KR920007834B1 - 와이어로드의 연속인발방법 - Google Patents

와이어로드의 연속인발방법 Download PDF

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KR920007834B1
KR920007834B1 KR1019850003483A KR850003483A KR920007834B1 KR 920007834 B1 KR920007834 B1 KR 920007834B1 KR 1019850003483 A KR1019850003483 A KR 1019850003483A KR 850003483 A KR850003483 A KR 850003483A KR 920007834 B1 KR920007834 B1 KR 920007834B1
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South Korea
Prior art keywords
wire rod
coating
lubricant
lubrication
wire
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KR1019850003483A
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English (en)
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KR850008113A (ko
Inventor
효지 하기다
다까시 후꾸다
시게루 마에다
히데오 이마무라
가즈도시 오가다
마사히로 후꾸오까
Original Assignee
스미도모 긴죠꾸 고오교오 가부시가기이샤
구마다니 노리후미
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Priority claimed from JP59102339A external-priority patent/JPS60260693A/ja
Priority claimed from JP16415084A external-priority patent/JPS6142415A/ja
Application filed by 스미도모 긴죠꾸 고오교오 가부시가기이샤, 구마다니 노리후미 filed Critical 스미도모 긴죠꾸 고오교오 가부시가기이샤
Publication of KR850008113A publication Critical patent/KR850008113A/ko
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Publication of KR920007834B1 publication Critical patent/KR920007834B1/ko

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C9/00—Cooling, heating or lubricating drawing material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
    • B63H—MARINE PROPULSION OR STEERING
    • B63H1/00—Propulsive elements directly acting on water
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C1/00—Manufacture of metal sheets, metal wire, metal rods, metal tubes by drawing
    • B21C1/006—Manufacture of metal sheets, metal wire, metal rods, metal tubes by drawing using vibratory energy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C9/00—Cooling, heating or lubricating drawing material
    • B21C9/02—Selection of compositions therefor
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    • C10M105/00—Lubricating compositions characterised by the base-material being a non-macromolecular organic compound
    • C10M105/08—Lubricating compositions characterised by the base-material being a non-macromolecular organic compound containing oxygen
    • C10M105/22—Carboxylic acids or their salts
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    • C10M111/00—Lubrication compositions characterised by the base-material being a mixture of two or more compounds covered by more than one of the main groups C10M101/00 - C10M109/00, each of these compounds being essential
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    • C10M111/04—Lubrication compositions characterised by the base-material being a mixture of two or more compounds covered by more than one of the main groups C10M101/00 - C10M109/00, each of these compounds being essential at least one of them being a macromolecular organic compound
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    • C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
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    • C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
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    • C10M2201/0623—Oxides; Hydroxides; Carbonates or bicarbonates used as base material
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Abstract

내용 없음.

Description

와이어로드의 연속인발방법
제1도는 본 발명에 따른 와이어로드의 연속인발방법을 예시하는 블록공정도.
제2도는 본 발명에 따라 윤활 에비처리에 대한 초음파적용 효과를 보여주는 그래프.
제3도는 초음파주파수와 인산칼슘아연피복무게(coating weight)사이의 관계를 보여주는 그래프.
제4도는 인산아연칼슘피복의 Ca/Zn 비율과 인산칼슘아연피복무게 사이의 관계를 보여주는 그래프.
제5도는 스테아린산칼슘의 농도와 스테아린산칼슘 피복무게 사이의 관계를 보여주는 그래프.
제6도는 스테아린산나트륨의 처리시간과 스테아린산아연 피복무게 사이의 관계를 보여주는 그래프.
제7도는 초음파 윤활 에비처리장치의 개략측면도.
제8도는 처리욕조의 개략정면도.
제9도는 주성분으로서 금속성 비누를 갖는 프리다이스윤활제(Predies lubricant)에 첨가된 4중 플루오르화에티렌수지의 량과 상기 윤활제를 사용하는 와이어인발작업의 인발력 사이의 관계를 보여주는 그래프.
제10도는 냉간단조공정에 있어서 윤활제피복의 접착성을 보여주는 그래프.
제11a도는 냉간단조전에 절단된 와이어로드의 모양의 보여주는 개략도.
제11b도는 냉간단조제품의 모양을 보여주는 개략도.
제12도는 본 발명의 윤활제와 종래의 윤활제를 각각 사용하여 와이어인발 및 냉간단조를 실시한 재료의 보우덴(Bowden) 시험결과를 서로 비교하는 그래프.
제13도는 본 발명의 실시에 있어서 재료의 보우덴시험의 결과를 보여주는 그래프.
