Square wire is usually manufactured through rolling in a high speed rolling mill where the temperature of steel must be above 1000 degree Celsius and the maximum rolling speed must exceed 120 meters per sec. The production of square wire can be up to the lengths of 10 kilometers. During the rolling process of square wire, a continuous rolling mill usually takes 25 to 30 passes.
Square wire is a material that is used in a wide range of applications. These applications include the automotive industry, electrodes, tire cord, connecting elements, wire products, springs, steel structures, and much more. This is why a square wire mill is designed and constructed with versatility in mind. As a square wire mill is energy intensive, it becomes important that the ideal solutions are included in the design without a compromise on flexibility. The production of all materials, alloys, and size ranges need to be carried out efficiently, providing high productivity.
A square wire mill usually requires
· Heating facilities to heat the raw material (also known as billet) to appropriate rolling temperatures.
· Rolling facilities equipped with guards, guides, rolls, and chocks.
· Appropriate equipments for heat treatment, laying, and coiling.
· Appropriate equipments for conveying and handling.
All these machines and equipments in a square wire mill must work properly in close coordination, in compliance with a control in gap time loss, cobbles, rolling temperatures, speed loss, con-conforming product, and the deviations in quality that leads to diversion or rejection.
Major requirements from a square wire mill
There are a few significant boundaries for rolling square wire in a square wire mill. An advanced square wire mill is mostly intended to work with OEE theory. OEE (overall equipment effectiveness) value of a square wire mill is the worth acquired by increased factory use, plant proficiency, and the yield time of the plant. The square wire mill usage is the accessible working time divided by the production time of the mill and is denoted in percentage. The square wire mill productivity is the running time divided by the accessed working time of the mill and denoted in percentage. The square wire mill yield time is the time for creating the top-rated item connected with the running time. The yield of product is denoted as the weight of the coil divided by the weight of the raw materials and is denoted in rate.
Square wire mills ordinarily have lower OEE than different sorts of mills due to the greater downtime required for stand changing, roll changing, and the adjustments in guide and groove during the movement of items. The square wire mill's OEE can be enhanced by reducing this downtime. The limit of hypothetical production of a mill is the limit that can be acquired with no losses, for example with 100 percent of yield, 100 percent use, and 100 percent of effectiveness. Though, the real limit is subject to the OEE level of the factory. In case that the OEE level of the mill is 60 percent then, at that point, the production limit of the mill stands at 60 percent of the hypothetical limit. The OEE level in a condition of craftsmanship square wire mill with a distinct advanced plant is typically at the degree of 80 percent.
In an advanced square wire mill, the fundamental spotlight is on usefulness and quality. High use, proficiency, and yield give high usefulness. Though, high usefulness itself isn't the main thing for the accomplishment of a square wire mill. It needs to deliver items that are worth to the clients and they get the quality square wire deserving of the amount which they are making for the square wire.
Flexibility of the square wire mill
In a square wire mill, the raw material steel is warmed above its temperature of recrystallization and gone through a few scores of the rolls in the moving factory. The common roll pass design used in square wire mills is squared. But the same mill can also produce square-oval, diamond-square, box passes, false round-oval, diamond-diamond, & round-oval designs as per requirements. In the square wire bar processes regularly size free rolling is being done, which means square wire of any size can be moved without the restrictions of the pass sizes of the rolls held in the plant. This is additionally being known as the adaptability of the series.
Moreover, the improvement of the pass timetable of an upstream moving mill empowers the recurrence of the roll changing to be significantly brought down. The more extensive the scope of the item size equipped for being moved with similar rolls, the more prominent is the impact of decreased recurrence of roll evolving. The size-free rolling isn't restricted to the completing mill. It can also be applied to the pre-completing plant.
Conclusion
The quality and productivity of a square wire production highly depends on the advancements of the square wire mill. The square wire mills equipped under Matta Drawing Works are highly advanced and produce high quality square wire and other end products.