BWE Ltd, formerly Babcock Wire Equipment Ltd, has operated from its Ashford headquarters in the Southeast of England since 1969, when the company first produced cold welding machines. Conform™ machines have been manufactured since 1976 when they were initially used for extruding round wire. Continuous development aimed at extending the capabilities of the Conform process led to an
increasing number of applications including magnet wire, electrical conductors, refrigeration tube and ultimately, in 1984, the introduction of the Conklad™ process for aluminium clad steel wire and CATV and fibre optic cables.
Extrusion is a process that uses pressure to force heated metal material through a die to create parts with a constant cross-section. There are two main types of extrusion: direct and indirect. Direct extrusion involves pushing the material through the die in the same direction as the ram movement, while indirect extrusion moves the material in the opposite direction of the ram. Extrusion can be performed hot or cold depending on the material, with hot extrusion allowing for more complex shapes from more readily extrudable metals like aluminum. Proper die material and lubrication are important for reducing friction during extrusion.
Continuous casting is a process used to cast metal into a continuous length. Molten metal is poured into a mold and solidifies into a casting as it travels downward. New molten metal is continuously supplied to the mold to keep the process going and produce a casting of indefinite length. The process requires precise control of parameters like molten metal flow to ensure smooth, continuous casting.
Continuous casting was conceived in the 1860s and has since led to major improvements in efficiency, productivity, and cost reductions for metal production. The process involves cleaning and equalizing molten metal in a ladle before pouring it into a tundish where impurities are removed, then the metal travels through water cooled copper molds to begin solidifying as it moves downward along supported rollers. The key advantages are 100% casting yield due to no waste metal, an automatic and consistent process, and reproducible mechanical properties.
Extrusion is a process where a block of metal is forced to flow through a die to reduce its cross-section. It is commonly used to produce cylindrical bars, tubes, or stock for other processes. Most metals require hot extrusion due to the large forces. Extrusion produces products with uniform properties and microstructure. Common extrusion defects include cracking, non-uniform deformation, and variations in grain structure. Extrusion equipment includes hydraulic presses in horizontal or vertical orientations and dies made of hardened tool steel. Process parameters like temperature, speed, and lubrication affect the required extrusion pressure.
The document discusses the rolling process used in metal forming. It describes rolling as a process where the thickness of metal is reduced by compressive forces from two opposing rolls. Rolling can be used for flat rolling to reduce thickness of rectangular cross-sections or shape rolling to form square cross-sections into shapes like I-beams. The document outlines different types of rolling like hot rolling, cold rolling, continuous rolling and shape rolling and describes the purposes and processes for each type.
The document discusses gating and risering concepts for metal casting. It defines gating as flow passages that distribute molten metal into a mold cavity. The main types of gates include top gates, bottom gates, branch gates, and horn gates. Risering involves vertical passages that store liquid metal and supply it to the casting as it solidifies, preventing shrinkage. The functions of risering are outlined. Types of risers include open risers exposed to air at the top and blinder risers fully enclosed in the mold.
The document discusses the history of sand casting, including early uses by the Assyrians in the 8th century BC and developments in the early 20th century with the invention of the sand slinger and sand mixer. It then provides details about the group's project to produce an exhaust manifold using sand casting, including explaining the process, materials, defects, and alternative manufacturing methods. Within the group, members will explain the different types of casting processes, the function of an exhaust manifold, suitable materials for an exhaust manifold, and details about the sand casting process.
Extrusion is a process that uses pressure to force heated metal material through a die to create parts with a constant cross-section. There are two main types of extrusion: direct and indirect. Direct extrusion involves pushing the material through the die in the same direction as the ram movement, while indirect extrusion moves the material in the opposite direction of the ram. Extrusion can be performed hot or cold depending on the material, with hot extrusion allowing for more complex shapes from more readily extrudable metals like aluminum. Proper die material and lubrication are important for reducing friction during extrusion.
Continuous casting is a process used to cast metal into a continuous length. Molten metal is poured into a mold and solidifies into a casting as it travels downward. New molten metal is continuously supplied to the mold to keep the process going and produce a casting of indefinite length. The process requires precise control of parameters like molten metal flow to ensure smooth, continuous casting.
Continuous casting was conceived in the 1860s and has since led to major improvements in efficiency, productivity, and cost reductions for metal production. The process involves cleaning and equalizing molten metal in a ladle before pouring it into a tundish where impurities are removed, then the metal travels through water cooled copper molds to begin solidifying as it moves downward along supported rollers. The key advantages are 100% casting yield due to no waste metal, an automatic and consistent process, and reproducible mechanical properties.
Extrusion is a process where a block of metal is forced to flow through a die to reduce its cross-section. It is commonly used to produce cylindrical bars, tubes, or stock for other processes. Most metals require hot extrusion due to the large forces. Extrusion produces products with uniform properties and microstructure. Common extrusion defects include cracking, non-uniform deformation, and variations in grain structure. Extrusion equipment includes hydraulic presses in horizontal or vertical orientations and dies made of hardened tool steel. Process parameters like temperature, speed, and lubrication affect the required extrusion pressure.
The document discusses the rolling process used in metal forming. It describes rolling as a process where the thickness of metal is reduced by compressive forces from two opposing rolls. Rolling can be used for flat rolling to reduce thickness of rectangular cross-sections or shape rolling to form square cross-sections into shapes like I-beams. The document outlines different types of rolling like hot rolling, cold rolling, continuous rolling and shape rolling and describes the purposes and processes for each type.
The document discusses gating and risering concepts for metal casting. It defines gating as flow passages that distribute molten metal into a mold cavity. The main types of gates include top gates, bottom gates, branch gates, and horn gates. Risering involves vertical passages that store liquid metal and supply it to the casting as it solidifies, preventing shrinkage. The functions of risering are outlined. Types of risers include open risers exposed to air at the top and blinder risers fully enclosed in the mold.
The document discusses the history of sand casting, including early uses by the Assyrians in the 8th century BC and developments in the early 20th century with the invention of the sand slinger and sand mixer. It then provides details about the group's project to produce an exhaust manifold using sand casting, including explaining the process, materials, defects, and alternative manufacturing methods. Within the group, members will explain the different types of casting processes, the function of an exhaust manifold, suitable materials for an exhaust manifold, and details about the sand casting process.
Powder metallurgy is a process for manufacturing parts from metal powders by compacting and sintering. Key steps include producing metal powders through methods like atomization or chemical reduction, blending powders and lubricants, compacting the blended powder in a die under pressure to form a green compact, and sintering the compact at high temperatures to bond the powder particles. The sintered parts have properties that cannot be achieved through conventional manufacturing and the process allows for high precision and low waste production of simple parts.
The document discusses the extrusion manufacturing process. Extrusion involves forcing a block of metal through a die to create solid or hollow shapes. There are different types of extrusion classified by direction (direct, indirect), operating temperature (hot, cold), and equipment (horizontal, vertical). Hot extrusion is done at high temperatures using lubrication while cold extrusion is done at room temperature. The document also discusses defects, drawing as a related process, and factors that affect extrusion forces.
The document discusses the ring compression test method for determining the coefficient of friction between a die and workpiece. It investigates the friction factors of aluminum rings under dry and lubricated conditions. The key findings are:
1) Lubrication reduces interface friction coefficients compared to dry conditions.
2) Friction coefficients decrease with reductions in ring height and outer radius but increase with increases in inner radius.
3) Molybdenum disulfide and zinc stearate provide the lowest friction, while dry conditions provide the highest, according to experimental, theoretical and analytical analyses.
This document discusses various metal forming rolling processes. It defines rolling as plastically deforming metal by passing it between rolls. There are different types of rolling processes including transverse, shaped, skew, ring, thread, tube, powder, and continuous casting and hot rolling. It also describes the classification and purposes of processes like transverse, shaped, skew, ring, thread, and tube rolling. Finally, it discusses sheet rolling processes including hot and cold rolling.
Non-traditional manufacturing processes is defined as a group of processes that remove excess material by various techniques involving mechanical, thermal, electrical or chemical energy or combinations of these energies
A project report on study on foundry industry belgaumBabasab Patil
This document provides an overview of the foundry industry and Sujay Enterprises, a foundry company in Belgaum, India. It discusses the facilities, clients, production process, testing capabilities and entrepreneur Chandrashekhar Iti who founded the company in 1982. Sujay Enterprises aims to meet customer requirements by delivering high quality castings on time with excellent service. The company has the infrastructure to produce gray iron and ductile iron castings along with machining and testing facilities.
Continuous casting is a steelmaking process where liquid steel is solidified into a semi-finished billet, bloom, or slab. In this process, liquid steel flows from a ladle into a water-cooled copper mold. As the steel exits the mold, it begins to solidify on the surface while the core remains liquid. The semi-solid steel strand is then cooled further through water sprays to fully solidify it into the desired cross-section. The continuous casting process allows for higher productivity and quality than traditional ingot casting.
The document discusses abrasive water jet machining (AWJM), which is a non-traditional machining process that uses the mechanical energy of high-pressure water and abrasive particles to remove material. It defines AWJM and describes the entrained and suspended types of AWJM systems, explaining how high-pressure water and abrasives are used to erode materials. Applications of AWJM include cutting of soft materials, textiles, leather, frozen foods, and uses in surgery and mass immunization.
Shell mold casting is a metal casting process that uses a resin-coated sand mixture to form a thin-walled mold shell around a metal pattern. The pattern is heated and pressed into the sand-resin mixture to form the shell, which is then cured in an oven. Two shell halves are joined to form the complete shell mold, into which molten metal is poured to create the casting. This allows for high-precision casting of small to medium parts like gear housings, cylinder heads, and connecting rods. The shell mold casting process provides advantages over sand casting like better surface finish and dimensional accuracy for the final casting.
