line and provide vibration isolation; inlet-outlet nozzles (12) which, with the movement of the soap chamber (3), prevent powder soap from escaping out of the system while the wire (1 ) enters the soap chamber (3); a rotary soap chamber bearing housing component (13), which supports the rotary soap chamber (3) on the system and prevents the soap chamber (3) from moving out of the system due to horizontal forces occurring during wire drawing; a mechanical reinforcement bar (14) which is a structural component that extends the service life of the bearing (10) and flanges (11 ) against the rotational movement of the radial soap chamber (3) and the forces applied by the wire (1 ) in the third axis; a locking clamp (15) which fixes the mechanical movement transmitted from the reducer and motor (5) and allows it to be transferred to the rotary soap chamber (3); a soap compression region (16) which, due to the radial motion originating from the rotary soap chamber (3), prevents the soap from moving away from the inlet of the rolling die (4), and which is a region located on the wire (1 ) where the inner grooved (7) section is machined conically towards the inlet of the rolling die (4), and where the soap particles delivered onto the wire (1 ) by the breaker path (8) become trapped between the core of the rolling die (4) and the wire (1 ), thereby performing the lubrication process; a soap chamber adjusting component (17), which, by means of a lock-nut compression function, allows the rotary soap chamber (3) to be tilted by ±10° relative to the horizontal plane, enabling compatibility with different wire drawing machines; and a mica (18), which is a transparent component made of mica material, which allows soap to be added when the system is stopped by opening and closing, prevents soap from spilling during rotation, and enables monitoring of the box’s fill level during system operation by means of its transparent property.

[0053] In wire drawing machines, the wire drawing process for steel wires (1 ) begins with mechanical or chemical scale removal processes. After the scale layer is removed by mechanical methods, roughness is created on the wire (1 ) with the help of abrasive belts, allowing the wire (1 ) to adsorb an appropriate amount of soap for the drawing process. In the mechanical scale removal system, soaps composed of fatty acids containing Sodium and Calcium in powder form, which are compatible with steel, are used. The invention enables these soap products to adhere better to the wire (1 ) and ensures that the soap deformed due to heating inside the soap chamber (3) during the wire drawing process, or the soap product that begins to bum after losing its moisture, is applied more effectively onto the wire (1 ).

[0054] In the wire drawing process, the wire (1 ) entering the soap chamber (3) with the soap it receives proceeds to the first rolling die (4). Then, the wire drawing head (2), through which the wire passes to the winding head, reduces the temperature by means of the heat exchange achieved with the cooling system inside the head. The wire (1 ) reaching the last winding on the head then enters the soap chamber (3) belonging to the second rolling die (4) and passes through the second rolling die (4). This process continues repeatedly until the desired diameter is achieved.

[0055] The invention ensures better soap adhesion for the soap box located before the rolling die (4) and enables the soap granules that become clumped due to moisture loss and the ones that solidify as a result of deformation or degradation to be used continuously without being separated from the system by keeping them in constant motion. This is achieved by continuously moving and breaking the soap particles that have increased in size due to reduced spacing between plates, which are processed inside the soap chamber (3) in a structure resembling a helix. When the soap particles passing through the grooved (7) section reach the end of the soap chamber (3), they fall onto the breaker path (8) to facilitate their smooth transition into the rolling die (4).

[0056] In the invention, to prevent the negative occupational health effects of soap dust in the system due to continuous movement, nozzles have been added to the inlet and outlet sections of the soap chamber (3).

[0057] In the invention, the wire (1 ) fed along the line is coiled around the wire drawing head

[0058] (2) after passing through the previous rolling die (4) to reduce its temperature. The winding sequence is adjusted to lower the temperature to a suitable level. The wire (1 ) whose temperature has been reduced then enters the rotary-drum-type soap chamber

[0059] (3), becomes coated with soap, and proceeds to the rotary reduction rolling die (4) located in front of the rotary-drum-type soap chamber (3). The wire (1 ) with the reduced cross-sectional area is coiled again around the wire drawing head (2), and these operations are repeated until the wire (1 ) reaches the desired diameter. In the invention, the reduction rolling die (4) and the rotary soap chamber (3) rotate at the same radial speed.

[0060] With the invention rotating at the same radial speed as the rolling die (4) located in front of the rotary soap chamber (3), an equal amount of soap is applied to all surfaces of the wire (1 ). This operation is achieved by the systematic functioning of the bearing (10), front and rear flanges (11 ), bearing housing component (13), locking clamp (15), and the rotary soap chamber (3).

