外文翻譯--述評(píng)創(chuàng)新鋼絲調(diào)直切斷機(jī)【中英文文獻(xiàn)譯文】,中英文文獻(xiàn)譯文,外文,翻譯,述評(píng),創(chuàng)新,立異,鋼絲,切斷,割斷,中英文,文獻(xiàn),譯文 Ashvin S. Patel et al. / International Journal of Engineering Science and Technology (IJEST) A REVIEW ON INNOVATION OF WIRE STRAIGHTENING CUTTING MACHINE ASHVIN S. PATEL Sr. Lecturer in Mechanical Engineering Department, Swami Sachchidanand Polytechnic College Sankalchand Patel Sahakar Vidyadham, Kamana Cross Road, Visnagar 384315, Dist: Mehsana, North Gujarat. India DR. J. M. PRAJAPATI Associate Professor, Mechanical Engineering Department, Maharaja Sayajirao University of Baroda, Baroda-390001, Gujarat, India. Abstract Now days, there are wide verity of wire products like welding electrode, weld mesh, heat treated kitchen baskets, automobile spark plugs and exhaust valves etc. For manufacturing all above products, wire is used as primary element and is to be straighten from coil form. Now straighten wire is to be cut into wire rod as per required length. For these sequential operations, wire straightening cutting machine is used. Now days, conventional type wire straightening cutting machine are being used in which wire is cut by stopper cutter head which is limited by its length as well as feeding speed. This paper surveys straightening and cutting process used in such machines. Although this review cannot be collectively exhaustive, it may be considered as a valuable guide for researchers who are interested to develop next generation of wire straightening cutting machines. Keywords: Wire straightening cutting machine (WSCM), Straightening, Cutting off 1. Introduction Wire Straightening and Cutting Machines (WSCM) are widely used to extend wires from a roll or coil in order to straight and to cut. These machines are offered with extensive features requiring diverse applications. Some machines are configured for straightening and cutting all kinds of cold drawing wires and other nonferrous metal wires. They may cut the wire as per requirements in the required dimension and thereafter, work continuously. These machines are complied with three different processes such as feeding, straightening and cutting off. These machines are available with various features such as different diameter size wires for straightening, different cutting lengths and standard multi-power motor for both straightening and cutting of wires. Figure 1 and figure 2 shows WSCM which can cut the wire below 4 mm diameter, and its working layout respectively [1]. Fig. 1 Wire Straightening Cutting Machine Fig. 2 Layout of Wire Straightening Cutting Machine 2. Units of WSCM As shown in layout of WSCM, it has basic parts like (1) Paying off, (2) Feeding, (3) Straightening and (4) Cutting Head with cutting off unit. ISSN : 0975-5462 Vol. 3 No. 5 May 2011 4209 In paying off unit, the wire may be paid off from a process such as a draw block or by more usual method employing a reel. Reel may be vertical or horizontal spindle. The vertical spindle should be used for wires up to approximately 2 mm to 4 mm in round. In feeding unit, feeding of the wire is usually done by grooved feeding rolls or “pinch rolls”. This mechanism is power driven and pinches or squeezes the material so that the wire is either pulled and/or pushed through the machine. The feeding pressure to the rolls can be applied by hand through cams or spring. Figure 3 shows feed roller and its arrangement in the machine. Fig. 3 Roller straightening Fig. 4 Rotary Arbor straightening Straightening is the apparent elimination and removal of stresses induced into the material to be straightened during its manufacture due to force and torque related influences. This applies to wire straightening, tube straightening, cable straightening, strip and profile shape straightening. Figure 3 and 4 show principle of roller straightening and rotary arbor straightening of wire. The roll straightened, consists of a series of rolls that are offset and which bend the wire beyond the elastic limit a number of time in two or more planes as the wire runs through. The rolls are adjustable and the straightness obtained depends upon the skill of the operator making the adjustment. This method is generally restricted to shaped wires such as hexagons, squares and flats except for minor straightening of round wire for removing coil bow before further forming. The rotary straightened arbor rotates around the sock and imparts bending stresses in an overlapping helical pattern that achieves a high degree of straightness inbound stock. The principle is that of a beam affect the moves around and along the wire at the same time producing a helix or wave disappears when