Full mould casting is a casting process that uses an expanded polystyrene foam pattern surrounded by sand. Molten metal is poured directly into the mould, vaporizing the foam and allowing the metal to fill the entire mould cavity. This process is similar to lost wax casting but uses a thermally decomposable foam pattern instead of wax. The foam pattern can be designed using computer tools before the casting process. Some advantages are it is cheaper than investment casting, requires no drafts or risers, and has good dimensional accuracy and surface finish.
Rautomead technology for continuous casting of oxygen free copper, copper-mag...Rautomead Limited
Rautomead Technology for Continuous Casting of Oxygen-free Copper, Copper-magnesium and Copper Conductor Alloys
We offer copper continuous casting technology and a range of copper wire and cable continuous casting machines.
The copper rod continuous casting machines are specifically designed for the processing of electrolytically-refined grade 'A' copper feedstock to produce 8.0mm diameter wire rods. They may be configured to produce rod up to 22.0mm diameter if required. The machines are intended to be operated for long periods of uninterrupted production of continuous cast copper wire rod.
RS machines are configured as integrated melting, holding and casting units, featuring graphite crucibles, protected in an inert gas atmosphere with high intensity graphite resistance heating.
RDG machines feature large Induction furnace technology. Machines are either single furnace integrated melting and casting or dual furnace with cathode melter feeding a holding furnace, depending on production output.
continuous casting machines for copper wire & cable operating costs
Rautomead have paid great attention to minimising the cost of operating the machine. Furnaces are totally enclosed and built up using high performance insulations to achieve minimum economic heat loss. Casting dies are inexpensive and may be changed individually
RS 3000 CuMg machine with graphite crucible technology is ideally suited for production of high quality copper magnesium alloy wire rod.
The graphite crucible removes oxygen from cathode feedstock which minimises losses of the magnesium alloying element.
Technology available for high magnesium content (0.4 – 0.6% Mg) alloy rod for use in the manufacture of overhead contact wires and cables for high speed trains, also for low magnesium content (0.1 -0.2% Mg) alloy rod for use in the manufacture of small diameter automotive data communication cables.
Rautomead technology is being used by suppliers of CuMg catenary contact wires on European High Speed train lines.
The massive construction project in progress in China to build 15,000 – 20,000km of new high speed train track features CuMg contact wires made from rods produced on Rautomead technology installed at cable factories around China.
This document provides an overview of manufacturing processes and gating systems for casting. It discusses the key elements of a gating system including the pouring basin, sprue, runner, gates, and riser. The objectives and factors affecting the performance of gating systems are outlined. Different types of gating systems like vertical, bottom, and horizontal are described. Formulas related to fluid flow and solidification time are also provided.
Electrochemical Machining (ECM) has established itself as one of the major alternatives to conventional methods of machining difficult - to - cut materials of and generating complex contours, without inducing residual stress and tool wear.
This seminar is devoted to the study of influences of variable ECM parameters like applied voltage and feed rate keeping other parameters constant on the surface roughness (Ra) using Response Surface Methodology (RSM).
The document discusses various types of automation in welding processes including manual, semi-automatic, automatic, automated, remote, and robotic welding. It describes the key stages in a welding operation sequence and provides examples of different techniques used for automation in welding applications from the 1920s to present day. Specific automation techniques are highlighted for different welding processes based on factors like production volume and part geometry.
This document summarizes new developments in gear hobbing machines and processes. It discusses how hobbing works to cut gears using a hob tool on a specialized milling machine. Modern developments include using powder metallurgical high speed steel tools which have higher toughness and lower costs than carbide tools. A new dry hobbing process has also been introduced to improve the working environment by eliminating coolant use. This dry hobbing process allows cutting speeds up to twice as fast as wet hobbing and provides benefits like reduced running costs and a safer environment.
Powder metallurgy is a process that involves compacting and forming metal powders into a solid object through sintering. It consists of 3 main steps - producing metal powders through various methods, compacting the powders into a green compact through pressing, and sintering the compact by heating it to fuse the particles together into a solid object. It allows for net-shape production of complex parts and close dimensional tolerances, and is used for applications where other fabrication methods are not suitable.
Abrasive water jet machining (AWJM) is a non-traditional machining process that uses a high-pressure stream of water mixed with abrasive particles to erode materials. It works by converting the kinetic energy of the water-abrasive jet into high pressure upon impacting the workpiece surface, removing material when the pressure exceeds the part's strength. The document discusses the AWJM process, including its mechanism of localized erosion, key parameters like water pressure and abrasive flow rate, applications in cutting a wide range of materials, advantages like flexibility and lack of heat, and limitations for hard or thick materials.
The document discusses various metal forming processes including forging. It defines forging as a process where a metal is heated and compressed in a die to obtain a final shape. The key types of forging are closed die forging using two dies and open die forging with simple shaped dies. Forging can be done hot or cold based on the temperature of the workpiece. Common forging operations aim to reduce cross-sectional area or change thickness. Forging produces grain structures that improve mechanical properties.
Here you are watching PowerPoint Presentation of EDM (Electrical Machining Process). It is a kind of unconventional machining process.Thanks for watching.
billet, rod, or tube are continuous cast, defined
as the continuous solidification and withdrawal
of product from an open-ended shaping mold.
Methods include both vertical and horizontal
casting, depending on product size, shape, and
volume. Casting vertically has certain inherent
technical advantages. The symmetry of cooling
promotes a uniform and predictable solidification
growth pattern and uniform axial loading
on the freshly solidified shell as it is withdrawn
from the mold. In tube or hollow section casting,
the vertical process has particular merit.
The disadvantages of vertical casting are
mostly logistic: difficulty in handling long
lengths of section; cut-off can be more difficult
to engineer and control; and it is generally a
semicontinuous operation. Horizontal casting
requires lower capital investment, is compatible
with lower production rates, and is a continuous
operation.
This article briefly reviews the history and
methods of copper alloy continuous casting;
the information is drawn from the very detailed
and extensive coverage of the subject in Ref 1
and the numerous publications of equipment
supply companies such as Rautomead, SMS
Meer, and so on
Investigation of the distribution of lead in three different combinations of ...Rautomead Limited
The main objective of this paper was to assess three leaded
brass samples (pending application with Copper Development
Association) using optical microscopy and mass
spectrometry to compare the distribution of lead. Based on
the mass spectrometry data, a great deal of variation was
not found within each of the samples based on five different
sample locations. Optical microscopy, scanning electron
microscopy and energy-dispersive X-ray spectroscopy
confirmed that the lead was homogenously distributed in
brass.
Powder metallurgy is a process for manufacturing parts from metal powders by compacting and sintering. Key steps include producing metal powders through methods like atomization or chemical reduction, blending powders and lubricants, compacting the blended powder in a die under pressure to form a green compact, and sintering the compact at high temperatures to bond the powder particles. The sintered parts have properties that cannot be achieved through conventional manufacturing and the process allows for high precision and low waste production of simple parts.
The document discusses the extrusion manufacturing process. Extrusion involves forcing a block of metal through a die to create solid or hollow shapes. There are different types of extrusion classified by direction (direct, indirect), operating temperature (hot, cold), and equipment (horizontal, vertical). Hot extrusion is done at high temperatures using lubrication while cold extrusion is done at room temperature. The document also discusses defects, drawing as a related process, and factors that affect extrusion forces.
The document discusses the ring compression test method for determining the coefficient of friction between a die and workpiece. It investigates the friction factors of aluminum rings under dry and lubricated conditions. The key findings are:
1) Lubrication reduces interface friction coefficients compared to dry conditions.
2) Friction coefficients decrease with reductions in ring height and outer radius but increase with increases in inner radius.
3) Molybdenum disulfide and zinc stearate provide the lowest friction, while dry conditions provide the highest, according to experimental, theoretical and analytical analyses.
This document discusses various metal forming rolling processes. It defines rolling as plastically deforming metal by passing it between rolls. There are different types of rolling processes including transverse, shaped, skew, ring, thread, tube, powder, and continuous casting and hot rolling. It also describes the classification and purposes of processes like transverse, shaped, skew, ring, thread, and tube rolling. Finally, it discusses sheet rolling processes including hot and cold rolling.
Non-traditional manufacturing processes is defined as a group of processes that remove excess material by various techniques involving mechanical, thermal, electrical or chemical energy or combinations of these energies
A project report on study on foundry industry belgaumBabasab Patil
This document provides an overview of the foundry industry and Sujay Enterprises, a foundry company in Belgaum, India. It discusses the facilities, clients, production process, testing capabilities and entrepreneur Chandrashekhar Iti who founded the company in 1982. Sujay Enterprises aims to meet customer requirements by delivering high quality castings on time with excellent service. The company has the infrastructure to produce gray iron and ductile iron castings along with machining and testing facilities.
Continuous casting is a steelmaking process where liquid steel is solidified into a semi-finished billet, bloom, or slab. In this process, liquid steel flows from a ladle into a water-cooled copper mold. As the steel exits the mold, it begins to solidify on the surface while the core remains liquid. The semi-solid steel strand is then cooled further through water sprays to fully solidify it into the desired cross-section. The continuous casting process allows for higher productivity and quality than traditional ingot casting.
The document discusses abrasive water jet machining (AWJM), which is a non-traditional machining process that uses the mechanical energy of high-pressure water and abrasive particles to remove material. It defines AWJM and describes the entrained and suspended types of AWJM systems, explaining how high-pressure water and abrasives are used to erode materials. Applications of AWJM include cutting of soft materials, textiles, leather, frozen foods, and uses in surgery and mass immunization.
Shell mold casting is a metal casting process that uses a resin-coated sand mixture to form a thin-walled mold shell around a metal pattern. The pattern is heated and pressed into the sand-resin mixture to form the shell, which is then cured in an oven. Two shell halves are joined to form the complete shell mold, into which molten metal is poured to create the casting. This allows for high-precision casting of small to medium parts like gear housings, cylinder heads, and connecting rods. The shell mold casting process provides advantages over sand casting like better surface finish and dimensional accuracy for the final casting.