본 발명은 냉간단조용 와이어로드(Wire rod)를 연속적으로 인발하는 방법으로서 와이어로드(강철봉을 포함)의 스케일(Scale)을 제거하고, 윤활예비처리를 한 후에 윤활처리를 하고 연속적으로 인발하여 와이어를 제작하는 방법에 관한 것이다.
냉간단조용 와이어로드에 대한 2차작업은 통상 단음 순서로 수행된다. 즉, 스케일제거(산세척)-윤활에비처리-윤활처리-건조-금속선인발-권선(Colling)의 순서로 이루어진다. 위에서 산세척, 윤활예비처리 및 윤활처리는 통상 배치처리방식으로 실시된다. 즉 종래에는 산세척된 와이어로드 코일을 가령 인산아연 등의 인산염용액속에 담그고, 그다음 가령 스테아린산나트륨 등의 윤활용액속에 담가서 와이어로드 표면에 스테아린산나트륨, 스테아린산아연 또는 인산아연과 같은 물질로 윤활피복을 형성시키는 것이었다. 지금까지는 만족할만한 윤활성을 부여하는데 충분한 두께의 피복을 얻기 위해서 긴 반응 기간이 요구되었으며, 이것은 오랜 처리시간을 필요로하고 인라인방식(in-line-system)을 어렵게 만든다는 이유때문에 상기 배치처리 방식이 사용되었다.
따라서 예를 들어 일본국 특허공개공보 제1981-163047호에서는 윤활예비처리와 윤활처리를 인라인방식으로 실시하므로서 실비비용을 절감하고 생산성을 향상시키는 방법을 제안하였다. 이러한 선행기술방법은 실용화되었다. 이 선행기술방법의 특징은 스케일을 제거한후에 와이어로드를 인산아연으로 피복(윤활예비처리)하고, 그 위에 다시 스테아린산칼슘으로 실내온도하에서 피복(윤활처리)을 한다음에 신속히 건조시켰다. 이러한 선행기술에 있어서 운전(가동)비용을 경감시키고, 요구되는 윤활제의 량을 단시간에 피복하며 단시간에 건조시키며 전체 공정라인을 과도히 확장함이 없이 인라인방식으로 만드는 것을 가능케 하였다.
그러나 선행기술방법에 있어서 배치처리방식이나 또는 인라인방식을 모두 윤활예비처리로서 인산아연용액을 사용하였으며, 따라서 윤활제 피복의 내열성에 있어서 만족스럽지 못한 단점을 가지고 있다.
상술한 바와 같이 일반적으로 금속선인발작업에 있어서 작업효율의 향상, 공구의 수명연장 및 인발금속선의 표면품질유지를 위해서는 윤활제가 필수 불가결한 것이다.
와이어(금속선)인발을 위한 윤활제는 다이스(dies)와 와이어로드 사이의 마찰을 감소시키므로서 보다 작은 인발력으로 와이어로드를 인발하고, 다이스의 마모를 방지하는 것을 가능케하여 준다. 이러한 기능이외에도 윤활제는 인발가공후에도 와이어의 표면에 견고한 피복층으로 남아 있어서 냉간성형(예를들어 볼트제작) 동안에도 효과적인 윤활제 역할을 하게되는 중요한 장점을 지니고 있다.
종래에는 주성분이 다음과 같은 금속성비누를 갖는 프리다이스윤활제가 통상 와이어 인발에 사용되었다.
금속성비누 : 60-80%(중량)
무기물질 : 20-40%(중량)
첨가제 : 약간 %(중량)
기본적인 윤활특성을 지니고 있는 금속성 비누를 주요성분으로 가지고 있는 종래의 와이어인발용 윤활제에 있어서는 알칼리 토류금속 또는 나트륨의 스테아린산염 또는 팔미린산염 들이 통상 사용되었다. 종래에 와이어 인발윤활제에 사용된 전형적인 무기물질은 석회로서 연속적인 대량생산 작업에 있어서 온도상승을 방지하여 주므로서 와이어로드와 다이스의 접착을 방지하고, 윤활제의 연화온도를 제어하여 준다. 종래기술에 사용된 첨가제는 격심한 와이어 인발작업조건 하에서 와이어로드와 다이스 사이에 접착을 방지하고 윤활성을 높이기 위하여 첨가하는 유황, 이황화 몰리브덴 및 흡연 등이 있다.
그러나 금속성비누를 주성분으로 가지고 있는 종래의 와이어 인발윤활제는 다른 습성윤활제들보다 나은 특성을 지니고 있었으나, 인발작업중에 발생되는 열에대한 내열성과 표면에 형성된 윤활제 피복의 점착성등과 같은 윤활특성을 여전히 불충분한 것이어서 와이어 인발다이스의 수명과 인발작업후에 냉간단조용 다이스의 수명을 단축시켰다.
