Cleaning and preparation for frictionless drawing

PUBLISHED: 14 Aug 09

Rod cleaning and wire drawing by DCCD process
Rod cleaning and wire drawing by DCCD process

The latest version of DCCD (Dry Cleaning, Coating and Drawing), incorporating the New-Coat coating, eliminates the most costly parameters in wire drawing operations, including elimination of acid and traditional wet pre-coating chemicals. The process is said to offer significant downstream benefits enabling users to target a total saving of 50% to 65% in production costs.

The DCCD process allows immediate substantial cost savings in the most demanding drawing applications including spring wire, high-tensile rope wire, bead wire, PC strand wire, AL cladded wire, plating wire, bright wire and CO2 welding wire.

Scale cracking by rod reverse bending is followed by ultra-fine brush cleaning. Brush pressure is automatically controlled and a powerful multi-function LVC/PDH ultra-high pressure coating system, installed in the first draft, permits inline high-performance dry coating, plasticising and lubrication of the bare rod.

Liquefied standard dry lubricants, the viscosity of which is automatically controlled during the drawing operation, completely eliminate traditional wet pre-coating chemicals including phosphate and borax pre-coatings.

Typical application of the DCCD process is in direct drawing from 5.5mm diameter mechanically descaled bare rod, with 0.83/0.88% carbon content, without pre-coating wet chemicals, with an output of 2.2tph and with a die life of 200 tons per die in the first draft. Lubricant film achieves frictionless drawing by physical separation of wire-die contact in all drafts, eliminating friction heat, enabling die wear of 0.1-0.3 micron per ton of wire drawn, with no speed limitation, dependent mainly on rod payoff and wire take-up modes.

Decalub, France
Tel: + 33 1 64 26 20 66

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