[0061] In the invention, by means of the grooved (7) system, the accumulation of soap at the front side of the rolling die (4) is prevented, and motion is imparted to the soap towards the inlet part of the soap chamber (3) along the wire (1 ). At the front inlet of the rolling die (4), the grooved (7) system takes on a conical structure, preventing the decrease of soap adsorption by the wire (1 ) due to radial speed.

[0062] With the breaker path (8) present in the invention, when the system operates for a long time and the soap loses all its moisture causing clumping, the clumped soap is broken down and turned back into powder soap. The rotary soap chamber (3), which is driven by the reducer, is mounted onto the bench with a plate for fixation. A soap chamber adjusting component (17) is provided to facilitate installation on wire drawing machines designed at different planar angles.

[0063] With a mica (18) mounted on the opening located on the rotary soap chamber (3), both insulation is achieved and the operator is enabled to monitor the soap quantity without stopping the system. In addition, the mica (18) is mounted in an openable / closable manner, providing convenience for both filling operations and monitoring of the filling level.

[0064] The invention, by means of a belt pulley system (6), transfers the motor power from the block operating together with the rotary rolling die (4) also to the soap chamber (3). By this means, no additional motor is required. The rotation speed of the soap chamber (3) is around 36 RPM. In the wire drawing process, the powder soap inside the drum- type soap chamber (3) settles on the wire (1 ) and enters the rolling die (4). In the system, the problem of soap burning or clumping during wire drawing is eliminated by means of the grooved (breaker) (7) system. The breakers are plates 2-3 mm in height and spaced 12-16 mm apart, welded or machined in a helical form onto the inner surface of the soap chamber (3). As the rolling die (4) is approached, the distance between these grooved (breaker) (7) plates decreases to 3 mm. With the aid of the grooved (breaker) (7) plates, the soaps approaching the rolling die (4) reach the breaker path (8) region, and through the design in this region, they can smoothly reach the mouth of the rolling die (4). The soap chamber adjusting component (17) has three stages and is provided to ensure compatibility with wire drawing heads (2) that have different angles relative to the ground. Since the soaps used are in powder form, the soap chamber (3) is designed as a closed system, and nozzles are located at the wire (1 ) entry and exit regions of the soap chamber (3); the inlet-outlet nozzles (12) largely prevent external powder escape and dusting problems. With the mica (18) mounted on the rotary soap chamber (3), the filling level of the chamber can be visually monitored even while the system is operating. The mica (18) is designed to allow opening and closing and is used for soap refilling when the system is stopped.

[0065] In the invention, the soap-related defects encountered in wire drawing soap chambers (3), such as clumping, tunnelling, high friction in the rolling die (4), and irregular lubrication on the surface of the wire (1 ), do not occur. By means of the invention, the soap is preserved in its initial form within the soap chamber (3), thereby increasing the amount of soap adhered by the wire (1 ). Since the soap adheres more strongly to the surface of the wire (1 ), soap-related defects have been minimised. By means of the invention, as the defects are kept under control, the soap can be used more efficiently. By means of the invention, soap consumption is reduced.

[0066] The soap forms a lubricating film layer between the wire (1 ) and the rolling die (4). Since this invention renders the lubricating film layer homogeneous on the surface of the wire (1 ), it increases the service life of the rolling die (4). By means of the groove (7) and the breaker path (8), the invention breaks down the burnt and clumped soap and turns it into powder form. By means of the grooved (7) system of the invention, the accumulation of soap on one side is prevented and continuous movement of the soap is ensured. It ensures the homogeneous mixing of soap particles of different sizes.

[0067] The invention is a rotary soap chamber (3) that can rotate simultaneously with the radial angle of the reducer and motor (5) in systems using rotary rolling dies (4) without requiring the use of an additional motor. This is achieved by the bearing (10), front and rear flanges (11 ), bearing housing component (13), and the locking clamp (15). The inlet-outlet nozzles (12) located at the ends of the rotary soap chamber (3) prevent the soap from leaving the chamber as a result of radial movement.