인발된 와이어로드들은 대부분 냉간단조하여 제품을 만든다. 그러나 최근에서 와이어 인발에 사용된 윤활제를 냉간단조공정으로 보내는 와이어의 표면에 부착되어 남아 있도록 하므로서 와이어에 별도로 윤활제를 도포하지 않고도 냉간단조하여 제품을 만들 수 있게 하는 경향이 대두되었다. 따라서 와이어인발작업후에 윤활피복의 보다 훌륭한 접착성과 인발작업후에 접착된 윤활제피복의 균열을 방지하는데 충분한 높은 내열성이 와이어 인발윤활제의 구비요건으로서 요구되어 왔으나, 이 요구에 대한 만족할 만한 해답을 줄 수 있는 성공적인 윤활제가 아직 발견되지 못하였다.
본 발명의 목적중에 하나는 와이어로드의 스케일을 제거하고, 윤활용 예비처리를 한다음에 윤활처리하고 건조한후에 인라인 시스템으로 와이어를 인발하여 높은 내열성을 갖는 윤활피복을 얻고, 종래기술방법보다 짧은시간에 와이어 인발작업을 효율적으로 수행하는 것을 가능케 하여주는 와이어로드의 연속인발방법을 제공하는데 있다.
본 발명의 다른 목적은 상술한 바와 같은 종래의 윤활제 문제를 해결할 수 있고, 마찰감소, 내열성, 와이어로드표면에 대한 부착성 및 접착성 등과같은 고도의 윤활제 특성을 가지고 있으므로 와이어 인발다이스와 냉각단조용 다이스의 수명을 연장시켜주는 와이어 인발용 윤활제를 제공하는데에 있다.
본 발명에 따른 연속적인 와이어 인발방법은 스케일을 제거하여 시전가열시킨 강봉을 70℃-90℃ 사이의 온도로 유지되고 초음파(주파수 10-60KHZ, 출력 25W/용액 1리터)를 적용시킨 인산아연칼슘용액(Ca/Zn=0.3-1.0)속을 통과시키므로서 예비윤활처리를 하고, 세척한 다음에 상온하에서 스테아린산 칼슘을 상기 와이어로드에 부착시키거나, 또는 70℃-90℃의 온도로 유지되는 스테아린산나트륨용액 속으로 통과시키므로서 윤활처리를 실시하고 건조시킨 다음에 인발하여 금속선을 제조한다. 또한 상기 와이어인발작업에 있어서 금속성비누를 주요성분으로 지니고 있는 프라다이스윤활제에다가 1-10중량%의 열가소성수지(예를들어 테프론, 폴리에틸렌, 나이론, 아크릴수지, 다탄산염)를 첨가시킨 것을 사용을 것을 특징으로 하고 있다.
와이어인발작업에 있어서 금속성비누를 주요성분으로서 가지고 있는 종래의 프라다이스윤활제에다가 열가소성수지를 첨가하는 것은 윤활제의 윤활특성을 상당히 향상시킨다는 것을 발견하였다. 즉, 금속성비누를 주요성분으로 가지고 있는 종전기술의 프리다이스 윤활제에다가 1-10중량%의 열가소성수지를 첨가하므로 마찰감소 및 내열성과 같은 윤활특성은 크게 향상시킬 수 있다.
열가소성수지를 1중량% 이하로 첨가하는 것은 윤활특성을 만족할만하게 향상시키기에는 불충분하다. 반면에 10중량% 이상을 첨가시키는 것은 비율을 과도히 증가시킬 것이며, 냉간단조후에 열처리를 하는 동안에 열분해가스를 발생시키는 결과를 초래할 수도 있다.
특히 플루오르(불소)함유중합체가 사용될때 위에서 명시한 것보다 1% 높게 첨가할 경우 냉간단조후에 열처리를 하는 동안에 불소가스의 발생위험이 따른다. 따라서 열가소성수지의 첨가비율을 결정할때는 주의를 크게 기울여야만 한다.
여기서 사용된 ＂금속성비누＂란 용어는 알칼리염 이외에 지방산, 수지산 및 나프텐산들의 나트륨염과 이들의 혼합물, 바람직하게는 스테아린산알루미늄, 스테아린산 아연 및 스테아린산 바륨 중의 하나 또는 둘 이상을 몇 중량% 만큼 첨가하여 90중량% 또는 그 이상의 스테아린산칼슘 또는 스테아린산나트륨을 함유하는 일반조성물(일반적으로 와이어 인발용 윤활제로서 사용되는 것)을 포함하는 상기 지방산 수지산 및 나프텐산들의 금속염을 의미하는 것으로 이해하여야 한다.
