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STEEL WIRE MANUFACTURING

STEEL WIRE MANUFACTURING. Wire drawing is a metalworking process used to reduce the cross-section of a wire by pulling the wire through a single, or series of, drawing die(s) Applications: Tension-loaded structural components Stringed musical instruments Types Cold working

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STEEL WIRE MANUFACTURING

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  1. STEEL WIRE MANUFACTURING Wire drawing is a metalworking process used to reduce the cross-section of a wire by pulling the wire through a single, or series of, drawing die(s) Applications: Tension-loaded structural components Stringed musical instruments Types Cold working At elevated temperatures

  2. PROCESS OF WIRE DRAWING • Pickling • The wire is pulled through the die, its volume remains the same, so as the diameter decreases, the length increases. • % of areal reduction

  3. Single block wire drawing machines • A bracket standing up to hold the die • A vertical drum which rotates and by coiling the wire around its surface pulls it through the die • The wire drum or "block" is provided with means for rapidly coupling or uncoupling • The block is also tapered • Snatching

  4. Continuous wire drawing machines • A series of dies • A block between each die • The speeds of the blocks are increased successively • Stringing-up • Intermediate anneals • Non-circular cross-section drawing

  5. Lubrication The following are different methods of lubrication: • Wet drawing • Dry drawing • Metal coating • Ultrasonic vibration • Copper sulphate solution

  6. Mechanical Properties • The strength-enhancing effect • Tensile strength can be as high as 3760 MPa Drawing dies • Tungsten carbide • Die angles usually range from 6–15 °

  7. OPTIMIZATION OF OPERATIONS IN A STEEL WIRE MANUFACTURING COMPANY Process flow chart :

  8. The preliminary study at the plant • Wire breakages and maintenance resulted in approximately 60% of the total idle time • Downtime of any one of the KOCH machines will affect the productivity of Bekeart • No specific schedule was prepared for preventive maintenance • The time consumed and the frequency of each fault was not studied • No specific task was taken to change or to revise subassemblies or machine members design which are giving trouble periodically.

  9. Productivity can be increased in numerous ways : • By reducing the input for the same level of output • By increasing the output with the same level of input • By combining both • By reducing down-time due to - Wire breakages, maintenance, reducing the material input, by using better quality of goods, improved utilization of resources, reduction in working capital GOAL: NEED TO IMPROVE THE PRODUCTIVITY

  10. IDLE-TIME ANALYSIS • Shift-to-shift detailed production chart of each machine • Reasoning for idle time occurrence per shift • Wire breakages were basically due to defective raw material, improper pickling and welding • Rare problems – very high time consumption • Regular problems – very less time consumption

  11. Decision variables The number of arrivals of the entity at the stores. The number of resources required Frequency and time of breakdown maintenance of the KOCH machines Utilization of the KOCH machines

  12. FINDINGS AND CONCLUSIONS Optimum Lot Size • The objective was to reduce the blocking of the coils in the process • The optimum arrival quantity – 42 Throughput • Increasing the arrival quantity • Adding an extra forklift

  13. FINDINGS AND CONCLUSIONS Preventive Maintenance

  14. THANK YOU PAVANKUMAR D. WADHONKAR T. Y. PROD ROLL NO. 20807066 (PE – 03 46)

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