Full mould casting is a casting process that uses an expanded polystyrene foam pattern surrounded by sand. Molten metal is poured directly into the mould, vaporizing the foam and allowing the metal to fill the entire mould cavity. This process is similar to lost wax casting but uses a thermally decomposable foam pattern instead of wax. The foam pattern can be designed using computer tools before the casting process. Some advantages are it is cheaper than investment casting, requires no drafts or risers, and has good dimensional accuracy and surface finish.
Rautomead technology for continuous casting of oxygen free copper, copper-mag...Rautomead Limited
Rautomead Technology for Continuous Casting of Oxygen-free Copper, Copper-magnesium and Copper Conductor Alloys
We offer copper continuous casting technology and a range of copper wire and cable continuous casting machines.
The copper rod continuous casting machines are specifically designed for the processing of electrolytically-refined grade 'A' copper feedstock to produce 8.0mm diameter wire rods. They may be configured to produce rod up to 22.0mm diameter if required. The machines are intended to be operated for long periods of uninterrupted production of continuous cast copper wire rod.
RS machines are configured as integrated melting, holding and casting units, featuring graphite crucibles, protected in an inert gas atmosphere with high intensity graphite resistance heating.
RDG machines feature large Induction furnace technology. Machines are either single furnace integrated melting and casting or dual furnace with cathode melter feeding a holding furnace, depending on production output.
continuous casting machines for copper wire & cable operating costs
Rautomead have paid great attention to minimising the cost of operating the machine. Furnaces are totally enclosed and built up using high performance insulations to achieve minimum economic heat loss. Casting dies are inexpensive and may be changed individually
RS 3000 CuMg machine with graphite crucible technology is ideally suited for production of high quality copper magnesium alloy wire rod.
The graphite crucible removes oxygen from cathode feedstock which minimises losses of the magnesium alloying element.
Technology available for high magnesium content (0.4 – 0.6% Mg) alloy rod for use in the manufacture of overhead contact wires and cables for high speed trains, also for low magnesium content (0.1 -0.2% Mg) alloy rod for use in the manufacture of small diameter automotive data communication cables.
Rautomead technology is being used by suppliers of CuMg catenary contact wires on European High Speed train lines.
The massive construction project in progress in China to build 15,000 – 20,000km of new high speed train track features CuMg contact wires made from rods produced on Rautomead technology installed at cable factories around China.
This document provides an overview of manufacturing processes and gating systems for casting. It discusses the key elements of a gating system including the pouring basin, sprue, runner, gates, and riser. The objectives and factors affecting the performance of gating systems are outlined. Different types of gating systems like vertical, bottom, and horizontal are described. Formulas related to fluid flow and solidification time are also provided.
Electrochemical Machining (ECM) has established itself as one of the major alternatives to conventional methods of machining difficult - to - cut materials of and generating complex contours, without inducing residual stress and tool wear.
This seminar is devoted to the study of influences of variable ECM parameters like applied voltage and feed rate keeping other parameters constant on the surface roughness (Ra) using Response Surface Methodology (RSM).
The document discusses various types of automation in welding processes including manual, semi-automatic, automatic, automated, remote, and robotic welding. It describes the key stages in a welding operation sequence and provides examples of different techniques used for automation in welding applications from the 1920s to present day. Specific automation techniques are highlighted for different welding processes based on factors like production volume and part geometry.
This document summarizes new developments in gear hobbing machines and processes. It discusses how hobbing works to cut gears using a hob tool on a specialized milling machine. Modern developments include using powder metallurgical high speed steel tools which have higher toughness and lower costs than carbide tools. A new dry hobbing process has also been introduced to improve the working environment by eliminating coolant use. This dry hobbing process allows cutting speeds up to twice as fast as wet hobbing and provides benefits like reduced running costs and a safer environment.
Powder metallurgy is a process that involves compacting and forming metal powders into a solid object through sintering. It consists of 3 main steps - producing metal powders through various methods, compacting the powders into a green compact through pressing, and sintering the compact by heating it to fuse the particles together into a solid object. It allows for net-shape production of complex parts and close dimensional tolerances, and is used for applications where other fabrication methods are not suitable.
Abrasive water jet machining (AWJM) is a non-traditional machining process that uses a high-pressure stream of water mixed with abrasive particles to erode materials. It works by converting the kinetic energy of the water-abrasive jet into high pressure upon impacting the workpiece surface, removing material when the pressure exceeds the part's strength. The document discusses the AWJM process, including its mechanism of localized erosion, key parameters like water pressure and abrasive flow rate, applications in cutting a wide range of materials, advantages like flexibility and lack of heat, and limitations for hard or thick materials.
The document discusses various metal forming processes including forging. It defines forging as a process where a metal is heated and compressed in a die to obtain a final shape. The key types of forging are closed die forging using two dies and open die forging with simple shaped dies. Forging can be done hot or cold based on the temperature of the workpiece. Common forging operations aim to reduce cross-sectional area or change thickness. Forging produces grain structures that improve mechanical properties.
Here you are watching PowerPoint Presentation of EDM (Electrical Machining Process). It is a kind of unconventional machining process.Thanks for watching.
billet, rod, or tube are continuous cast, defined
as the continuous solidification and withdrawal
of product from an open-ended shaping mold.
Methods include both vertical and horizontal
casting, depending on product size, shape, and
volume. Casting vertically has certain inherent
technical advantages. The symmetry of cooling
promotes a uniform and predictable solidification
growth pattern and uniform axial loading
on the freshly solidified shell as it is withdrawn
from the mold. In tube or hollow section casting,
the vertical process has particular merit.
The disadvantages of vertical casting are
mostly logistic: difficulty in handling long
lengths of section; cut-off can be more difficult
to engineer and control; and it is generally a
semicontinuous operation. Horizontal casting
requires lower capital investment, is compatible
with lower production rates, and is a continuous
operation.
This article briefly reviews the history and
methods of copper alloy continuous casting;
the information is drawn from the very detailed
and extensive coverage of the subject in Ref 1
and the numerous publications of equipment
supply companies such as Rautomead, SMS
Meer, and so on
Investigation of the distribution of lead in three different combinations of ...Rautomead Limited
The main objective of this paper was to assess three leaded
brass samples (pending application with Copper Development
Association) using optical microscopy and mass
spectrometry to compare the distribution of lead. Based on
the mass spectrometry data, a great deal of variation was
not found within each of the samples based on five different
sample locations. Optical microscopy, scanning electron
microscopy and energy-dispersive X-ray spectroscopy
confirmed that the lead was homogenously distributed in
brass.
Rautomead Limited are UK-based specialists in continuous casting of non-ferrous metals and construction of continuous casting equipment for copper, copper alloys, gold and silver, dental alloys and feed rod for Conform machines.
For a period of over 30 years Rautomead Limited has specialised in the design, manufacture and sale of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries around the world.
Rautomead promote Advanced Metals Technology Collaboration for research and development of new processing technology for non ferrous metals
www.rautomead.co.uk
sales@rautomead.co.uk
Characteristics of Hypoeutectic Cu-Zr Alloy Rods Manufactured by Vertical Upw...Rautomead Limited
The focus in this study is therefore on applying a vertical upwards continuous casting (VUCC) mass-production
method to the pilot-scale manufacturing of Cu-Zr alloy rods. The microstructure and physical characteristics of these
VUCC rods were subsequently investigated and compared with rods produced by CMC. In addition, the wire-drawing
capability of the VUCC rods was examined, and the adaptability of the VUCC method to the mass production of
hypoeutectic Cu-Zr alloys was fully investigated.
2.
Rautomead Continuous Casting Technology for Brass RodRautomead Limited
Rautomead Limited are UK-based specialists in continuous casting of non-ferrous metals and construction of continuous casting equipment for copper, copper alloys, gold and silver, dental alloys and feed rod for Conform machines.
For a period of over 30 years Rautomead Limited has specialised in the design, manufacture and sale of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries around the world.
Rautomead promote Advanced Metals Technology Collaboration for research and development of new processing technology for non ferrous metals
www.rautomead.co.uk
sales@rautomead.co.uk
This lecture describes the function and design of all parts of the running and gating systems used in the production of castings. The students will be able to tackle the design of a simple running system in a systematic manner. Basic knowledge of foundry processes and basic mathematics is assumed.
On first reading, it might seem strange that Rautomead, a leading company specialising in continuous casting technology, should publish a Practical Guide on wire drawing practice in the copper wire and cable industry.
Since 1994, Rautomead has supplied over fifty oxygen-free copper (Cu-OF) rod casting machines to companies all over the world, the majority of whose previous experience had been exclusively in using only tough pitch copper (Cu-ETP) rod. By its nature, the behaviour of Cu-OF in the initial
stages of rod breakdown from 8mm as-cast rod is a little different from Cu-ETP. Minor changes to die drafts in older rod breakdown machines are recommended to achieve greater area reductions than may have been used previously.
Rautomead is fortunate to have David Bluck as a member of the company’s technical staff.
David has many years previous experience of technical management in the wire drawing
industry and has been able to assist Rautomead customers both in the introduction of Cu-OF rod into
their existing wire drawing lines and more generally in optimising performance of their wire drawing operations.
This Practical Guide is designed to encapsulate the most common issues Rautomead has encountered in copper wire drawing, to classify the types of faults occurring and to offer practical guidelines as to how these should be overcome.
The information in this advisory paper is given in good faith and with the objective of providing practical assistance. It is intended to supplement the place of technical information which may be provided for their equipment by wire drawing equipment manufacturers.
Sir Michael Nairn
Chairman
Rautomead Limited
Effect of water flow rate casting speed alloying element and pull distance on...Rautomead Limited
Most parameters that control the solidification of castings, and consequently,
microstructure and mechanical properties, are: chemical composition, liquid metal treatment,
cooling rate and temperature gradient. In this work, characterization of the influence
of water flow rate, casting speed, alloying element and pull distance on tensile strength,
elongation percentage and microstructure of continuous cast copper alloys has been carried
out. A significant different in tensile strength, elongation percentage and grain structure
has been investigated and it was also found that these parameters could improve the physical
and mechanical properties of samples. As a particular example, water flow rate could
improve the elongation of samples from 10% to 25%.