또한 여기서 말하는 ＂금속성비누를 주요성분으로 하는 프리다이스 윤활제＂라는 용어는 60중량% 이상의 금속성비누, 20중량% 이상의 무기물질(석회와 같은것), 그리고 및(약간) 중량%의 첨가제(유황, 이황화물리브덴 및 흑연중의 하나 또는 둘이상)를 함유하는 윤활제를 의미하는 것으로 이해되어야 하며, 즉 이 용어는 공지된 와이어 인발윤활제에 적용될 수 있는 것이다.
여기서 말하는 ＂열가소성수지＂라는 용어는 폴리에틸렌수지, 폴리프로필렌수지, 테프론(상표)으로 알려진 불소함유중합체, 폴리스틸렌수지, 비닐아세탈수지, 폴리아크릴수지, 폴리메타크릴수지, 폴리염화비닐수지, 폴리염화비닐리덴수지, 폴리아크릴로니트릴수지, 폴리비닐에테르수지, 폴리비닐케톤수지, 폴리에테르수지, 폴리탄산수지, 열가소성폴리에스테르수지, 폴리아미드수지, 디엔수지, 폴리우레탄수지, 실리콘수지 등에 사용하는 것으로 이해하여야 한다. 이 수지들은 단독으로 또는 둘이상의 배합으로 사용된다.
열가소성수지는 주로 크기가 대략 ㎛의 직경을 갖는 분말형태로 첨가된다.
본 발명을 첨부도면을 이용하여 상세히 설명하면 다음과 같다.
제1도는 본 발명에 따른 방법의 처리공정들을 보여주는 블록공정도이다. 도시한 바와 같이 와이어로드가 공급대(1)로부터 풀려나오고, 스케일제거공정(2)에서 예를들어 쇼트블라스팅에 의해 스케일을 제거한다. 그 다음 와이어로드를 예열장치(3)속에서 일정한 온도(80㎎ 이상)로 사전가열한 다음 윤활예비처리공정(4)에서 초음파를 가하고 있는 인산아연칼슘용액(Ca/Zn=0.3-1.0) 속으로 와이어로드를 통과시켜서 윤활예비처리를 한다. 상기 인산아연칼슘용액을 70-90℃ 온도로 사전가열한다. 그다음 헹구는 과정(5)을 가진후에 예비처리된 와이어로드를 윤활처리공정(6)에서 스테아린산칼슘 또는 스테아린산나트륨으로 윤활하여 표면에 부착시킨다. 스테아린산칼슘으로 윤활처리하는 것은 실내온도하에서 실시된다. 그러나 스테아린산나트륨은 공정(6)에서 윤활처리를 위하여 70-90℃로 사전가열시켜야 한다. 윤활처리 후에는 건조공정(7)에서 와이어로드의 윤활제피복을 충분히 건조시킨 다음에 와이어 인발공정(8)에서 프리다이스윤활제와 함께 인발되고, 권선기(Coiler)(9)에 의하여 권선된다.
스케일제거공정(2)에서 사용되는 와이어로드의 스케일 제거방법은 제한되어 있지 않다. 스케일제거공정(2)에서는 산세척, 쇼트블라스팅 및 롤벤딩등이 스케일제거공정(2)에서 와이어로드의 스케일을 제거하기 위하여 사용될 수 있다. 상기 세 가지의 방법중에서 쇼트블라스팅이 인라인시스템에서 인산코팅을 위하여 가장 선호되고 있다.
본 발명에 따른 방법은 내열성이 훌륭한 인산아연칼슘(Ca/Zn=0.3-1.0)이 인산처리공정(4)에서 윤활처리를 위하여 와이어로드를 사전 처리하기 위하여 사용된다. 인산아연칼슘피복의 결정수를 제거하는 온도는 415℃이며, 반면에 지금까지 사용된 인산아연피복의 결정수를 제거하는 온도는 280-290℃이다. 이것은 종래의 인산아연피복은 와이어 인발작업시에 발생하는 열(통상 300℃까지 발생)에 의하여 결정수를 상실하게 되므로서 피복에 크랙을 야기시키는 것을 의미한다.
이와는 반대로 위에서 설명한 바와 같이 본 발명에 따른 인산아연칼슘피복의 결정수를 제거하는 온도는 415℃이므로 인발작업에 의한 피복의 크랙이 발생하지 않는다.