the streets pattern overlaps and straight wire is produced. Straightness is controlled by various factors, but mainly feeds, speeds and the condition of the straightening dies. The straightness and surface condition of the wire is depended on the straightened dies because the rotary arbor is friction device with the die material is compatible with the wire and the contour presents enough area to support the load of bending. The center distance between the straightened dies must be within specific limits for a particular wire diameter to give the correct beam effect and bending stress to produce a straight product. “Cutting off” or shearing process is followed by the straightening process. There are two general classifications of cut off mechanisms; one being the stationary shear where in the wire is actually stopped during the cutting cycle, and the other the “travel-cut” or flying shear in which the shearing mechanism moves along with the wire during the cutting cycle. The flying shear cut off is superior to the stationary shear type; for many applications using soft wire or small diameters. However, the stationary shear will give satisfactory results. When running hard wire or alloy through a high speed rotary arbor, flying shear is necessary, since if the wire were stopped for cutoff in the arbor, it may become overworked and overheated and break could result. In such type of machine, the energy of cutting is usually supplied by a flywheel and is transmitted either directly or through clutch or brakes. Here in projected machine, power of motor is transmitted to flywheel by belt and pulley. Figure 5 and figure 6 shows flying shear in WSCM. Major parts of cutting unit in the machine are fly wheel, guide bar/scaling unit, stands, cutting block and cam mechanism. Fig. 5 Cutting Mechanism with fly wheel Fig. 6 Guide Bar/scaling units 3. Working of WSCM Wire coil is mounted on the paying off unit. At time of start, wire is fed between the spring operated rollers of feeding unit, they pull the wire from paying off unit and push in to rotating spinner. The rotating spinner straightens the wire and again the roller of feeding unit pull the wire from spinner and push it in to cutter nozzle and then Guide bar where an adjustable spring loaded stopper which can be adjusted -depending on the rod length required, blocks movement of wire. The blocking of movement of wire results in an increase pressure on the spring and the resulting pressure actuates the cutter nozzle under the reciprocating cutting tool resulting in a complete cutting stroke. A tapered support arrangement at the cutting end aids in aligning the scaling unit incorporating the stopper mechanism in line with machine axis[1]. 4. Objective of Review By referring various resources, wire is used as a raw material for various products like welding rod, weld mesh, fins, etc. In most wire industries WSCM is used to straighten and cut the wire at pre determined length. In conventional type WSCM below 3.15mm wire diameter, as wire diameter decrease, the length of wire rod reduces. To remove limitations and improve the productivity of the machine, WSCM is to be reviewed for its innovation. 4.1. Wire Straightening Methodology Mr. Marcus Paech in 2008 describes the power requirements for the process material deformation process is based on the working principle and the main characteristics of the straightening process. A simulation program is available to support the assessment of the power requirements. Simulation in turn is based on a theoretical model of alternate elastic/plastic deformation and the relationship between bending moment and curvature during bending operations. This article describes advanced semi-automatic straightening technology. Advanced straightening technology uses process simulation (Figure 7) to determine optimal spacing and maximum straightening range. Figure 8 shows the geometric factor like roll diameter, wire diameter, spacing between rolls etc. affecting on the position of straightening rolls. Optimization of spacing is based on the level of finished product quality that the customer wants as well as the material characteristics. Advanced straightening technology features a modular design, minimal component count, a user-friendly Human Machine Interface and the availability of process and setup data prior to the start of the process. The flexibility of the design and the ability to manipulate the number and spacing of the rolls, which are the main variables, produce a system which can be used to make customer-specific products in small lot sizes [2]. He in 2001, alsodescribes identification methods and procedures