This document provides an overview of continuous casting of aluminium, specifically focusing on strip casting and wire bar casting technologies. It describes the basic principles of continuous casting, including key features like using rotating drums or belts to form a mould for molten aluminium. It discusses different types of casters like twin drum casters, single drum casters, and those using belts or blocks. It also addresses properties of continuously cast products and their behavior in further processing like rolling. The document aims to give readers an understanding of the possibilities and limitations of continuous casting aluminium.
This lecture helps to understand the basic principles of die forging and the characteristic features of special aluminium die forging processes. It aims at learning about the basic design of dies in order to obtain optimum part qualities and tool life. General understanding of metallurgy and deformation processes is assumed.
The document describes the Van Bommel Dedusting Technology (VBDT), which provides an end-of-pipe solution to reduce dust from urea products. The VBDT uses equipment like a magnet, lump breaker, elevator, and double aspirator to remove fines, broken product, dust and ultra-fines from urea, producing a premium-grade product. It has been proven to successfully handle high capacity loading and unloading. The VBDT can be a cost-effective way to improve urea product quality and working conditions by producing dust-free urea granules or prills.
Square Automation is an ISO certified company with 30 years of experience designing and manufacturing electrical panels. It has 3 manufacturing facilities totaling 30,000 square feet located in Mumbai. The company produces a wide range of electrical panels including power control centers, motor control centers, synchronizing panels, bus ducts, and more. Key features include CPRI verified short circuit strength testing, modular designs, high quality painting and powder coating, and technical specifications ensuring durability, safety, and reliability. Major clients include numerous power and infrastructure companies.
Cimmco Limited is a public company that manufactures railway wagons, coaches, and industrial machinery using cutting, pressing, and welding processes. The company produces various types of closed wagons for transporting commodities, including the BCNHL wagon. The BCNHL wagon construction process begins with cutting materials, pressing them into shape using hydraulic presses and power hammers, and welding the parts together. Key parts of the BCNHL wagon include the underframe, centre sill, roof, body ends, and wheels, which are assembled to form the finished wagon.
The document provides information about the ring gear production process at MPT Amtek Automotive Ltd. It describes the company's background and achievements. It then outlines the various manufacturing stages involved in producing ring gears, including bending, slitting, flash butt welding and trimming, normalizing, cold sizing, CNC machining, hobbing, chamfering, punching, washing, induction hardening, and tempering. Quality checks are conducted after key stages to ensure dimensional and geometric specifications are met.
BHEL summer training report on ROLE OF CNC MACHINE IN MANUFACTURING OF 500/60...Nawneet Thakur
This document provides an overview of the role of CNC machines in manufacturing stator bars for large turbo generators between 500-1000MW at Bharat Heavy Electricals Limited (BHEL). It discusses how CNC machines such as the Robel bar centre machine are used in BHEL's Heavy Electrical Equipment Plant to cut, bend, and transpose conductors for stator bar winding with high precision and accuracy for large generators. The document also provides background on BHEL, CNC machines, and the various sections involved in stator bar manufacturing.
High performance mist lubricant for increased tool life. Superior machining performance on large jobs with mist lubricant, Beruform STO 110. A global supplier of electromechanical systems for hydro-power plants found itself in a spot of bother when performance of the coolant did not meet its expectation
in its newly installed machining centre for large complex jobs.
With a revised MQL system in place, Beruform STO 110 by Bechem was tried out against the earlier recommended
coolant. Berfuform STO 110 outperformed the recommended
coolant in every performance parameter measured with
increase in tool life and savings in coolant consumption
Visit: www.bechemindia.com
VEMC is now an APOEM (Authorised Pump Original Equipment Manufacturer) of Kirloskar Brothers Ltd. In today’s time, we provide complete fluid and energy management solutions for a wide array of projects in Water Supply, Power Plants, Irrigation, Oil & Gas etc.
The document discusses Dayline Spray Systems, a company that provides powder coating equipment and systems. It describes some of their main products including powder spray equipment, powder spray booths, ovens for curing powder and paint, and conveyorized powder coating plants. It then provides technical details and specifications for some of these products, including powder spray guns, spray booths, electrical curing ovens, and considerations for designing conveyorized coating systems.
This document provides information about diaphragm valves for aseptic and sterile applications manufactured by AVCON Controls Pvt. Ltd. It discusses the company profile, manufacturing facilities, testing and certification processes, surface finish, aseptic valve components including diaphragms and valve body configurations, end connections, types of aseptic diaphragm valves, and spares and accessories.
This document was prepared by Zenithar Team to show the machinery support portfolio in the electromechanical industry. For switchgears, for transformers, for epoxy resin casting, for molding, and for CT, PT solutions, Zenithar is a convenient partner to help the right machinery solutions.
report of industrial training done at MAKINO.
For over two decades, Makino Auto Industries Pvt. Ltd. has been the trusted name in the automotive industry. The company's product range of Automotive clutch assemblies, brake assemblies and components are amongst the category leaders in India and discerning markets of the world.
Established in 1990 Makino has 4 plants in India. Started as a Friction Disc manufacturer and now a complete clutch & Brake Solution Provider.
Experts of Automotive Clutches & Brakes (2W, 3W and 4W applications)
Working with major OEM in India for 2 W and 3 W applications
Vision is to provide technologically advanced clutches & brakes for existing and future vehicles.
"MAKINO is committed to consistently provide the Original Equipment Manufacturer and vehicle owner quality products.
This document provides information on pipeheads from KraussMaffei Berstorff for PVC pipe production. It discusses their nine pipehead sizes that cover a broad range of diameters and applications. It also describes benefits like perfect pipe quality, a stable process, tight wall thickness tolerances, and a wide processing window. The document provides details on pipehead models, dimensions, throughputs, applications for pressure classes, and the benefits of multilayer PVC pipe production.
42CT Ducted Chilled Water Fan Coil Unit for Standard Chiller and District Coo...Carrier Singapore
Carrier room fan coil terminals provide unsurpassed year round comfort, with high cooling performance. Carrier 42 series terminal requires very little space and is easy to install. Piping, drain and wiring connections are readily accessible to save installation time and field labor expense.
The document summarizes the work done at the Diesel Locomotive Works in Varanasi, India. It describes the various workshops that manufacture and assemble parts for diesel locomotives, including the heavy welding shop, heavy machine shop, rotor shop, and paint shop. The heavy welding shop performs various arc welding techniques to join metal parts. The heavy machine shop uses machines like lathes and CNC to cut and shape metal parts. The rotor shop focuses on manufacturing and assembling turbochargers that provide fresh air to the locomotive engines. After assembly, the locomotive parts are sent to the paint shop for final painting and markings.
1) The document describes a PLC-based hydraulic auto ladle system for pouring molten aluminum in a casting and forging industry.
2) Previously, the pouring process was manual which lacked accuracy and consistency. The new automated system uses a PLC and hydraulic cylinder to tilt a ladle at a controlled speed and angle for pouring.
3) The system aims to increase pouring accuracy and reduce temperature loss/defects by automating the process and eliminating human errors. Key components include a tilting ladle, hydraulic cylinder, control panel with PLC, and safety components like limit switches.
Двигатели серии VSS / VSH диаметр 19-125мм PhytronArve
The document discusses phytron VSS/VSH stepper motors that are suitable for use in vacuum applications. Key points:
- The motors use special materials and conditioning processes to minimize outgassing and withstand high/low temperatures in vacuum environments.
- Stepper motors are well-suited for precise positioning in vacuum as they can hold position without feedback. The VSS/VSH series can operate in challenging conditions like radiation and cryogenic temperatures.
- The motors are used for applications like precisely aligning optical instruments in microscopes, particle accelerators, and molecular analysis devices.
Двигатели серии VSS / VSH диаметр 19-125мм PhytronArve
The document discusses phytron VSS/VSH stepper motors that are suitable for use in vacuum applications. Key points:
- The motors use special materials and conditioning processes to minimize outgassing and withstand the vacuum environment.
- Stepper motors are well-suited for precise positioning applications in vacuum as they can precisely control position without feedback sensors.
- The VSS/VSH series is manufactured in Germany to high quality standards using materials that meet stringent space application requirements for low outgassing.
- Customization is available for specialized requirements including different temperature ranges, gearing options, and sensors.
We, Achieve Hydraulics and Pneumatics, are manufacturer, exporter and supplier of Compact Hydraulic Cylinders, Power Pack Systems and Manifold Blocks. Offered products are acclaimed by the clients for their high efficiency and precise dimensions.
Similar to BWE conform process (Continuous Rotary Extrusion) (20)
Computational fluid dynamic simulations of solidification for enhancing speed...Rautomead Limited
In this research experiment computational fluid dynamic (CFD) models were constructed, within Ansys Fluent TM v.R1, to investigate phenomena occurring during the Vertically Upwards Continuous Casting (VUCC) of 8 mm diameter, oxygen free copper (OFCu) for alterations to the casting speed. The simulated influence of heat transported over a 0.1 mm air gap formed within the casting die was investigated and a value for the die wall heat transfer coefficient (hc) of (9.0 ± 0.2) 104 W/m2K, was extracted. Using this value for hc, simulations of the entire casting crucible and die were made for casting speed settings: pushback motion at 0.06 m/s, average; dwell motion (pause) at 0.05 m/s, average; and continuous motions at 0.022 m/s, 0.015 m/s and 0.008 m/s; and were validated against literature values for measured thermal distribution within the casting die. The fastest casting speed for 8 mmOFCu was investigated and a trend between simulated solidification front and measured grain growth direction was identified, highlighting,
the casting motions pushback and dwell yield improved casting conditions. Fluid flow rate was investigated within the casting crucible and showed a small influence on casting due to natural convection relative to flow within the die, 0.001 ± 0.0005 m/s compared with 0.1 ± 0.01 m/s for pushback casting, respectively.
