Equipment for acid-free steel rod cleaning & wire drawing
Decalub’s Dry Cleaning, Coating and Drawing (DCCD) process enables ‘completely dry’ steel rod coating and lubrication to happen in-line at unlimited rod entry speed and consuming virtually zero energy. The company is confident that “the process is one of the most outstanding ever obtained in rod cleaning and wire lubrication”.
DCCD means that traditional wet pre-coatings, including phosphate, borax, and their substitutes are eliminated resulting in cost savings on consumables.
Decalub says: “This process is used in the most demanding drawing applications, greatly reducing the die wear, enabling the highest drawing speeds, with all carbon steel rods and wires up to 0.90%C. It incorporates our frictionless wire lubrication system – LVC/PDH – which also excels in demanding applications and offers immediate substantial cost savings in the production of quality wires including spring, rope, bead, PC strand, plating wire, CO2 welding wire, colleted nail wire and so on.”
The innovative LVC/PDH rod/wire dry coating and lubrication technology that enables a controlled fusion of standard dry lubricants, or their blends, regardless of their melting properties. This results in a ‘liquefied’ substance that provides an exceptionally consistent and highly adherent hard lubricant film whose weight is adjustable at all line speeds.
This technology achieves a hard residual coat for spring wire, high-tensile rope wire and PC strand wire, and a light water-soluble film for plating wire (or bright wire) of highly reflective quality.
For example, 5.5mm (0.218”) 0.83%C mechanically descaled bare rod is LVC/PDH coated and drawn in-line to 1.85mm (0.073”) at 13.5m per second (2,700 feet per minute). Due to the frictionless conditions, the temperature of the exiting wire does not exceed 45°C (113°F), resulting in greatly improved wire fatigue limits.
Decalub cites other benefits as up to eight times longer die life, elimination of low-level torsion problems, and consistent and improved wire ductility with torsion tests showing a deviation of only +/– 5%.
Futhermore, the DCCD system is fully automatic, very simple to install on any wire dry drawing machine – no hot liquid tanks, no hot air blowers, no air wipes – and the equipment can be operational within a day.