Wire Rods and Wire Rod Mills Aug13

Wire Rods and Wire Rod Mills...

Wire Rods and Wire Rod Mills Steel wire rods are an all-round talent since they are the key product of steel industry with multiple uses. They are used as the material for fasteners, springs, bearings, wire ropes, chains, cables, wire meshes, wire fencings, tyre cord, reinforcement in railway sleepers, and many other uses. They are used for the components needed for the automotive industry, chemical industry, power stations and machine engineering. Unlike cold-rolled sheets, heavy plates, pipes, sections and other steel products, wire rods are seldom used as hot rolled for final products, but they are manufactured into machine parts after undergoing one or more stages of so called post-processing such as heat treatment, forging and wire drawing at specialist plants. Wire rods are generally drawn down to a specific diameter before being subjected to forging or other forming operations in secondary processing. In many cases, the size of the wire rods before being subjected to these forming operations is to be less than the minimum size of 5.5 mm that can be supplied as rolled. Generally each of the wire rod product is developed with due attention to its behaviour at the post-processing stages. What is required for a steel plant regarding wire rods is good processibility and fulfilment of the required properties after the processing. Furthermore, since the costs of the post-processing is sometimes several times the price of the wire rods, it is increasingly important to reduce the total integrated manufacturing cost from the steel material to the final product. Also thermo mechanically treated (TMT) reinforcement bars of 6 mm, 8mm and 10 mm basically required for the building construction are produced in the wire rod mills. The following generally characterizes the wire rod products. Product grades are widely varied from...

Cold heading quality steels and cold heading process...

Cold heading quality steels and cold heading process Cold heading quality (CHQ) Steel is the raw material which is used for the production of fasteners such as bolts, screws, nuts, rivets, nails, and other similar complex parts.  Traditionally fasteners have been manufactured using the thread cutting or by hot working method. But now the trend is moving towards using the cold working process to enhance productivity and to keep the cost down. It also provides good surface finish and dimensional accuracies to the fasteners. Cold heading process Cold heading process revolves around the concept of altering initial steel “blank” through force, using a series of tools and dies to change the blank into a finished product. The actual volume of steel remains unchanged, but the process maintains or improves its overall tensile strength. Cold heading is a high speed manufacturing process that relies on metal flow due to applied pressure as opposed to traditional metal cutting. It is a type of forging operation which is carried without the application of any heat. During the process material in the form of a wire is fed into the cold heading machine, cropped to length and then formed in a single heading station or progressively in each subsequent heading station. During cold heading load should be below the tensile strength, but above the yield strength of the material to cause plastic flow. The cold heading process uses high speed automated “cold-headers” or “part formers.” This equipment has the ability of transforming a wire into an intricately shaped part with tight and repetitive tolerances using a tooling progression at speeds up to 400 pieces per minute. The cold heading process is volume specific and the process uses dies and punches to convert a specific “slug” or blank of...