IS:398
(Part II & V), ASTM:B-498 BS:4565 & as per PGCIL Specifications
P.C.
Single Wire, Indented & Stress relieved
3.00 -
4.00
IS:6003
Ball
Bearing WireEN-31/SAE-52100
1.60 -
16.00
IS:4398 or as per Buyer's Specification
Spring
Steel Wire
0.60 -
16.00
IS:4454
Spring
Washer Wire (En45 A)
6.00
- 18.00
As
per Buyer's Specification
Tiller
Spring Wire
8.50
- 13.50
As
per Buyer's Specification
Lift
Spring Wire (50 crv4)
7.00
- 16.50
As
per Buyer's Specification
Spoke
Wire
2.00
- 4.00
IS:6902
C.H.Q.
Wire
1.50
- 14.00
As
per Buyer's Specification
Needle
Wire
0.50
- 4.50
As
per Buyer's Specification
Umbrella
Rib Wire
1.50
- 3.00
IS:4223
Rivet
Wire
1.00
- 5.00
As
per Buyer's Specification
Wires
are made from wire rods. The processing of wire rod is subject
to many variations depending upon the end use of the wire.
Based on the properties required by the wire, the quality
and chemical composition of wire rods is selected. The following
are the three principal operations generally carried out for
wire manufacturing:
Preparation
of wire rod viz., Pickling, Rinsing & Phosphating
Wire
Drawing
Finishing
(Coating / Annealing, etc
Pickling,
Rinsing & Phosphating
Pickling
is essentially a chemical de-scaling operation. The wire rods
received from the wire rod mills has on its surface a layer
of scale, which is very hard and essential to be removed before
drawing. The wire rod is pickled in Hydrochloric acid solution
for removal of the scale, in tanks lined with acid-proof bricks
or steel tanks lined with fiberglass. The wire rods are then
washed in water jets and finally dipped in warm water tanks.
The
coils from the rinsing tanks are immersed in a hot borax and
phosphate bath and finally immersed in a lime bath for lime
coating, which facilitates lubrication during wire drawing.
Hairpin hooks are used to transfer wire rod coils, which are
handled by overhead cranes, designed specially to avoid self-rotation
of hairpin hooks.
Wire
Drawing
There
are two processes of drawing: -
(i) Dry Drawing; and
(ii) Wet Drawing
The pickled and coated wire rod is fed into wire drawing machine
after necessary pointing of the rod end. The diameter is subsequently
reduced in a number of drums as per the requirement. Controlled
cooling of the wire during is most essential to maintain good
quality. The drawing machines are designed to cool the wire
at the inside of blocks and outside of dies by water-cooling.
Patenting
The
patenting process is essential for only High Carbon Wires.
It is an operation where the microstructure of steel is changed
to obtain malleability, necessary for wire drawing. This operation
is carried out in oil-fired / electrically heated furnaces,
where wire rod is heated above critical temperature for necessary
transformation of microstructure. The heated wires are required
to be quenched in a Lead bath to obtain the necessary grain
formation.
The
whole operation is a continuous process in which number of
wire rods are pulled through the patenting furnace and Lead
bath by suitable coiling machine.
Finishing
- Galvanizing
The
drawn wires are rewired to be given certain finishes depending
upon the quality and the end use of the wire. The types of
wires that are to be galvanized are - ACSR Core Wire, Armoring
Wire, Cycle Spoke Wire and certain types of mild steel wires.
This
plant consists of pay-off reels, cleaning equipment, washing
bath, fluxing bath, galvanizing furnace and take-up frame.
The whole operation is a continuous process and wires are
fed in the galvanizing plant as described earlier. The wire
is degreased in the Lead furnace and finally cleaned in the
cleaning bath. Before being fed into galvanizing furnace,
the wire is washed and flux coated.
Basic
Raw Materials The essential raw
materials required for the project are:
1) High carbon Wire Rods
2) Zinc
3) Lead
Besides
the above, various process materials like Hydrochloric acid,
Sulphuric Acid, Lime, Soap, Drawing lubricants, Fuel oil,
Dies, Copper Sulphate, Zyolion, etc. are required during the
numerous manufacturing process.
High
Carbon Steel wire rods are available from the following manufactures:
1) Usha Martin industries Ltd.
2) Vizag Steel Plant
3) TISCO
4) Hindustan Zinc Ltd.
ACSR
Core Wire