Examination of anti-bacterial properties of Cu and Cu alloys and potential ap...Rautomead Limited
Report:-
Copper has been utilised throughout early human existence as a disinfectant used to clean
wounds and prevent infection. However, following the birth of antibiotics and
pharmaceutical drugs, the use of copper as an antimicrobial material severely declined.
Copper as an antimicrobial surface agent is now beginning to re-emerge in medical
institutions due to the rise of viruses and drug resistant bacteria, known as “superbugs”,
over the past century.
Yet, many institutions are hesitant on the reimplementation of copper as a surface agent.
This project aims to demonstrate the antimicrobial effectiveness of copper and its alloys
against an E. Coli O157:H7 strain as well as displaying the potential applications that an
antimicrobial copper surface agent can be applied to. Henceforth, the purpose of this
project is to formulate a systematic literature review, whereby the results from other
research papers will be compared and adopted into a novel concept of attempting to track
bacterial transmission through the use of a video-based monitoring system.
Examination of anti-bacterial properties of Cu and Cu alloys and potential ap...Rautomead Limited
This document summarizes a research project examining the antimicrobial properties of copper and copper alloys and potential applications. The project was undertaken by Jack Buchanan at the University of Dundee in collaboration with Rautomead. Key findings included that copper destroys bacteria through contact killing using copper ions. Higher copper purity alloys were found to have greater antimicrobial effectiveness. Applications identified included use in medical settings, food handling, and reducing hospital-acquired infections. Future work proposed testing methodologies and hypotheses developed to determine optimal alloys for preventing bacterial growth. Potential uses for Rautomead's customers producing high copper alloys without side effects were also discussed.
Continuous Casting of Dilute Copper Alloys for Drawing to Wire in Specialist ...Rautomead Limited
Presentation given by Sir Micahel Nairn, Chairman Rautomead Limted, at Interwire 2019.
Abstract
Many modern industrial applications of copper-based conductor wires call not only for high electrical conductivity, but also for other matching physical properties, including high tensile strength, high softening temperatures, creep resistance, abrasion resistance and corrosion resistance, while maintaining also good ductility.
The paper shows examples of dilute copper alloys offering these properties and techniques and equipment which have been developed by Rautomead for reliable, continuous production to narrow chemical tolerances.
To enable the processing of new complex high performance alloys by improving ...Rautomead Limited
This doctoral thesis investigated improving the capacity and performance of continuous casting equipment to enable the processing of new complex high-performance alloys. The research included comparing the microstructure and mechanical properties of products made by continuous casting versus traditional and established methods. Additional objectives examined the effect of casting speed, alloying elements, water flow rate, pull distance, melt temperature, cleanout cycle, casting direction and super-cooler size on the structure and properties of continuously cast copper rod and lead alloy. Microstructural analysis using optical microscopy, SEM, EDX and tensile testing were employed to evaluate the materials. The research aimed to optimize continuous casting parameters to improve casting quality and efficiency for complex alloy processing.
EFFECT OF ANTIMONY ADDITION RELATIVE TO MICROSTRUCTURE AND MECHANICAL PROPERT...Rautomead Limited
It is well documented that the addition of antimony in pure lead increases tensile strength and reduced elongation. The goal of the present work is to identify the cause of these phenomena by investigation of the effects of the addition of Sb (1.25%) on the structure of pure continuously cast lead and lead alloy rods. The microstructure and morphology of both pure lead and lead 1.25% antimony were examined by digital optical microscope and scanning electron microscope respectively. Energy Dispersive X-ray Spectroscopy (EDX) was used to identify alloying elements. The results showed that the effect of additions of antimony on mechanical properties of lead-antimony alloys is mainly due to the solid solubility of the antimony element. Homogenized distribution of the antimony results in a decrease in the grain size of the pure lead. These smaller grains mean higher strength so long as there is a homogeneous grain structure
RAUTOMEAD TECHNOLOGY FOR CONTINUOUS CASTING OF OXYGEN-FREE COPPER AND DILUTE...Rautomead Limited
Paper by Sir Michael Nairn, Chairman of Rautomead Limited, Dundee, U.K.
presented at the Global Continuous Casting Forum, during the Interwire 2015 Trade Exposition, being held in Atlanta, Georgia, USA
organised by WAI
27 – 30 April 2015
RAUTOMEAD TECHNOLOGY FOR CONTINUOUS CASTING OF OXYGEN-FREE COPPER, COPPER-MA...Rautomead Limited
Rautomead Chairman, Sir Michael Nairn, presented a paper at the ICDC seminar in Mumbai on 30 November 2014. Sir Michael talked about “Rautomead Technology for Continuous Casting of Oxygen Free Copper, Copper Magnesium & Other Copper Conductor Alloys” and reflected on the development and evolution of Rautomead continuous casting technology during its 35 year history.
Analysis and quantification of grain size in various dhp copper tubes manufac...Rautomead Limited
Abstract. Deoxidized High Phosphorus (DHP) Copper tubes are frequently used in numerous
industrial and household applications. To ensure the acceptability of DHP copper tubes prepared by
various industrial processes, the quality of the DHP copper tubes must be evaluated and one of the
best ways to do so is to examine the microstructure and metallography and quantify grain size. In
this paper the authors considered the average grain size of copper tube samples made traditionally
as well as by the planetary rolling and CastTube process. Because of the small thickness of the
CastTube samples, in certain circumstances traditional methods of grain counting were not
plausible and a new procedure for grain counting needed developed. This paper is about the
development and evaluation of grain sizes in continuously cast tube samples using both the
planimetric procedure (ASTM E112) and a new method, which will be herby, referred to as the
“total grain counting method”. This paper also concludes that there is a large difference in the grain
size of tubes with different manufacturing methods.
Rautomead Limited Newsletter Issue 12 continuouscasting.com
For over 30 years Rautomead Limited has specialised in the design and manufacture of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries worldwide.
Rautomead plants are being successfully applied to production of oxygen-free copper, a wide range of copper-based alloys, precious metals and zinc. Forms include wire rod, straight length bars, flats and hollow sections. According to material and section, the casting process selected may be vertical upwards, vertical downwards or horizontal. The machines may be used either as integrated melting, holding and casting machines, or may be arranged to be fed with pre-alloyed molten metal.
The Rautomead Continuous Casting System is based on electric resistance heating of its furnaces, with graphite containment crucibles, graphite heating elements and casting dies. This technology is particularly suited for production of high purity, high quality oxygen-free copper and copper alloy wire rods (copper silver, copper magnesium, copper tin).
The upward casting equipment may be used to manufacture rods of all diameters between 8.0mm and 30mm diameter and is suitable feedstock for wire drawing and continuous rotary extrusion processes. End use applications include: superfine wire, automotive wires, contact wire and trolley wires for high speed trains, data communication cables, CTC and transformer strips as well as enamelled wires.
Rautomead’s R&D facility at the factory in Dundee (casting equipment, technicians, design and operational experience) is available to companies who wish to commission experimental and research work to develop technology and tooling for the manufacture and processing of new alloys and materials. Rautomead’s partnership with the University of Dundee provides access to sophisticated laboratory equipment as well as support with analytical evaluation and academic contributions to the R&D effort
Rautomead Newsletter issue 11 pink
continuouscasting.com
For over 30 years Rautomead Limited has specialised in the design and manufacture of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries worldwide.
Rautomead plants are being successfully applied to production of oxygen-free copper, a wide range of copper-based alloys, precious metals and zinc. Forms include wire rod, straight length bars, flats and hollow sections. According to material and section, the casting process selected may be vertical upwards, vertical downwards or horizontal. The machines may be used either as integrated melting, holding and casting machines, or may be arranged to be fed with pre-alloyed molten metal.
The Rautomead Continuous Casting System is based on electric resistance heating of its furnaces, with graphite containment crucibles, graphite heating elements and casting dies. This technology is particularly suited for production of high purity, high quality oxygen-free copper and copper alloy wire rods (copper silver, copper magnesium, copper tin).
The upward casting equipment may be used to manufacture rods of all diameters between 8.0mm and 30mm diameter and is suitable feedstock for wire drawing and continuous rotary extrusion processes. End use applications include: superfine wire, automotive wires, contact wire and trolley wires for high speed trains, data communication cables, CTC and transformer strips as well as enamelled wires.
Rautomead’s R&D facility at the factory in Dundee (casting equipment, technicians, design and operational experience) is available to companies who wish to commission experimental and research work to develop technology and tooling for the manufacture and processing of new alloys and materials. Rautomead’s partnership with the University of Dundee provides access to sophisticated laboratory equipment as well as support with analytical evaluation and academic contributions to the R&D effort
Rautomead Newsletter issue 03
continuouscasting.com
For over 30 years Rautomead Limited has specialised in the design and manufacture of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries worldwide.
Rautomead plants are being successfully applied to production of oxygen-free copper, a wide range of copper-based alloys, precious metals and zinc. Forms include wire rod, straight length bars, flats and hollow sections. According to material and section, the casting process selected may be vertical upwards, vertical downwards or horizontal. The machines may be used either as integrated melting, holding and casting machines, or may be arranged to be fed with pre-alloyed molten metal.
The Rautomead Continuous Casting System is based on electric resistance heating of its furnaces, with graphite containment crucibles, graphite heating elements and casting dies. This technology is particularly suited for production of high purity, high quality oxygen-free copper and copper alloy wire rods (copper silver, copper magnesium, copper tin).
The upward casting equipment may be used to manufacture rods of all diameters between 8.0mm and 30mm diameter and is suitable feedstock for wire drawing and continuous rotary extrusion processes. End use applications include: superfine wire, automotive wires, contact wire and trolley wires for high speed trains, data communication cables, CTC and transformer strips as well as enamelled wires.
