Fig-1
The manufacturing process is divided into rough drawing, medium drawing, fine drawing, and extra-fine drawing.
In almost all case, water soluble drawing oils are used and their ingredients
and emulsification structure change according to the diameters of cables
and the velocity of drawing process.
1) Function
Drawing oils have two different functions, regardless of the cable size.
One is L: Lubricity function to protect the cable from surface damage
and burning. The other is sludge D: Dispersion force function to disperses
the metal friction sludge and the Metal reaction product between the metal
and the oil to eliminate from the inlet of drawplate and capstan.
For rough drawing and so-called in-line(low speed)process in which drawing machine and the next process are connected, the drawing oil should be emulsion type based on High viscosity and its density should be set up to 10% more or less. And the weight of the ratio of L to D is declined to L.
For medium drawing, being final sage of material process, the drawing oils have to be selected from the view point of making good material without snap troubles for the next step of process. So the weight of the ratio of L to D is shifted to D side.
For fine drawing, comparing to rough and medium drawings, the ratio of
L to D is more shifted to D side to make final merchandise more clean surface.
And snap accident is more likely to happen from this stage due to sludge
of capstan and drawplate.
For the sake of increasing cleaning effect, not only the fundamental lubricity
is decreasing but also metal ion soluble into the system is increasing.
And the surface of processed material is decreasing but also metal ion
soluble into the system is increasing. And the surface of processed material
comes in unstable situation, which leads to changing color problems after
the elapse of days. Too much using surfactants to increase the cleaning
effect causes of make bubble. And to control the bubbles, using much bubble
control chemicals leads to poor gilding effect and bad vanish coating.
For extra-fine drawing, more washable drawing oils are used for bonding
magnetic wires purpose.
The relation between Diameter and Lubricity & Dispersion force is illustrated
in Fig-2.
2) Ingredients
Base oil: mineral oils, animal or vegetable/plant oils and synthetic oils are used. According to the size of diameters of cables, the balance of contents changes to adjust viscosity.Oiliness chemicals: materials to react with metal, such as soap, ion tic activator and fats and oils.
Emulsifier: materials to disperse basic oils and oiliness chemicals into water. The adding quantity and species change according to the quantity of basic oils and oiliness chemicals.
The molecule weight of basic oils in case of rough drawing ranges from
1000 to 600. For the rest of drawings, The molecule weight steps down by
200 respectively. For fine and extra-fine drawings, esters with low
viscosity and good lubricity are used.As oiliness chemicals react with
metal and make some complex and accelerate the deterioration of the liquid.Their
activity strength has to be considered carefully．Emulsifier’s emulsify
and disperse basic oils, They have also oiliness effect and sludge disperse
force effect.
3) Maintenance
Except for some special cases water-soluble drawing oils are mainly used
for their cooling effect and prices. Therefore, the maintenance of the
liquid has to be paid special attention to water-caused problems. Particularly,
comprising ingredients ratio will be changed. Metal ions, out・comings
of deteriorated ingredients and the development of bacteria’s deteriorate
the oil functions. The increasing such kind of materials in drawing
oils invites physical troubles of cutting and chemical changing matter
after completion as merchandise.
By measuring the quantity of these by-products and investigating their characters the using situation of the drawing oils could be recognized. Arranging to prevent the drawing oils from out・coming of such by-products is one of the best methods to appeal as good quality guarantee.
HOME
