Important Features of Rolling of Wire Rods Mar27

Important Features of Rolling of Wire Rods...

Important Features of Rolling of Wire Rods Wire rods are normally rolled in a high speed rolling mill, where steel temperature is above 1,000 deg C, maximum speed of rolling exceeds 120 metres per second (m/s) and coils of wire rod produced can be upto 10 kilometers (km) long. During rolling of wire rods, usually 25 passes to 30 passes are taken in a continuous rolling mill. Wire rod is a material which has a very wide application. From components for the automotive industry, tire cord, electrodes, connecting elements such as nuts and bolts, springs, wire and wire products, steel reinforcements, and so on, everything is based on wire rod. That is why wire rod mill is normally designed with versatility in mind. The mill being an energy intensive mill, it becomes necessary that the optimum solutions are incorporated in the mill design without compromising on the flexibility. All size ranges, materials and alloys need to be produced efficiently and with high productivity in the wire rod mill. Wire rods are required to meet the wire rod users’ requirements of surface and internal quality as well as physical, chemical, mechanical, and metallurgical properties. Wire rods undergo post-processing such as drawing, forging, or machining into desired shapes and heat treatment for enabling the product to achieve the desired strength. Thus, the wire rods are required to be capable of ensuring good performance of the produced parts wherever they are used, and at the same time, to have good workability at different stages of the post-processing. The user of wire rods has three basic requirements namely (i) to eliminate or simplify one or more of the secondary or tertiary processing to improve productivity and reduce processing cost, (ii) to improve the functionality, i.e. to extend the...

Steel Wire Rods

Steel Wire Rods Steel wire rod is a semi-finished product which is rolled from steel billet in a wire rod mill and is used primarily for the manufacture of wire. For a steel plant it is a finished product. The steel for wire rod is produced by all the modern steelmaking processes, including the basic oxygen and electric furnace processes. Steel wire rod is usually cold drawn into wire suitable for further processing such as cold rolling, cold heading, cold upsetting, cold extrusion, cold forging, or hot forging. Although wire rod may be produced in several regular shapes (round, square, hexagonal, and rectangular), most of the wire rods rolled are round in cross section. Round wire rod is usually produced in nominal diameters of 5 mm to 15 mm, advancing in increments of 0.5 mm.  ISO 16124:2004 gives diameters of round steel wire rods ranging from 5 mm to 50 mm, advancing in increments of 0.5 mm up to 20 mm and thereafter in the increments of 1 mm. As the wire rod comes out of the rolling mill, it is formed into coils. The coils are secured either tying with a wire or strapped with a strapping band. In each coil, wire rod is continuous without any break.  Internal diameter of a wire rod coil usually varies in the range of 810 mm to 910 mm depending on the mill equipment. The external diameter of the wire rod coil depends on its weight and usually it is in the range of 1100 mm to 1300 mm. The coil weight can vary from mill to mill and normally it is in the range of 600 kg to 2.5 tons. Coil weights that exceed the capabilities of the rolling mill sometimes can be obtained by welding...

Wire rod

                      Wire rod  Wire rod is a hot rolled steel product classified its shape. It is a rolled alloy or plain carbon steel product, produced from a semi mainly billet. It has a round, rectangular or other cross-section. In case of rounds its diameter ranges from 5.5 mm to 14 mm. Wire rod is wound into coils and transported in this form. In case the diameter is higher the product is called ‘Bar in coil’. Fig 1 shows wire rod coil.       Fig 1 Wire rod coil Wire rod coil is held in a unit with at least four steel straps in the transverse direction and transported and stored without further packaging. Before the steel strapping is applied, the wire rod must be sufficiently compressed. The strapping is fixed in the transverse direction with a single circumferential strap so that the strapping does not slip and cause the coil to come apart. Wire rod coils must be handled carefully owing to its sensitivity to mechanical damage. Damage may be prevented by correct handling and the use of suitable handling and slinging equipment (e.g. crossbars, C hooks, coil mandrels, webbing slings, chain slings). Lifting or setting down the wire rod coils with excessive force results in distortion, which is detrimental to further processing. The permissible loading capacity of the slinging and handling equipment and the lifting capacity of the lifting gear must also be taken into account. If the metal strapping is damaged or broken, the wire coils loosen and may result in tangled wire rod or other damage. Loosened wire rod coils result in problems during handling and during unrolling prior to further processing. Wire Rod is used for many products. It is the raw material for the wire drawing units. Different uses of...