Batch Wire Rod Lubrication Coating After Shot Blast Descaling
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Solution Overview
Problem
Existing lubrication treatments for metal wire rods, such as phosphate/soap treatment and coat-type aqueous lubricants, face environmental burdens, inefficiencies, and non-uniform coating issues, particularly in in-line systems, leading to low throughput and production inefficiencies.
Innovation Solution
A batch lubrication treatment method involving shot blast descaling with a specific gap condition (L/(d×N)≥1.1) followed by applying a lubricant containing inorganic and organic acid salts, with a balanced solid weight ratio and viscosity, and optional preliminary heating to form a uniform coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If in-line system is used for coat-type lubrication treatment, then environmental burden is reduced, but throughput per hour decreases and production efficiency deteriorates
Solution Approach 1:
The treatment process is divided into separate batch treatment stages rather than continuous in-line processing. The batch system allows multiple wire rods to be treated simultaneously in discrete batches, with each batch receiving shot blast cleaning followed by lubricant application and drying in separate treatment chambers or zones, thereby maintaining environmental benefits while improving overall throughput through parallel processing.
Solution Approach 2:
The system dynamically adjusts the treatment cycle time and batch size based on production requirements. The batch treatment duration can be optimized for each cycle, and multiple batches can be processed in sequence or parallel, allowing flexibility in maintaining high throughput while preserving the environmental advantages of coat-type lubrication treatment.
2Productivity
If linear velocity is increased in in-line system, then throughput per hour improves, but drying time becomes insufficient and drying failure occurs
Solution Approach 1:
The shot blast cleaning is performed as a preliminary action before lubricant application, creating an optimally prepared surface that enhances lubricant adhesion and drying efficiency. This preliminary surface preparation ensures that subsequent drying occurs more effectively and uniformly, allowing sufficient drying time even at higher throughput rates.
Solution Approach 2:
The batch treatment system maintains continuous useful action by immediately proceeding from shot blast cleaning to lubricant application and then to drying without idle transitions. This continuous sequence of operations ensures that drying occurs under optimal conditions throughout the entire treatment cycle, preventing drying failure while maintaining high productivity.
3Object-affected harmful factors
If shot blast is used for cleaning treatment of coiled metal wire rod, then environmental burden and operator burden are reduced, but descaling becomes insufficient and coating uniformity deteriorates
Solution Approach 1:
The shot blast treatment parameters are optimized by adjusting the gap distance L/(d×N) to specific ranges, shot blast intensity, and treatment duration. These parameter changes ensure thorough descaling while maintaining coating uniformity. The optimized parameters create optimal surface conditions that promote uniform lubricant application and drying, achieving both environmental benefits and high coating quality.
4Manufacturing precision
If acid washing or alkaline degreasing is used for cleaning treatment, then coating adhesion improves, but energy consumption increases and environmental burden increases
Solution Approach 1:
The chemical cleaning methods (acid washing and alkaline degreasing) are replaced with mechanical shot blast cleaning. This substitution eliminates the need for heating large volumes of chemical solutions and reduces waste treatment requirements, significantly lowering energy consumption and environmental burden while achieving comparable or superior coating adhesion through mechanical surface preparation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Significantly reduces environmental impact, enhances production efficiency, and ensures uniform lubrication coating formation on metal wire rods, improving lubricity and reducing friction during wire drawing processing.
Implementation Method 1
a descaling step of performing shot blast treatment of a coiled metal wire rod
Implementation Method 2
a lubrication coating formation step of applying a lubricant to the metal wire rod after the descaling step
Data Source
AI summary
An object is to provide a lubrication treatment method of a metal wire rod, in which not a combination of acid washing/alkaline degreasing and phosphate/soap treatment each causing a large burden on the environment, but shot blast and a coat-type treatment agent are used to allow for a significant reduction in burden on the environment, and a batch manner is applied to allow for practical production efficiency and uniformly form a lubrication coating on a metal wire rod. The object is achieved by a lubrication treatment method of a metal wire rod, which is a method for lubrication treatment of a coiled metal wire rod in a batch manner, including a descaling step of performing shot blast treatment of a coiled metal wire rod, and a lubrication coating formation step of applying a lubricant to the metal wire rod after the descaling step, in which the coiled metal wire rod satisfies L/(d×N)≥1.1 in the descaling step under the assumption that the coil width is L, the wire diameter of the metal wire rod is d, and the number of coil turns is N, and the lubricant contains one or more coating base components (A) selected from the group consisting of an inorganic salt and an organic acid salt, and a lubrication component (B).