Rautomead’s R&D facility at the factory in Dundee (casting equipment, technicians, design and operational experience) is available to companies who wish to commission experimental and research work to develop technology and tooling for the manufacture and processing of new alloys and materials. Rautomead’s partnership with the University of Dundee provides access to sophisticated laboratory equipment as well as support with analytical evaluation and academic contributions to the R&D effort
Rautomead Newsletter issue 01
continuouscasting.com
For over 30 years Rautomead Limited has specialised in the design and manufacture of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries worldwide.
Rautomead plants are being successfully applied to production of oxygen-free copper, a wide range of copper-based alloys, precious metals and zinc. Forms include wire rod, straight length bars, flats and hollow sections. According to material and section, the casting process selected may be vertical upwards, vertical downwards or horizontal. The machines may be used either as integrated melting, holding and casting machines, or may be arranged to be fed with pre-alloyed molten metal.
The Rautomead Continuous Casting System is based on electric resistance heating of its furnaces, with graphite containment crucibles, graphite heating elements and casting dies. This technology is particularly suited for production of high purity, high quality oxygen-free copper and copper alloy wire rods (copper silver, copper magnesium, copper tin).
The upward casting equipment may be used to manufacture rods of all diameters between 8.0mm and 30mm diameter and is suitable feedstock for wire drawing and continuous rotary extrusion processes. End use applications include: superfine wire, automotive wires, contact wire and trolley wires for high speed trains, data communication cables, CTC and transformer strips as well as enamelled wires.
Rautomead’s R&D facility at the factory in Dundee (casting equipment, technicians, design and operational experience) is available to companies who wish to commission experimental and research work to develop technology and tooling for the manufacture and processing of new alloys and materials. Rautomead’s partnership with the University of Dundee provides access to sophisticated laboratory equipment as well as support with analytical evaluation and academic contributions to the R&D effort
Rautomead Limited is a Scottish company founded in 1978 that designs and sells continuous casting machines for precious metals. It has 50 employees and has sold 360 machines total, 133 of which are for precious metal production. It operates out of several facilities in Dundee, Scotland for R&D, spare parts, and machine assembly. Rautomead is an expert in various types of continuous casting and has sold over 130 machines to mints worldwide for gold and silver casting since 1985. Their technology uses graphite materials and components to cast precious metals without contamination.
For over 30 years Rautomead Limited has specialised in the design and manufacture of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries worldwide.
Rautomead plants are being successfully applied to production of oxygen-free copper, a wide range of copper-based alloys, precious metals and zinc. Forms include wire rod, straight length bars, flats and hollow sections. According to material and section, the casting process selected may be vertical upwards, vertical downwards or horizontal. The machines may be used either as integrated melting, holding and casting machines, or may be arranged to be fed with pre-alloyed molten metal.
The Rautomead Continuous Casting System is based on electric resistance heating of its furnaces, with graphite containment crucibles, graphite heating elements and casting dies. This technology is particularly suited for production of high purity, high quality oxygen-free copper and copper alloy wire rods (copper silver, copper magnesium, copper tin).
The upward casting equipment may be used to manufacture rods of all diameters between 8.0mm and 30mm diameter and is suitable feedstock for wire drawing and continuous rotary extrusion processes. End use applications include: superfine wire, automotive wires, contact wire and trolley wires for high speed trains, data communication cables, CTC and transformer strips as well as enamelled wires.
Rautomead’s R&D facility at the factory in Dundee (casting equipment, technicians, design and operational experience) is available to companies who wish to commission experimental and research work to develop technology and tooling for the manufacture and processing of new alloys and materials. Rautomead’s partnership with the University of Dundee provides access to sophisticated laboratory equipment as well as support with analytical evaluation and academic contributions to the R&D effort.
www.rautomead.com
sales@rautomead.com
RAUTOMEAD TECHNOLOGY FOR UPWARDS CONTINUOUS CASTING OF COPPER ALLOYSRautomead Limited
RAUTOMEAD TECHNOLOGY FOR UPWARDS CONTINUOUS CASTING OF COPPER ALLOYS
Paper given by Brain Frame, MD Rautomead at teh IWCC technical Seminar, Santiago, Chile, March 2013
CONTINUOUS CASTING OF COPPER MAGNESIUM CONDUCTOR ALLOYSRautomead Limited
This document summarizes the continuous casting process for producing copper magnesium (CuMg) wire rod, which requires tight alloy tolerances for strength and conductivity in electrical applications like high speed rail systems. It describes the Rautomead vertical casting process using a graphite crucible and heating system that maintains precise alloy composition control through oxygen reduction and specialized magnesium addition methods. This process has been proven to produce CuMg wire rod meeting high quality standards for train speeds over 400 km/h.
Rautomead - The Manufacture of Brass Rod for Machining and Forging ApplicationsRautomead Limited
Rautomead Limited paper describing the process and equipment to manufacture around 150 tonnes per month, using either virgin metals or scrap brass feedstock.
Rautomead Limited are UK-based specialists in continuous casting of non-ferrous metals and construction of continuous casting equipment for copper, copper alloys, gold and silver, dental alloys and feed rod for Conform machines.
For a period of over 30 years Rautomead Limited has specialised in the design, manufacture and sale of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries around the world.
Rautomead promote Advanced Metals Technology Collaboration for research and development of new processing technology for non ferrous metals
Rautomead Continuous Casting Technology for Railway and Automotive ApplicationsRautomead Limited
Rautomead offer a range of machines designed to cast Copper Magnesium and other conductor alloys for Railway Contact and Messenger Wires and Automotive wiring Harness.
Rautomead Limited are UK-based specialists in continuous casting of non-ferrous metals and construction of continuous casting equipment for copper, copper alloys, gold and silver, dental alloys and feed rod for Conform machines.
For a period of over 30 years Rautomead Limited has specialised in the design, manufacture and sale of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries around the world.
Rautomead promote Advanced Metals Technology Collaboration for research and development of new processing technology for non ferrous metals
www.rautomead.co.uk
sales@rautomead.co.uk
Using recycled concrete aggregates (RCA) for pavements is crucial to achieving sustainability. Implementing RCA for new pavement can minimize carbon footprint, conserve natural resources, reduce harmful emissions, and lower life cycle costs. Compared to natural aggregate (NA), RCA pavement has fewer comprehensive studies and sustainability assessments.
Batteries -Introduction – Types of Batteries – discharging and charging of battery - characteristics of battery –battery rating- various tests on battery- – Primary battery: silver button cell- Secondary battery :Ni-Cd battery-modern battery: lithium ion battery-maintenance of batteries-choices of batteries for electric vehicle applications.
Fuel Cells: Introduction- importance and classification of fuel cells - description, principle, components, applications of fuel cells: H2-O2 fuel cell, alkaline fuel cell, molten carbonate fuel cell and direct methanol fuel cells.
Advanced control scheme of doubly fed induction generator for wind turbine us...IJECEIAES
This paper describes a speed control device for generating electrical energy on an electricity network based on the doubly fed induction generator (DFIG) used for wind power conversion systems. At first, a double-fed induction generator model was constructed. A control law is formulated to govern the flow of energy between the stator of a DFIG and the energy network using three types of controllers: proportional integral (PI), sliding mode controller (SMC) and second order sliding mode controller (SOSMC). Their different results in terms of power reference tracking, reaction to unexpected speed fluctuations, sensitivity to perturbations, and resilience against machine parameter alterations are compared. MATLAB/Simulink was used to conduct the simulations for the preceding study. Multiple simulations have shown very satisfying results, and the investigations demonstrate the efficacy and power-enhancing capabilities of the suggested control system.
Optimizing Gradle Builds - Gradle DPE Tour Berlin 2024Sinan KOZAK
Sinan from the Delivery Hero mobile infrastructure engineering team shares a deep dive into performance acceleration with Gradle build cache optimizations. Sinan shares their journey into solving complex build-cache problems that affect Gradle builds. By understanding the challenges and solutions found in our journey, we aim to demonstrate the possibilities for faster builds. The case study reveals how overlapping outputs and cache misconfigurations led to significant increases in build times, especially as the project scaled up with numerous modules using Paparazzi tests. The journey from diagnosing to defeating cache issues offers invaluable lessons on maintaining cache integrity without sacrificing functionality.
CHINA’S GEO-ECONOMIC OUTREACH IN CENTRAL ASIAN COUNTRIES AND FUTURE PROSPECTjpsjournal1
The rivalry between prominent international actors for dominance over Central Asia's hydrocarbon
reserves and the ancient silk trade route, along with China's diplomatic endeavours in the area, has been
referred to as the "New Great Game." This research centres on the power struggle, considering
geopolitical, geostrategic, and geoeconomic variables. Topics including trade, political hegemony, oil
politics, and conventional and nontraditional security are all explored and explained by the researcher.
Using Mackinder's Heartland, Spykman Rimland, and Hegemonic Stability theories, examines China's role
in Central Asia. This study adheres to the empirical epistemological method and has taken care of
objectivity. This study analyze primary and secondary research documents critically to elaborate role of
china’s geo economic outreach in central Asian countries and its future prospect. China is thriving in trade,
pipeline politics, and winning states, according to this study, thanks to important instruments like the
Shanghai Cooperation Organisation and the Belt and Road Economic Initiative. According to this study,
China is seeing significant success in commerce, pipeline politics, and gaining influence on other
governments. This success may be attributed to the effective utilisation of key tools such as the Shanghai
Cooperation Organisation and the Belt and Road Economic Initiative.
International Conference on NLP, Artificial Intelligence, Machine Learning an...gerogepatton
International Conference on NLP, Artificial Intelligence, Machine Learning and Applications (NLAIM 2024) offers a premier global platform for exchanging insights and findings in the theory, methodology, and applications of NLP, Artificial Intelligence, Machine Learning, and their applications. The conference seeks substantial contributions across all key domains of NLP, Artificial Intelligence, Machine Learning, and their practical applications, aiming to foster both theoretical advancements and real-world implementations. With a focus on facilitating collaboration between researchers and practitioners from academia and industry, the conference serves as a nexus for sharing the latest developments in the field.