본 발명의 방법은 윤활처리에 있어서 충분한 인산칼슘아연피복 중량을 달성하고 피복중량을 제어하기 위하여 초음파를 사용하는 것을 특징으로 하고 있다. 이것은 인산아연칼슘용액의 인산아연용액보다 화학전환 처리에 대하여 덜 민감하고, 피복중량을 달성하기 어렵기 때문이다. 그러나 제2도에 도시한 바와 같이 인산 칼슘 아연 피복중량은 초음파를 용액에 적용시켜 중량을 증가시킨다. 제2도에 도시한 결과는 다음과 같은 처리조건하에서 얻어진 것이다.
농도 160포인트
온도 80℃
초음파주파수 1KW에서 50KHz
제3도에 도시한 바와 같이 그 용액에 작용된 초음파의 주파수는 10KHz 이하일때은 소음을 발생하고, 한편 60KHz 이상일때에는 충분한 피복중량을 얻는데 효과적이 아니기 때문에 10KHz-60KHz 범위가 바람직하다. 초음파 출력은 용액 1리터당 25W가 바람직하다.
인산아연칼슘피복의 Ca/Zn 비율은 다음과 같은 이유로 0.3-1.0 범위로 결정된다. 제4도는 인산아연칼슘피복의 Ca/Zn 비율(용액농도 160포이트)와 피복중량 사이의 관계를 보여주고 있다. 제4도에서 알 수 있는 바와 같이 Ca/Zn비가 0.3이하일때는 Ca의 첨가효과가 작으며, 내열성이 충분치 못하다. 한편 Ca/Zn 비가 1.0이상일때에는 화학전환처리에 대한 민감성이 충분하지 못하고, 예정된 피복중량(
Figure kpo00001
6g/㎡) 및 금속성 비누의 피복중량(
Figure kpo00002
1g/㎡)을 얻기 힘들다. 따라서 칼슘아연 피복의 Ca/Zn 비율은 0.3-1.0 범위가 바람직하다.
인산아연칼슘피복중량이 6g/㎡ 또는 그 이상인 예정된 피복 중량은 인산아연칼슘용액의 농도가 160포인트 이상일때만이 10-20초의 짧은 기간에서 얻어진다.
한편 용액농도가 200포인트 이상일때는 피복중량이 농도증가에 비례하여 얻어지지 않으므로 비경제적이다. 따라서 인산아연칼슘피복중량의 하한치 6g/㎡로 미리 결정하였다. 내열성이 낮은 종래의 인산아연 피복은 하한피복중량으로서 7-8g/㎡가 요구되었다. 그러나 본 발명의 인산아연칼슘피복은 높은 내열성을 갖기 때문에 피복중량은 6g/㎡와 같이 낮아도 충분한 것이다.
본 발명의 방법에 따라 윤활처리를 위한 초음파예비처리에 사용되는 장치는 제7도 및 제8도에 도시한 바와 같이 다수의 초음파적용장치(12)들이 하나의 원통형처리욕조(11)의 외주표면주위에 수직 또는 수평으로 한쌍씩 평행하게 또는 엇갈리게 배치되어 있고 처리욕조(11)의 입구측과 출구측으로부터 각각 돌출한 양쪽의 용액수류기(13)들과 처리용액(19)의 공급과 수집을 위한 처리용액탱크(15) 사이에는 귀환파이프(14)들이 장치되어 있으며, 처리용액탱크(15)로부터 처리욕조(11)로 공급관(17)을 통하여 처리용액을 공급하여 주는 펌프(16)로 구성되어 있다.
상술한 바와 같은 구조로 되는 장치에 의하여 인산아연칼슘용액에 초음파를 적용시켜 교반하여 주므로서 공동현상(Cavitation)에 의하여 와이어로드(18)의 표면에 신속히 접착시키게 한다. 또한 초음파를 적용시키거나 또는 적용시키지 있고 또는 초음파 적용장치의 주파수 또는 출력을 변화시키므로서 인산아연칼슘피복의 중량을 조절하는 것을 가능케하였다.
윤활공정은 윤활예비처리공정 후에 와이어로드를 실내온도하에서 (1)칼슘스테아린산용액을 통과시키거나, (2) 70-90℃로 가열된 스테아린산나트륨용액 속으로 통과시켜서 처리한다.
상기(1)의 스테아린산칼슘으로 윤활처리를 실시함에 있어서는 제5도에 도시한 농도와 피복중량 사이의 관계에서 알 수 있는 바와 같이 일정한 피복중량 5g/㎡ 이상을 얻기 위하여서는 농도가 300g/1 이상이 되어야 한다. 스테아린산 칼슘이 와이어로드에 부착하도록 하기 위하여 습식도포(피복용액)는 건식도포(피복분말)방법중 어느것이든 사용할 수 있으나, 윤활제의 피복중량과 윤활피복의 접착성을 고려할때 습식도포에 의한 피복이 바람직하다. 물리적 접착을 위하여 통상 2-3초의 처리시간이 필요하다.
