Wire industry

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The wire industry involves the manufacturing of metal wire products through a process known as wire drawing. Wire drawing is achieved by pulling undrawn wire through a die and straining it under high temperatures forming it into wire.

Dies of various sizes and varying conditions can be utilised in order to produce wire of different sizes such a fine wire and super fine wire. Each wire sizing requires unique dies and stranding in order to form correctly.

Various metals including copper, aluminium and steel can be used to create metal wire. Wire has many applications and is used worldwide in industries such as power and communications.

During the wire drawing process, lubricants are essential for ensuring that wire drawing is both efficient and effective. As material is exposed to high temperatures and high speeds during the stranding process, wires can often be prone to breakages while being manufactured. A wire drawing lubricant can assist in the smooth passage of wires through the strands.

Wire drawing lubricants are used to aid in the drawing of the metal, the lubricant decreases friction through the dies and allows the wires to pass smoothly ensuring the best finish on the product less wear on the machines and reduced wire breakage as a result.

A wire drawing lubricant also ensures cleanliness within the wire drawing machines, acting as a detergent for the solution within the wire drawing machine and ensuring a clean finish on the drawn wires.

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What kind of lubricants do you use in the wire industry

There are several specially designed lubricants to match each wire drawing industry’s needs and application.

The different wire drawing lubricants include:

Copper wire drawing lubricants – Designed specifically for use in copper wire manufacturing, this lubricant has been formulated to work best with copper and offers optimal protection to copper wires and drawing machines. They offer a superior anti-corrosion property that protects machine parts and wire surfaces.
Aluminium wire drawing lubricants – These lubricants have been designed for aluminium wire drawing. Their formulation has been specifically designed for use with pure aluminium and aluminium alloy. Due to their low viscosity, they aid in separating aluminium fines and pumpability in high-speed slip machines.

Lubricants for wire drawing industries are required to meet many specifications to meet the needs of the specific wire drawing process.

A wire drawing lubricant designed for the copper wire industry needs to be water-soluble, whereas an aluminium wire drawing lubricant needs to be created using neat oils. Both types of lubricant need to offer high performance and are designed for continuous annealers.

While different lubricants may offer unique properties, all must provide optimum boundary lubrication to protect dies and provide optimal surface finish to the drawn wires. Wire drawing lubricants need to offer high resistance to thermal degradation to ensure extended service life and continued performance during high-temperature applications.

How do lubricants improve wire drawing?

Wire drawing lubricants can improve wire drawing production by increasing efficiency, decreasing the need for maintenance, and protecting the wires from damage or breakage.

One of the key benefits of incorporating a good wire drawing lubricant is the cleanliness inside of the wire drawing machine. A lubricant aids in the cleaning and maintenance of the solution which can be prone to bacteria and fungal buildup if not efficiently maintained and lubricated with the correct solution.

By offering maximum protection, good resistance against bacterial and fungal attacks within the machine and working well with detergent additives in the machine, wire drawing lubricants are essential for the continued running and management of wire drawing machines.

By using Metalube’s wire drawing technology, wire drawing manufacturers were able to achieve the following results:

“By offering a superior product for the wire drawing industry, Metalube can confidently provide the leading lubricants to our customers.”

Andy Lewis, Commercial Manager

The Right Wire Drawing Lubricant

Selecting the right lubricant is crucial for achieving the best performance, productivity and end product within your wire drawing machine.

As outlined above, the right lubricant reduces wear on dies and machinery, improves wire surface quality, improves cleanliness reduces bacterial and fungal build up and enhances production efficiency.

You’ll need to factor in the metal type, desired wire properties, and machine operating conditions. It’s important to evaluate the different lubricants and their unique applications for compatibility with your specific wire drawing processes, ensuring they meet performance and environmental standards.

This is why consulting with an expert on the various lubricants can provide valuable insights, helping manufacturers choose lubricants that maximize productivity and product quality.

Challenges in the wire drawing industry

There are several key challenges in the wire drawing industry, including maintaining material integrity, cleanliness in the machine, managing friction/wear, ensuring equipment longevity, and addressing environmental concerns.

The consistency in material quality is critical, as slight deviations can significantly affect the wire’s properties and the drawing process’s efficiency.

Friction and wear between the wire and the dies pose a major challenge, requiring the use of specialized lubricants to minimize wear and potential damage to the machinery and ensure the wire’s surface quality.

Wire breakage is also a significant issue and can be one of the key contributors towards potential downtime within the wire drawing manufacturing plant.

However, selecting the appropriate lubricant requires an intricate understanding of the drawing conditions and metal properties.

The global nature of the wire drawing industry introduces additional complexities, including market fluctuations that affect raw material costs and demand.

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Environmental Considerations in Wire Drawing

We understand that the wire drawing industry is increasingly focusing on sustainable practices in order to minimize its environmental footprint.

Eco-friendly lubricants, designed to reduce harmful emissions and improve biodegradability, an important factor for companies looking to reduce their carbon footprint.

Metalube are a company dedicated to delivering the most environmentally friendly products and ensuring that every element of our manufacturing process is aligned with an environmentally friendly commitment.

Since 2019, Metalube has adopted many sustainable practices ensuring that we are doing everything possible to make our operation environmentally friendly.

From installing solar panels, incorporating electric forklifts, adopting recycling and re-used panels into our storage process, we have maximised our efforts to offer a truly sustainable lubricant product.

Maximize Your Wire Drawing Operations

If you’re looking to maximise the performance and efficiency of your wire drawing production, getting the most effective lubricant is essential.

Our advanced lubricants and innovative solutions are designed to enhance your wire drawing operations, offering improved efficiency, superior wire quality, and reduced environmental impact.

We have specialised solutions to meet each wire drawing production and can help you find the optimal solution.

Contact us for a consultation or to explore a trial of our cutting-edge products. Let our expertise help you optimize your wire drawing processes and stay ahead in a competitive industry.