ACEP Magazine edition 4th launched on 05.06.2024Rahul
This document provides information about the third edition of the magazine "Sthapatya" published by the Association of Civil Engineers (Practicing) Aurangabad. It includes messages from current and past presidents of ACEP, memories and photos from past ACEP events, information on life time achievement awards given by ACEP, and a technical article on concrete maintenance, repairs and strengthening. The document highlights activities of ACEP and provides a technical educational article for members.
TIME DIVISION MULTIPLEXING TECHNIQUE FOR COMMUNICATION SYSTEMHODECEDSIET
Time Division Multiplexing (TDM) is a method of transmitting multiple signals over a single communication channel by dividing the signal into many segments, each having a very short duration of time. These time slots are then allocated to different data streams, allowing multiple signals to share the same transmission medium efficiently. TDM is widely used in telecommunications and data communication systems.
### How TDM Works
1. **Time Slots Allocation**: The core principle of TDM is to assign distinct time slots to each signal. During each time slot, the respective signal is transmitted, and then the process repeats cyclically. For example, if there are four signals to be transmitted, the TDM cycle will divide time into four slots, each assigned to one signal.
2. **Synchronization**: Synchronization is crucial in TDM systems to ensure that the signals are correctly aligned with their respective time slots. Both the transmitter and receiver must be synchronized to avoid any overlap or loss of data. This synchronization is typically maintained by a clock signal that ensures time slots are accurately aligned.
3. **Frame Structure**: TDM data is organized into frames, where each frame consists of a set of time slots. Each frame is repeated at regular intervals, ensuring continuous transmission of data streams. The frame structure helps in managing the data streams and maintaining the synchronization between the transmitter and receiver.
4. **Multiplexer and Demultiplexer**: At the transmitting end, a multiplexer combines multiple input signals into a single composite signal by assigning each signal to a specific time slot. At the receiving end, a demultiplexer separates the composite signal back into individual signals based on their respective time slots.
### Types of TDM
1. **Synchronous TDM**: In synchronous TDM, time slots are pre-assigned to each signal, regardless of whether the signal has data to transmit or not. This can lead to inefficiencies if some time slots remain empty due to the absence of data.
2. **Asynchronous TDM (or Statistical TDM)**: Asynchronous TDM addresses the inefficiencies of synchronous TDM by allocating time slots dynamically based on the presence of data. Time slots are assigned only when there is data to transmit, which optimizes the use of the communication channel.
### Applications of TDM
- **Telecommunications**: TDM is extensively used in telecommunication systems, such as in T1 and E1 lines, where multiple telephone calls are transmitted over a single line by assigning each call to a specific time slot.
- **Digital Audio and Video Broadcasting**: TDM is used in broadcasting systems to transmit multiple audio or video streams over a single channel, ensuring efficient use of bandwidth.
- **Computer Networks**: TDM is used in network protocols and systems to manage the transmission of data from multiple sources over a single network medium.
### Advantages of TDM
- **Efficient Use of Bandwidth**: TDM all
TIME DIVISION MULTIPLEXING TECHNIQUE FOR COMMUNICATION SYSTEM
BWE conform process (Continuous Rotary Extrusion)
1. ™ Conform, Conklad, Twinex and Parorbital are Trade Marks of BWE Ltd.
CONFORM™ TECHNOLOGY
FOR COST EFFECTIVE
MANUFACTURE OF COPPER STRIP
Dr J. R. DAWSON
BWE Ltd, UK
Introduction: BWE Ltd
BWE Ltd, formerly Babcock Wire Equipment Ltd, has operated from its Ashford
headquarters in the Southeast of England since 1969, when the company first
produced cold welding machines. Conform™ machines have been manufactured
since 1976 when they were initially used for extruding round wire. Continuous
development aimed at extending the capabilities of the Conform process led to an
increasing number of applications including magnet wire, electrical conductors,
refrigeration tube and ultimately, in 1984, the introduction of the Conklad™ process for
aluminium clad steel wire and CATV and fibre optic cables.
The company has evolved into a highly specialised engineering organisation
occupying 35,000 ft2
of factory and office space close to Ashford town centre.
Investment in Research and Development is centred on a complete Conform/Conklad
plant used for developing new applications, carrying out pilot production for customers
and for training customers' personnel. Investment in modern manufacturing methods
has seen the replacement of traditional machines with computer controlled machines
enabling the company to supply cost-effective high quality dies and tooling. The
company's policy of strict quality control is backed up by the 6,000 ft2
assembly and
test bay where all plant is dry run prior to despatch.
In addition to designing and manufacturing Conform and Conklad Machines, BWE Ltd
also designs and manufactures wire cleaning systems (Parorbital™) and a range of
cold pressure welders for non-ferrous wire and rod.
BWE has a highly skilled work force dedicated to continuous improvement of design,
manufacture, quality and performance. Sales and service are available through a
world-wide network of agents and distributors who have direct access to the
company's engineering and contract management departments ensuring that
customers' requirements are dealt with promptly and efficiently.
The Conform/Conklad Process
The Conform process (Figure 1) uses a single wheel with a groove in its periphery to
accept feedstock rod (or particulate feed in some cases). Since the area of contact in
the groove greatly exceeds the area of contact between the feedstock and the
enclosing shoe, rotation of the wheel drives the feedstock into the deformation zone
where sufficient pressure and heat are generated for extrusion.
The twin groove process (Figure 2) was developed by BWE for extruding precision
round and multi-void aluminium tubing and is used extensively to produce tubes for
heat exchangers. The use of two feedstock rods gives several advantages. For hollow
products, where the tooling contains a mandrel or male die, the two streams of
2. plasticised aluminium give a balanced flow of material through the tooling and hence a
more concentric product. A wider range of product sizes is possible than with single
groove operation and a higher output rate is possible.
A further advantage of the twin groove process is the ability to use the BWE Twinex™
system. The Twinex arrangement uses two feedstock rods entering a single wheel
with two grooves. The two flows of metal enter special tooling with either a single or
double die. For large sections, the two flows are mixed and extruded as a single
product. For smaller sections the two flows do not mix, but emerge as two separate
extrusions. The Twinex system emulates two machines in one, allowing the machine
to cover a much greater range of product sizes and increasing output and reducing
down time and wastage.
The BWE Conklad process (Figure 3) extends the capabilities of the Conform
machine by utilising the twin groove tangential mode of operation. Here the tooling is
positioned such that the product is extruded at a tangent to the wheel, and a core may
be passed directly through the tooling. With CATV or fibre optic cores the aluminium
sheath is extruded oversize in the tangential mode, allowing the core to be introduced
through the specially designed tooling into the centre of the tube. After cooling the
aluminium sheath is drawn to its final size, in-line with the Conklad process. The
Conklad process for OPGW/CATV has been patented by BWE. For aluminium clad
steel a similar arrangement is used but to achieve a metallurgical bond between the
steel core and the aluminium sheath, the aluminium is extruded under pressure,
directly onto the steel wire.
As well as product flexibility Conform/Conklad technology has other major benefits;
a) low capital cost
b) high production rates
c) close tolerances
d) low installation and maintenance costs
e) low energy consumption
f) continuous production
g) low scrap levels
The feedstock used for the production of copper strip is electrolytic tough pitch copper
rod produced by continuous casting and rolling or oxygen-free copper rod, produced
by the Rautomead RS casting machine. Rod diameters from 8mm to16mm can be
used, depending on the product range and productivity required. For the Conform
machine to operate under optimum conditions the feedstock rod should be fairly soft
therefore a maximum yield stress of 130 MPa is specified.
3. Conform Machinery for the Manufacture of Copper Strip
A typical BWE Conform line for the production of copper strip consists of the following
equipment (Figure 4):
• feedstock pay-off
• feedstock straightener
• (feedstock cleaning system)
• Conform machine
• Control system
• product cooling system
• (in-line Quality Control and measurement equipment)
• product handling system
These are described as follows:
Feedstock Pay-Offs and Straighteners
The feedstock pay-off and straightener are simple non-powered units, the Conform
machine has sufficient power to pull off the feedstock rod through the straightener.
Feedstock Cleaning System
The feedstock, when it enters the Conform machine, must be free from oxide, oil,
grease and any other contaminants. In some cases, in-line feedstock cleaning must
be used, especially when the feedstock has been wax-coated to prevent oxidation.
The feedstock cleaning system used with BWE Conform machines is either the BWE
Parorbital system or an ultrasonic system.
The principle of the Parorbital system, shown in Figure 5, is a combined mechanical
and chemical cleaning action. Each cleaning head comprises entry and exit air knives
to prevent the escape of cleaning fluid, and six hydro-converters which perform the
cleaning. Each hydro-converter contains two tungsten carbide dies, of slightly larger
diameter than the feedstock rod. A high velocity jet of cleaning fluid is injected into the
hydro-converter in such a way to create a powerful vortex around the feedstock rod.
The vortex of fluid causes the copper rod to orbit at high speed, and scrubs the
surface of the rod against the tungsten carbide dies.
Whether the cleaning system is Parorbital or ultrasonic, the combination of chemical
and mechanical cleaning actions means that the cleaning fluids can be quite dilute.
Therefore the hazards associated with highly corrosive chemicals are avoided.
Conform Machine
The heart of the Conform machine (Figure 6) is the grooved wheel and shaft
assembly. This is mounted in roller bearings that incorporate multiple seals to retain oil
and prevent the ingress of foreign material. A separate pressurised, filtered and cooled
lubrication system ensures the bearings are adequately lubricated and correct
operating temperatures are maintained. The bearings are held in a rugged steel frame
that is extended to carry the pivoted shoe and the hydraulic shoe retaining system.