상기(2)의 스테아린산나트륨으로 윤활처리를 실시함에 있어서는 배치처리시스템을 사용할 수 있다. 상기 스테아린산나트륨에 의한 윤활처리에 있어서는 와이어로드의 표면에 부착하는 스테아린산아연층을 형성하기 위하여 윤활예비처리에 의하여 형성된 인산아연칼슘피복과 스테아린산나트륨 용액사이에 치환이 일어난다. 이 윤활처리에 있어서는 통상 1g/㎡ 이상의 치환층 피복중량을 달성하는 것이 요구된다. 이를 위해서는 제6도에서 스테아린산나트륨으로 처리하는 시간과 스테아린산아연 피복중량 사이의 관계로부터 알 수 있는 바와 같이 20초 이상의 시간을 필요로 한다.
상기 (1) 또는 (2)의 윤활처리방법은 와이어 인발공정에서 프리다이스윤활제가 사용될 경우에는 생략할 수도 있다.
본 발명의 방법에 있어서 프리다이스윤활제는 내열성과 윤활특성을 향상시키기 위하여 첨가된다. 본 발명의 방법에 사용되는 프라다이스윤활제는 금속성비누를 주성분으로 함유하고, 테프론, 폴리에틸렌, 나이론, 아크릴수지 또는 타탄산염과 같은 열가소성수지를 1-10중량% 정도로 첨가한 윤활제이다. 열가소성수지는 테프론과 같은 수지의 내열성과 낮은 마찰특성을 이용하기 위하여 금속성비누윤활제에 첨가된다. 또한 열가소성수지의 첨가량은 1% 이하를 첨가할때에는 인발력에 대한 충분한 효과를 나타내지 못하며, 반대로 다량을 첨가할때 효과는 크지만 소요되는 비용을 고려하고 분해가스, 예를들어 베프론은 불소가스를 발생한다는 사실을 고려하여 첨가량의 상한을 10%로 결정하였다.
제9도는 금속성비누를 주성분으로 함유하는 와이어 인발윤활제(함유성분 : 스테아린산칼슘 70중량%, 석회 27중량%, 유환 3중량%)에다가 4중 플루오르화 에틸렌(＂테프론＂ 상표)을 첨가하는 량과 와이어로드(일본 공업규격 S45C에 해당)를 와이어로 인발하는데 필요로하는 인발력 사이의 관계를 그래프로 표시하고 있다. 상기 제9도는 윤활예비처리로서 인산아연으로 피복된 직경 5.5㎜ø의 와이어로드를 단면 감소율이 각각 약 20%와 30%로 되는 두개의 상이한 와이어로 인발할때의 결과를 보여주고 있다.
제9도에서 4중 플루오르화 에틸렌을 함유하는 수지의 첨가량이 1중량%를 초과할때 인발력이 급격히 감소되는 경향을 나타낸다는것을 알수 있다. 이러한 경향은 다른 열가소성수지를 첨가할 경우에도 마찬가지로 나타난다는 것이 확인되었다. 제9도의 그래프는 윤활성을 증가시키기 위해서는 열가소성수지를 대량으로 첨가하는 것이 바람직하며, 그러나 환경오염과 경제성을 고려하여 첨가량을 10중량% 이하로 제한하여야 한다는 것을 보여주고 있다.
제10도는 아무런 수지도 첨가하지 않은 프리다이스 윤활제와 열가소성수지를 첨가한 프리다이스윤활제와 열가소성수지를 첨가한 프리다이스 윤활제를 사용할때 윤활제의 와이어로드 표면에 대한 점착성을 비교한 결과를 그래프로 보여주고 있다.
제10도의 시험에 사용된 와이어 선인발윤활제, 열가소성수지와 시험에 사용된 윤활예비처리 방법은 제9도의 시험에서 사용된 것과 똑같으며, 사용된 와이어로드 ALSI의 10B22M에 해당하는 붕소강이었다. 피복중량은 다음과 같은 방법으로 측정되었다.
인산아연 또는 인산칼슘으로 피복된 윤활예비처리 직경 22㎜ø의 붕소 와이어로드를 아무런 수지도 첨가하지 않은 프리다이스윤활제와 23중량%의 4중 플루오르화에틸렌을 첨가한 프리다이스윤활제를 모두 사용하여 단면감소율이 약 21.4%인 직경 19.5㎜ν의 와이어로드로 인발하여 냉간단조(압출하여 볼트를 제작하였음)를 실시하였으며, 이때 각 압출 단면축소시에 인발와이어로드(압출단면감소율=0)의 표면에 있는 잔류 윤활제의 비율을 알기 위하여 시료채취를 하였다.
