Analysis of 9 kinds of common defects in cable drawing: 43 causes and solutions

Class 1: disconnection

Cause 1: The connector is not secure

Solution: adjust the current, power time and pressure of the welding machine to improve the welding quality

Cause 2: wire has impurity

Solution: strengthen the acceptance of raw materials

Cause 3: The matching mold is unreasonable

Solution: adjust the mold to eliminate the phenomenon of too large and too small deformation

Cause 4: Die hole shape is incorrect or not smooth

Solution: mold repair in strict accordance with the standard, sizing area should not be too long, to ensure the finish of the mold hole

Cause 5: The reaction force is too large

Solution: adjust the winding number on the drum wheel

Cause 6: The drum wheel is pressed

Solution: adjust the winding number of drum wheel, correct the worn drum wheel

Cause 7: Poor lubrication

Solution: Check the lubrication system, determine the composition and temperature of lubricant

Cause 8: Aluminum rods are wet

Solution: Prevent the aluminum rod from being damp. Do not use the wet aluminum rod temporarily

Class 2: incorrect size and shape

Cause 1: Die holes are worn

Solution: measure the wire diameter frequently, and replace the mold when it is found to be out of tolerance

Cause 2: The wire is thinned

Solution: adjust the matching mold to improve the lubrication effect

Cause 3: Use the wrong mold

Solution: Measure the wire diameter after threading

Cause 4: The cable is scratched

Solution: check the quality and lubrication of die holes

Cause 5: The mold is skewed

Solution: pay attention to straighten up the mold and repair the mold base

Class 3: scrapes, bruises, scrapes

Cause 1: There are jumper wires on the conical drum

Solution: the surface of the drum wheel is polished and the Angle is correct

Cause 2: The drum wheel has grooves

Solution: remove the drum wheel to repair polishing

Cause 3: There are damaged wires on the device

Solution: the interface of drum wheel is uneven, and the regulating wheel is not flexible

Cause 4: Cable disks collide

Solution: The wire trays should be placed with "T" and separated from each other during transportation

Cause 5: The ground is uneven

Solution: renovate the ground and lay steel plates

Cause 6: The cable is too full

Solution: Stick to your post, concentrate and play according to the rules

Category 4: peeling, pitting, triangular mouth, burr

Cause1: wire has flying edge, inclusion, shrinkage hole

Solution: strengthen inspection, unqualified do not put into production

Cause 2: die hole is not smooth, deformation, etc

Solution: strict inspection, unqualified mold is not on the machine

Cause 3: Poor lubrication

Solution: improve the lubrication effect

Cause 4: The drum wheel is not smooth and the sliding rate is too large

Solution: polish the surface of drum wheel and adjust the matching mold

Category 5: ripple, snake

Cause 1: improper mold matching

Solution: adjust the mold matching, and the deformation degree of the finished mold shall not be too small

Cause 2: serious vibration of wire drawing machine

Solution: repair and reinforce the equipment to eliminate vibration

Reason 3: the wire rod shakes badly

Solution: adjust the tension and keep the winding speed stable

Cause 4: the shape of die hole is inappropriate

Solution: the length of the sizing area should be appropriate, not too short or even not

Cause 5: uneven and unclean lubrication supply

Solution: ensure uniform lubricant supply and filter the lubricant for use

Category 6: continuous scratches

Cause 1: wire scratch

Solution: check all parts in contact with the wire, such as guide wheel and wire bar

Cause 2: the lubricating fluid temperature is too high

Solution: strengthen cooling and adopt forced cooling if necessary

Cause 3: the lubricant has high alkali content and is not clean

Solution: Test regularly, keep the composition of lubricant and ensure its cleanness

Cause 4: the die hole is not smooth and defective

Solution: strengthen the repair and management of molds, and do not use unqualified molds

Cause 5: the lubrication area of die hole is blocked

Solution: filter the lubricating fluid to eliminate metal chips and various impurities in the lubricating fluid.

Category 7: oxidation, water stain and oil stain

Cause 1: insufficient lubrication and high lubricating fluid temperature

Solution: ensure sufficient supply of lubricating fluid and strengthen the cooling of lubricating fluid

Cause 2: splash of lubricating fluid

Solution: block the splashing part, and wipe the wire with felt at the outlet of the finished product line

Reason 3: the storage site is not clean, and the greasy gloves dirty the wire rod

Solution: adhere to 5S management to ensure the cleanness of the workplace

Category 8: full, partial, disordered, tight and loose winding

Cause 1: improper cable arrangement adjustment

Solution: adjust the wire width and position according to the specifications of the take-up reel

Cause 2: improper take-up tension

Solution: adjust the take-up tension and speed

Cause 3: the wiring arrangement mechanism is faulty

Solution: observe carefully and eliminate it in time

Cause 4: the take-up reel is irregular

Solution: select qualified wire reel to put on the machine

Cause 5: too full take-up

Solution: strengthen monitoring. In case of automatic disc change, reset the number of footplates or overhaul the equipment

Class 9: unqualified performance

Cause 1: mechanical properties such as tensile strength, elongation and bending are unqualified

Solution: the total deformation degree is small, the raw materials are unqualified, and the causes of uneven deformation will lead to unqualified mechanical properties. Therefore, qualified raw materials should be selected, the total deformation degree should be increased, and the temperature rise in the process of wire drawing should be controlled

Cause 2: unqualified resistivity

Solution: mainly unqualified raw materials, followed by improper annealing process