Thus the relative deflections of the wheel and tooling are kept to an absolute minimum,
enabling good product tolerances to be maintained, despite the high operating forces
4. involved. The main shaft is driven by an infinitely variable, thyristor controlled DC
electric motor, via an epicyclic gearbox. The power output envelope from the drive is
matched to the production rates specified.
The pivoted shoe that carries the tooling is inserted and retracted by hydraulic
cylinders operated from the pendant control panel on the machine. When closed the
shoe is clamped in place by hydraulic cylinders. This system gives easy start up
conditions and minimises the risk of damage from overload when operating an
unfamiliar product, since the clamp pressure can be released, allowing the shoe to
back off.
The BWE range of Conform machines consists of 5 models, the 285, 315, 350, 400
and 550 machines. The 350, 400 and 550 machines have Conklad, ie tangential
extrusion capability. The numbers refer to the diameter of the Conform wheel. The
power requirements of the machines increase with size; typically from 120 kW for a
285 machine to 400 kW for a 550 machine. The power requirements to convert
copper rod feedstock into strip are quite low and therefore power requirements are not
the main issue when selecting a Conform machine for this product. The limiting
factors are the size of tooling that will fit into the machine and the output rate required.
The capabilities of the machines for production of copper strip are listed in the
appendix to this paper.
Control System
The Conform line is controlled by an industrial computer system with highly
specialised software to provide the following features:
• Measurement and recording of operating parameters such as temperatures,
speeds, machine load etc.
• Tabular display of primary, secondary and control parameters.
• Graphic display on one second time base of any four primary parameters over the
last 24 hours.
• Graphic display on one tenth second time base of any four control parameters.
• File recording of primary, secondary and control parameters.
• Review of recorded files.
• Control of dynamic systems, such as pay-off, capstan, take-up, heaters, etc.
• Alarms.
• Calibration of system inputs and outputs.
• Set up and calibration of control loops.
Product Cooling System
The universal system for cooling the extrusion wheel and tooling and product
produced consists of a storage tank with the product cooling trough mounted on top.
To the rear of the tank is the pumping station containing a pump and heat exchanger
for each cooling circuit. The high volume pump maintains the required level and flow
velocity for the product cooling circuit. The low volume circuit supplies cooling to the
extrusion wheel and tooling. Flow control valves for each of the cooling circuits are
mounted on the front of the tank. A closed system is used to enable the water
contacting the product and tooling circuits to be softened.
Special features of the cooling system have been developed to control the cooling rate
of the product upon leaving the extrusion die. A rapid quench or a more gradual cooling
5. rate are possible. This in turn gives control over the grain structure and hence
properties of the extruded strip.
Quality Control and Measuring Equipment
Quality control and product measurement, if required, can be effected with in-line
equipment. An eddy current detector will locate product defects. Product dimensions
can be measured and recorded with a laser gauge. All of these devices operate at all
line speeds and can be set up to give control and warning alarms for the purpose of
Statistical Process Control.
Product Handling System
Product handling systems to produce coiled or straight length products can be
provided. For coiled product, a drum take-up, controlled by a catenary system is used.
The product can be wound onto a normal drum or a collapsible drum to produce coils.
The catenary system is designed to handle a wide range of products and can be
operated with various tensions down to near zero.
Tooling
The extrusion die is held in the pivoting shoe in a die chamber, (Figure 7). The die
chamber holds the abutment(s) that fit into the wheel groove(s) and divert the flow of
copper into the die chamber. The die chamber ensures accurate alignment of the
tooling and allows tooling to be pre-assembled for rapid changes. The die chamber
accommodates a wide range of product dies. The geometry and material selection of
the tooling are essential to the production of a high quality product. Surface finish and
dimensional tolerances depend on the accuracy of the tooling. The materials used for
tooling must provide a balance of hardness, toughness and strength to give good wear
rates along with the strength to resist the pressures and temperatures of extrusion.
Tooling is critical to the operation of a Conform plant, in terms of product quality and
economics of production. In recognition of this BWE has invested in a state of the art
tooling manufacturing facility. By using the latest generation of CNC machine tools,
BWE can supply high quality production tooling at very economic prices. Technical
support provided by BWE specialists ranges from monitoring tooling life and advising
on design, materials and running conditions to carrying out development projects
aimed at improving output or tooling life.
6. Manufacturing Operations
A Conform line for the production of copper strip can be carried out as a 24 hour
operation at about 75% utilisation. Even from a cold start the machine quickly heats to
operating temperature and can be at full output speed within a few minutes. Pre-
heating the tooling to operating temperature in a furnace further improves this time.
Feedstock coils and full drums of product can be changed without stopping
production. To change feedstock coils the line speed is reduced and the fresh coils of
feedstock rod are placed on the pay-offs. The ends of the new coils are welded to the
ends of the old coils using a BWE cold butt welder. The line speed is than ramped up
to normal running speed and operation continued. Similarly the line speed can be
reduced to remove a full drum of product and replace a new drum on the take up.
Manning requirements for a Conform line are low. Two operators are required to start
the line and to change feedstock coils or output drums. During normal running only
one operator is required to monitor the line and remove flash. In some plants one
operator is used to run two lines.
Tooling changes are necessary to change products, or when a set of tooling reaches
the end of its life. To change tooling quickly, the new tooling set is prepared in advance
and can be heated to operating temperature in an oven. The extrusion is stopped, the
shoe is opened and the old tooling set is removed. The new tooling set is inserted in
the shoe, the shoe is closed and operation can begin immediately. In this way a tooling
change can be carried out in only a few minutes. This ability to rapidly change
products gives the benefit of very low stock holding requirements. The Conform
machine can be very quickly set up to manufacture a particular size of strip. Many
manufacturers supply copper strip to order, with no stockholding whatsoever.
Product Quality
Copper strip manufactured by the Conform process is used in electrical products
such as magnets, transformers and motors, where dimensional and electrical
properties are important. The electrical properties meet the requirements of all
standards for such products and are generally better than rolled products. There is no
porosity or local variation in dimensions. Surface finish is excellent. The strip is ready
for enamelling or polymer insulation without any further treatment. The strip is
produced in the fully annealed condition with a UTS of approximately 250 MPa, yield
stress 70 MPa and elongation 50%. The grain structure is fine and regular, consistent
with the regular flow pattern of material through the Conform machine. A major quality
concern with rolled copper strip is the condition of the edge and corner radius. The
rolling process usually produces inconsistent corners often with “roll-ins” i.e. small
amounts of the surface rolled over. This problem does not exist with strip extruded by
Conform where the corners radii and edges match the shape of the extrusion die.
7. Economics
Alternative methods to produce copper strip require the use of shaving, drawing, rolling
and annealing equipment. The annealing stage is especially time-consuming, involving
a heating, dwell and cooling cycle. By contrast the Conform process converts
feedstock to annealed strip in one operation. Typically the production cost of copper
strip manufacture by Conform is 30 to 50 % less than alternative methods.
Another major economic factor is inventory reduction. With a Conform operation, the
raw material and work-in-progress levels are much lower than with a rolling mill. A
rolling operation requires up to four sizes of input rod as well as inventory holding at
each stage in the process. Also the lead time to produce a particular product means
stocks of finished products are often held.
By contrast the Conform process produces a wide range of product sizes from a
single infeed size. There is no inter-stage inventory since there is only a single
process step. Since the lead time to produce a batch of strip can be as little as a few
hours no stockholding of finished products is required.
Conclusion
Conform is well established as a reliable and cost effective method of manufacturing
copper strip and similar products. Compared to alternative manufacturing methods,
Conform has the following advantages:
• Lower capital outlay
• Lower labour cost
• Lower power cost
• Less space required
• Lower maintenance cost
• Lower replacement parts cost
• Less scrap
• Higher production rates
• Finished annealed product
• Greater lengths, limited only by take up capacity
• Short changeover times
• Lower stockholding requirements
• Shorter delivery lead times
8. Appendix
Conform Machine capabilities for Copper Strip Manufacture
Conform 285
General Parameters with 8.0 mm Diameter Feedstock
Minimum product dimension 0.80 mm
Maximum circumscribing circle diameter 28.00 mm
Minimum cross sectional area 4.00 mm2
Maximum cross sectional area 65.00 mm2
Maximum extrusion speed 100 m/min
Maximum output 340 kg/hr
General Parameters with 12.4 mm Diameter Feedstock
Minimum product dimension 1.50 mm
Maximum circumscribing circle diameter 28.00 mm
Minimum cross sectional area 15.00 mm2
Maximum cross sectional area 150.00 mm2
Maximum extrusion speed 100 m/min
Maximum output 800 kg/hr
Conform 350
General Parameters with 12.4 mm Diameter Feedstock
Minimum product dimension 1.50 mm
Maximum circumscribing circle diameter 35.00 mm
Minimum cross sectional area 16.00 mm2
Maximum cross sectional area 150.00 mm2
Maximum extrusion speed 100 m/min
Maximum output 850 kg/hr
General Parameters with 16.0 mm Feedstock
Minimum product dimension 2.00 mm
Maximum circumscribing circle diameter 60.00 mm
Minimum cross sectional area 25.00 mm2
Maximum cross sectional area 300.00 mm2
Maximum extrusion speed 100 m/min
Maximum output 1100 kg/hr
9. Conform 350 Twinex
General Parameters with (2x) 12.4 mm Diameter Feedstock
Minimum product dimension 1.50 mm
Maximum circumscribing circle diameter 15.00 mm
Minimum cross sectional area (2x) 16.00 mm2
Maximum cross sectional area (2x) 60.00 mm2
Maximum extrusion speed 100 m/min
Maximum output 1700 kg/hr
Conform 550
General Parameters with 19.0 mm Diameter Feedstock
Minimum product dimension 3.00 mm
Maximum circumscribing circle diameter 80.00 mm
Minimum cross sectional area 35.00 mm2
Maximum cross sectional area 650.00 mm2
Maximum extrusion speed 100 m/min
Maximum output 2200 kg/hr