즉 윤활제피복의 접착성은 다음의 비율로 이해할 수 있다.
Figure kpo00003
잔류윤활제피복율의 값이 크면 클수록 피복의 접착성이 좋아지거나 또는 윤활제가 더많이 남아있고, 따라서, 냉간단조 작업도중에 늘어붙는 현상이 덜하다. 본 발명의 방법에 사용된 냉간단조에 있어서 제11a도에 도시된 와이어로드(직경 : do)는 제11b도에 도시한 바와 같이 두부를 인장하지 않고, 약 80%의 최대누계단면 감소율을 갖는 볼트모양(생크의 직경 : d1)으로 형성된다. 이 경우 단면감소율은 다음식으로 표시된다.
Figure kpo00004
제10도에 예시된 결과로부터 3중량%의 4중 플루오르화에틸렌을 첨가한 프리다이스 윤활제는 윤활피복의 접착성에 있어서 아무런 수지도 첨가하지 않은 윤활제보다 명백히 우수하다는 것을 알 수 있다. 이것은 4중 플루오르화에틸렌을 첨가하면 윤활제의 내열성을 향상시키며, 가공중에 발생되는 열에 의한 약화를 방지하여 준다는 것을 말하여 준다.
제12도는 전술한 냉각단조 공정에서 얻어진 압출봉(압출단면감소율 : 약 79.5)을 사용한 보우덴시험(시험편의 표면을 강구로 마찰시켜 슬라이딩 회수에 해당하는 마찰계수를 결정하는 보우덴시험기를 사용하여)의 결과를 보여주고 있다.
제12도에서 3중량%의 4중 플루오르화에틸렌을 첨가한 프리다이스윤활제로 피복된 와이어로드는 아무런 수지도 첨가하지 않은 프리다이스윤활제로 피복된 와이어로드보다 명백히 마찰계수가 낮고, 마찰계수의 증가에 있어서도 낮다. 따라서 제12도는 열가소성수지를 첨가한 프리다이스 윤활제는 윤활특성 및 윤활피복의 접착성이 있어서 우수하다는 것을 보여주고 있다.
[실시예]
제1도에 예시한 라인구조로 되는 설비에 의하여 와이어로드의 스케일을 제거하기 위한 쇼트블라스팅을 사용하고, 제7도 및 제8도에 도시한 윤활을 위한 초음파 예비처리장치를 이용하여 직경 5.5㎜ø(S45C)의 재료를 다음과 같은 작업조건하에서 각각 4.95㎜ø및 4.6㎜ø의 와이어로드로 인발하였다.
작업조건
(1) 스케일제거조건
쇼트블라스팅재료 : 직경 0.3㎜ø의 강구알맹이
쇼트, 밀도 : 약 300㎏/㎡
(2) 예열방법
스팅송풍 : 80℃의 수증기
(3) 윤활예비처리조건
윤활예비처리제 : 인산아연칼슘용액(Cu/Zn=0.5)
처리조건 : 160 포인트(농도)×80℃(온도)×15(반응시간), 초음파 : 50KHz, 1KW
(4) 윤활피복조건
(i) 스테아린산칼슘을 사용할때
농도 : 300g/리터
온도 : 실내온도
시간 : 3초
(ii) 스테아린산나트륨을 사용할 때
농도 : 90g/리터
온도 : 80℃
시간 : 25초
(5) 건조조건
적외선건조로 : 건조로 온도 80℃
(6) 와이어 인발조건
프리다이스윤활제 : 3% 테프론을 첨가한 스테아린산칼슘을 주성분으로 하는 윤활제
단면감소율 : 약 19%(5.5㎜ø 4.95㎜ø)
약 30%(5.5㎜ø 4.6㎜ø)
와이어연발속도 : 80m/분
표 1은 종래 기술방법과 비교하여 본 발명에 따른 방법의 인발력을 나타낸 표이다.(윤활예비처리 : 인산 아연, 프리다이스윤활 : 스테아린산칼슘을 주성분으로 하는 시중판매 윤활제)
[표 1]
Figure kpo00005
제10도는 권선후에 와이어로드의 보우덴 시험결과(윤활제 피복의 윤활특성과 접착성)을 보여주는 도면이다. 표 2는 본 발명의 방법과 종래기술 방법의 비교에서 ø9=0.2일대 슬라이딩회수를 보여준다.