for applying the straightening process to receive a specified wire quality. The optimal design and integration of a straightening process requires in advance identification of the straightened material and its production. Objective and established possibilities of identification are available and should therefore be used as standard practice in the wire industry. Guidelines for the identification of a straightening process are structured on the basis of an interdisciplinary approach covering those processes which take place both upstream and downstream from the straightening process [3]. Fig 7. Simulation of wire straightening process Fig. 8 Geometric factors associated with the positioning of straightening roll The article by Witels Apparate-Maschinen Albert GmbH, Germany describe the required off set as well as number of roller required for straightening process [4]. M. Nastran, K. Kuzman describes influencing of the material properties of the wire to allow stabilization for bending or straightening process. As per paper, experimental work proves that it is possible to change the yield strength of the wire by an appropriate pre-setting of the filler in the roller straightener. It also describes numerical analysis of straightening process. This work obtained results are used for developing a numerical system capable of defining the inter meshing of the roller so that the yield strength of the material is optimally constant [5]. Fig 9. Experimental wire straightener mounted on a bending machine . They also develop an analytical model of the wire straightener by using MatLab and describe an algorithm for influencing the mechanical properties of wire by controlled cyclic deformation. The undertaken experimental work as shown in figure 9 proves that it is possible to influence the part geometry by different presetting of the rollers in the roller straightened, which means different amount of reversed plastic deformations [6]. Carl Sjogren from Sjogren Industries Inc., USA describes for choosing the right wire straightener for specific applications as wire straightener is device for guiding, killing, stress relieving, and casting of all types of wire, ferrous and non-ferrous [7]. P. Ralli Street explains the methods of straightening wire of circular cross section by passing the wire through straightening dies. The wire as shown in figure 9 is forced to pass through said buses called as straightening dies in such a way that their eccentric rotation may bend the wire in a cyclic way. In the rotating rotor, the wire of diameter D is subject to bending ?1 for straightening purposes equal to the number of buses [8]. Fig. 9 Principle of Wire Straightening Method J. Balica and M. Nastranb explain the use of genetic programming to predict the wire geometry after forming. Wire straightening process is physically very complicated and thus almost impossible to describe it analytically. So the dependence of the output, parameters has been modeled experimentally. Genetic programming approach is the basis for later on-line adjustments of the wire straightener. By solving the problem of wire straightening and arch geometry stabilization, a great step towards better productivity and machinery efficiency has been made. For a production company it is a precondition for a market position [9]. 4.2. Cutting Methodology Wiesenfeld, Yair wire straightening and cutting process and machine as shown in figure1 which feeds, straightens, and cuts wire and which uses a servomotor in dual motor. In continuous mode, short wire parts are cut at a high cut off rate. In intermittttent mode, lode wire parat are cut where in each cut is triggered by a singnal. In new machine, cutting mechanism, shwon in figure 2 includes a servomotor, mechanical reduction gear box, driving mechanism, rotating disc mounting on the shaft, acam follower, proximity switch, wire cutter, cut off arm, cut of shaft, cut off quill, cut off knife and cut off clamp. Such a mechanism shows stopper less cutting head as shown in figure 11[10]. Fig. 10 Wire straightening cutting machine Fig. 11 Cutting mechanism N. Peric and Ivan Petrovic present new concept of a flying shear control system based on optimal position control with a moving target. The position control is optimal in the sense that the flying shear drive accelerates/decelerates with the driving torque as small as possible. The developed and implemented position control algorithms, with appropriately selected parameters of speed and armature current controllers and with a corresponding correction signal added to the blade velocity reference, ensure high cutting accuracy in both the discontinuous