[0068] The mechanical reinforcement bar (14) is a structural metal component added to extend the service life of the bearing (10) and flanges (11 ) against radial rotation and the forces applied by the wire (1 ) on the third axis. The soap compression region (16) is the area that prevents the soap from moving away from the inlet of the rolling die (4) as a result of radial movement originating from the rotary soap chamber (3), where the inner grooved (7) section is machined conically towards the inlet of the rolling die (4). Here, soap dispersion is prevented. The soap chamber adjusting component (17) is the mechanism used to form the system on the same plane by fine-adjusting the planar angle between the platforms of the rolling die (4) and the wire drawing head (2) located in different wire drawing machines and the ground. With the mica (18) located on the rotary soap chamber (3), the filling level of the soap chamber (3) can be easily monitored by the operator, and soap spillage during rotation is prevented.

Claims

CLAIMS1. A cold wire drawing process and an improved soap chamber comprising:- at least one wire drawing head (2), which includes a water flow path, around which the wire (1 ) whose diameter is reduced is coiled, and which allows the temperature of the coiled wire (1 ) to decrease during the period until the coiled wire (1 ) enters the next rolling die (4), and which rotates at different speeds according to the diameter-reduction ratio;- a soap chamber (3) which contains soap, through which the wire (1 ) passes and becomes coated with soap, and which rotates at the same radial speed as the rolling die (4);- a rolling die (4) which is driven by a reducer and motor (5) and which, by means of the cold deformation method, shapes the wire (1 ) and provides the reduction of its diameter;- a reducer and motor (5) which, together with the belt pulley system (6), enable the rotation of the rolling die (4) and the rotary soap chamber (3);- a belt pulley system (6) which, with the movement of the reducer and motor (5), enables the rotation of the rotary soap chamber (3);- a groove (7) formed by welding plates onto the inner surface of the soap chamber (3), preventing the soap from accumulating on one side, ensuring its continuous movement, and enabling the homogeneous mixing of soap particles of different sizes;- a breaker path (8) which is a machined region where the soap conveyed by the groove (7) towards the rolling die (4) is collected and which allows the soap to move smoothly towards the mouth of the rolling die (4);- a machine fixing plate (9) which is a plate mounted to fix the rotary-drum- type soap chamber (3) onto the wire drawing bench;- front and rear bearings (10) which, by the mechanical movement received from the reducer and motor (5), allow the rotary soap chamber (3) to rotate around its own axis;- front and rear flanges (11 ) which fix the bearing (10) and the soap chamber (3) on the axis of the line and provide vibration isolation;- inlet-outlet nozzles (12) which, with the movement of the soap chamber (3), prevent powder soap from escaping out of the system while the wire (1 ) enters the soap chamber (3);- a rotary soap chamber bearing housing component (13), which supports the rotary soap chamber (3) on the system and prevents the soap chamber (3) from moving out of the system due to horizontal forces occurring during wire drawing;- a mechanical reinforcement bar (14) which is a structural component that extends the service life of the bearing (10) and front and rear flanges (11 ) against the rotational movement of the radial soap chamber (3) and the forces applied by the wire (1 ) in the third axis;- a locking clamp (15) which fixes the mechanical movement transmitted from the reducer and motor (5) and allows it to be transferred to the rotary soap chamber (3);- a soap compression region (16) which, due to the radial motion originating from the rotary soap chamber (3), prevents the soap from moving away from the inlet of the rolling die (4), and which is a region located on the wire (1 ) where the inner grooved (7) section is machined conically towards the inlet of the rolling die (4), and where the soap particles delivered onto the wire (1 ) by the breaker path (8) become trapped between the core of the rolling die (4) and the wire (1 ), thereby performing the lubrication process;- a soap chamber adjusting component (17), which, by means of a lock-nut compression function, allows the rotary soap chamber (3) to be tilted by ±10° relative to the horizontal plane, enabling compatibility with different wire drawing machines;- a mica (18), which is a transparent component made of mica material, which allows soap to be added when the system is stopped by opening and closing, prevents soap from spilling during rotation, and enables monitoring of the box’s fill level during system operation with its transparent property.

2. A cold wire drawing process and an improved soap chamber according to claim 1 , comprising a groove (7) and a breaker path (8) that break down burnt and clumped soap and turn it into powder form.

3. A cold wire drawing process and an improved soap chamber according to claim 1 , comprising a groove (7) which is coiled in a helical form with a width of 2-3 mm and spacing of 12-16 mm, the distance between the plates decreasing as they approach the rolling die (4).

4. A cold wire drawing process and an improved soap chamber according to claim 1 , wherein the soap chamber (3) comprises a bearing (10), front and rear flanges (11 ), a bearing housing component (13), and a locking clamp (15), which enable it to rotate simultaneously with the radial angle of the reducer and motor (5) in systems using a rotary rolling die (4) without requiring the use of an additional motor.

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