An aluminum wire design problem

Hello all,

I am a Mechanical Engineering student at Oklahoma State University, and a member of a group project for a Manufacturing Processes course. As part of the course we were put in teams of 4 and given the
following task:

We were instructed to design a process for the manufacture of 2024 Al wire. Our starting point is a hot rolled rod of 9.0 mm in diameter, which we must reduce to a final wire size of 0.72 mm by utilizing a multi die commercial practice without intermediate annealing. We must focus on defining the complete process parameters including semi angles, lengths, reduction pass schedule, lubricant, drawing velocities, etc.

We have started the design process, but find ourselves making rather slow headway as no hints or relative information have been given to us.

The scope of this project is really out of the scope of the course. We have not even covered drawing yet. We really are in need of assistance and would really appreciate your real world experience and expertise.


Thanks in advance

Hello there 73dodgedart (An interesting choice of a name),

You will find all through your professional career that you will find yourself in manufacturing processes you never studied at university so it is good to get such a project now. I'm sure you will enjoy this challenge.


While we don't think we should be solving your problem, we can certainly send you in the right directions.

The standard aluminum rod diameter used for electrical wire in the USA and Canada is 3/8 inch so 9 mm is OK at 0.3543 inches diameter

The standard electrical conductor grade of aluminum used is 1350 which is mostly for high voltage ACSR (Aluminum Conductor Steel Reinforced) non-insulated overhead cable feeding cities and low/ medium voltage insulated distribution cable. There are of course a number of aluminum alloys used in the electrical industry but 2024 is not usually used.


1) For the 2024 aluminum drawing machine comprising a pay off, the drawing machine itself and a take up or spooler(single reel for stop and go or dual reel for continuous operation)contact;

A.) Niehoff Endex North America Inc. at www.niehoff-usa.com/ and E-mail with Don Neville and/ or Edmond Torbey. This email address is being protected from spambots. You need JavaScript enabled to view it.
B.) SAMP USA Inc. at www.sampinc.com/ AND talk with the sales manager This email address is being protected from spambots. You need JavaScript enabled to view it.

These companies can provide you with the processing speeds and drawing die progressions (Likely referred to as "Taper Drafting") as well as an up to date machine brochure including the size of the pay off coil, take up drawing reel and recommended drawing oil (lubricant). Also ask them for a pointer and stringer so you can string up the drawing machine the first time and every time thereafter you change finish wire diameter or if the wire breaks inside the drawing machine. If you need a final in-line induction anneal, talk with them about this.

2) For the aluminum multiple upset rod welder (For continuous pay off), contact

A.) T. Fukase & Co., Ltd (Japan) at www.fukase.co.jp/ There is an inquiry sheet there.
B.) Micro Products Company at www.micro-weld.com/ contact Ed Harrington This email address is being protected from spambots. You need JavaScript enabled to view it.

3) For the drawing lubricant information contact;

A.) RichardsApex at www.richardsapex.com/ Contact Drew Richards at This email address is being protected from spambots. You need JavaScript enabled to view it. He may also be able to give you some recommendation about the drawing die cone angles and drawing die materials.

4) For the drawing lubricant system (Storage tanks, aluminum fines filtration, temperature control, pumping and return) contact;

A.) Filtertech at filtertech.com/ They also have a featured system titled Aluminum Wire Production & Filtration System Concepts at filtertech.com/aluminum-wire-production-...-system-concepts.php Contact them at This email address is being protected from spambots. You need JavaScript enabled to view it.

5) For the drawing die information, contact;

A.) Fort Wayne Wire Die, Inc. at www.fwwd.com/ Contact This email address is being protected from spambots. You need JavaScript enabled to view it. or fill out the general inquiry form. You need to know their recommendations for die angles, and die materials. Be sure to tell them the drawing lubricant, the finish line speed and calculate the rod entry speed for them.
B.) Paramount Die www.paradie.com/ Contact them at This email address is being protected from spambots. You need JavaScript enabled to view it. Again you need to know their recommendations for die angles, and die materials. Be sure to tell them the drawing lubricant, the finish line speed and calculate the rod entry speed for them.

6) For the Wire Drawing Take Up Reels contact;

A.) The Pentre Group (England) at www.pentregroup.com/ and check out the steel "SF" drawing reel. Contact This email address is being protected from spambots. You need JavaScript enabled to view it. They are represented in the USA by JJ Lowe Associates Inc. at www.jjlowe.com/ Contact Thomas Twitmyer at This email address is being protected from spambots. You need JavaScript enabled to view it. if you are having some problems.


After all this, you will be an expert in commercially drawing 2024 aluminum alloy wire and you should get an A+ on your project provided of course that you put some reasonable effort into the project. Try to get(pdf)technical brochures from all. Just so you know, people in the wire and cable industry are all a good bunch of folks. Likewise make sure that all know that you are doing an assigned mechanical engineering project at university and that you need their help. Now get to work! (Just kidding around of course.)

Regards
Peter J. Stewart-Hay P. Eng. (Mechanical)
Principal
Stewart-Hay Associates
www.Stewart-Hay.com
519 641- 3212