and continuous modes of operation. The algorithms also allow automatic transition from one mode to the other, thereby permitting on-line scrap minimization by computing the optimal combination of different custom-length sections. The significant economic effects of its operation are due to high reliability, high quality, accuracy of cutting, energy savings, and especially, scrap reduction. With appropriate modifications, the described algorithms can also be used in the automation of metal-processing plants [11]. Finite element analysis was performed by T.S. Kwak, Y.J. Kim, W.B. Bae to investigate the effect of the die clearance on shear planes in the fine blanking with the following conclusions like (i) When the clearance was increased, the shear band of the material was widely spread and it lead to earlier fracture. (ii) When the clearance was increased, the width and depth of the die-roll was increased. (iii) When the clearance was decreased, the depth of the fracture zone was decreased and the depth of the shear zone was increased. (iv) FE analysis shows that reduced clearance between the punch and die improves the quality of sheared parts [12]. 5. Concluding Remarks The present article has been authored with the intention of focusing on the latest advances and to highlight the opportunities provided by the implementation of innovation in wire straightening cutting machine. Straightness of wire is depends on various parameters such as wire diameter, die spacing and helix angle, material properties (like tensile strength, yield strength, geometry etc...). In this paper, article 4.1 describes various methods for straightening process and steps for advances the same. Article 4.2 describes the latest method of cutting in the same machine. Below 3.15 mm wire diameter for Mild steel, rotary arbor straightening method and stopper cutting off mechanism are used. Additionally, the reviewed approaches, which are attempted in the context of the present paper, may lead to some valuable conclusions as stopper less flying shear method is to be adopted to innovate the machine. More over simulation between the flying shear and straightening method is made for implementation of this machine in industry successfully. Acknowledge It is with particular pleasure that I acknowledge the assistance and encouragement of Prof. B. P. Patel, Assistant Professor of U. V. Patel Engineering College, Kherva, Ganpat University, Kherva whose persistent preoccupation reliability resulted in many contributions included in this work and for providing the valuable guidance and allowing the time for the same. References [1] B P. Patel and A.S.Patel, “Productivity Improvement through Automation of Cutting Head in Wire Straightening Cutting Machine” International Conference on conversions of science and engineering in education and research,2010. (ICSE-2010.) April 21-23, 2010. pp. 128. [2] Marcus Paech, “Advanced semi-automatic straightening technology”, Wire Journal International, 7/7/2008, pp. 4-12. [3] Marcus Paech, “Roller straightening process and peripherals” WIRE 2/2001, pp. 76-82 [4] Witels Apparate-Maschinen Albert GmbH, “How to Determine the Required Positions of the Straightening Rolls” The International Magazine For The Wire & Cable Industries ? 2008 , www.witels-albert.de [5] M.Nastran, K. Kuzman, “Stabilization of Mechanical Properties of the wire by roller straightening” ,Journal of Materials Processing Technology, Volumes 125-126,September 2002, pp. 711-719 [6] M. Nastran, K. Kuzman, “Cyclic loading of low carbon cold drawn wires – the possibility to stabilize the yield stress” [7] Carl Sjogren “Choosing the Right Wire Straightener for Specific Applications”, The International Magazine For The Wire & Cable Industries ? 2008 , www.sjogren.com [8] P. Ralli Street, “Wire straightening method” Patent, GR-177 78 Athens(GR). Patent no.WO93/13892, 22/07/1993. [9] J. Balica and M. Nastran, “An on-line predictive system for steel wire straightening using genetic programming” Engineering Applications of Artificial Intelligence 15 (2002), pp.559–565. [10] Wiesenfeld, Yair, “ Wire Straightening And Cut-Off Machine And Process” International publication no- WO 01/74513 A1, International Patent Classification: B21F 11/00, (19) world Intellectual Property Organization, 2001. [11] Nedjeljko Peric and Ivan Petrovic, “Flying Shear Control System” IEEE Transactions on Industry Applications Vol. 26. NO. 6, 1990, pp. 1049-1056. [12] T. S. Kwak, Y. J. Kim, W.B. Bae, “Finite element analysis on the effect of die clearance on shear planes in fine blanking” Journal of Materials Processing Technology 130–131, 2002, pp. 462–468.