[표 2]
Figure kpo00006
표 3은 전술한 조건(단, 인발단면감소 : 5.5ø→4.95ø)하에서 와이어로드들을 인발하고, 그 다음 이들을 고장력볼트로 냉간단조하는데 각각 사용된 와이어 인발다이스와 냉낙단조다이스의 수명을 종래기술에 있어서의 수명과 비교하여 나타낸 표이다.
[표 3]
Figure kpo00007
* 다이스의 마모 및 손상에 따른 교환전까지 제품의 톤수로 수명을 표시하였음.
표 1, 표 2 및 제13도에서 알 수 있는 바와 같이 본 발명에 따른 윤활제피복은내열성과 접착성에 있어서 종래기술의 인산아연피복보다 우수하다.
따라서 와이어인발다이스와 냉간단조다이스의 수명은 본 발명의 방법에 의하여 크게 연장되는 것이다.
전술한 바와 같이 본 발명의 방법에 있어서 인산아연칼슘을 윤활예비처리제로서 사용하기 때문에 종래기술의 인산아연피복의 경우보다 높은 결정수 제거온도와 보다 높은 내열성을 얻는 것이 가능해졌으며, 또한 초음파 적용장치를 사용하기 때문에 인산아연칼슘피복의 피복무게를 보장하고 자유로이 조절하는 것을 가능하게 하였다.
뿐만아니라 윤활제로 예비처리된 와이어로드를 스테아린산칼슘 또는 스테아린산나트륨으로 윤활처리하기 때문에 윤활특성은 물론 내열성이 향상될 수도 있다.
또한 테프론과 같은 열가소성수지를 첨가한 금속성비누를 주성분으로 갖는 종래의 윤활제를 와이어로드 인발작업시에 프리다이스윤활제로서 사용하기 때문에 윤활피복의 내열성과 윤활특성을 향상시키고, 냉간가공 공구들의 수명을 크게 연장시키는 것이 가능케하였다.
위에서는 본 발명을 실시하기 위한 선호된 방법을 설명하고 예비하였지만 본 발명은 전술한 실시예에 국한되는 것이 아니며, 첨부된 청구범위내에서 여러가지로 실시될 수 있다는 것이 명백하다.

Claims (7)

  1. 와이어로드의 연속 인발방법으로서, 이 방법은 상기 로드의 스케일을 제거하는 공정과; 상기 로드를 예열시키는 공정과; 70-90℃로 가열된 인산아연칼슘용액으로 상기 와이어로드를 통과시키므로써 윤활처리를 위하여 예비처리하는 공정과; 상기 예비처리된 와이어로드를 세척한후에 스테아린산칼슘 또는 스테아린산나트륨으로 윤활처리시키는 공정; 및 상기 윤활처리된 와이어로드를 건조시킨후 연속적으로 이동시키면서 와이어로 인발하는 공정을 포함하는 와이어로드의 연속인발방법.
  2. 청구범위 1에서, 윤활처리를 위한 예비처리공정에 있어서 인산아연 칼슘용액에 초음파를 적용시키는 것을 특징으로 하는 방법.
  3. 청구범위 2에서, 상기 인산아연칼슘에 적용시키는 초음파의 주파수가 10-60KHz이고 출력이 25W/용액 1리터인 것을 특징으로 하는 방법.
  4. 청구범위 1에서, 상기 인산아연칼슘용액의 성분비(Ca/8m)를 0.3-1.0으로 하는 것을 특징으로 하는 방법.
  5. 청구범위 1에서 윤활공정에 있어서 예비처리된 와이어로드가 실내온도하에서 스테아린산칼슘으로 피복되는 것을 특징으로 하는 방법.
  6. 청구범위 1에서 70-90℃의 온도로 가열한 스테아린산나트륨용액속으로 상기 예비처리된 와이어로드를 통과시켜 피복하는 것을 특징으로 하는 방법.
  7. 제1 내지 6항중 어느 한 항에 있어서, 열가소성 수지와 같은 첨가제 1-10중량%를 갖는, 그 주요성분으로서 금속성비누를 함유하는 윤활제를 프리다이스 윤활제로서 사용하여 상기 건조된 와이어로드를 처리하는 공정을 포함하는 것을 특징으로 하는 방법.
KR1019850003483A 1984-05-21 1985-05-21 와이어로드의 연속인발방법 KR920007834B1 (ko)

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JP59-102339 1984-05-21
JP84-102339 1984-05-21
JP59102339A JPS60260693A (ja) 1984-05-21 1984-05-21 伸線用潤滑剤
JP16415084A JPS6142415A (ja) 1984-08-03 1984-08-03 線材の連続伸線方法
JP59-164150 1984-08-03

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