MXPA01001786A - Method and apparatus for manufacturing a wire - Google Patents

Abstract

A method and an apparatus for manufacturing a wire, particularly a sawtooth wire for all-steel sawtooth wire card clothings, wherein the surface of a wire-shaped intermediate product, such as a wire already provided with sawteeth, is smoothened in an electropolishing process in an electrolyte bath containing an electrolyte. A relative movement is produced between the electrolyte and the intermediate product during the electropolishing process. The apparatus includes a device for producing a relative movement between the electrolyte and the intermediate product contained in the electrolyte bath.

Description

METHOD AND APPARATUS FOR MANUFACTURING A WIRE DESCRIPTIVE MEMORY The invention relates to a method for manufacturing a wire, in particular a wire with saw teeth for card linings with saw teeth completely made of steel, wherein the surface of an intermediate product in the form of a wire, like a wire already provided With saw teeth, it is smoothed in an electropolishing process which is carried out in an electrolyte bath containing an electrolyte; The invention also relates to an apparatus suitable for carrying out said methods. All-steel sawtooth wire carcases are used, for example, in the processing of textile fibers into yarns, non-woven fabrics or the like. The individual sawtooth wires of all-steel sawtooth wire cuttings usually have a height of less than 2mm and a width in the area of the tooth tips of 0.2mm or less. In order to manufacture such fine sawtooth wires, typically, initially, an initial material in the form of wire is subjected to one or more stretching procedures, where different heat treatment procedures can be carried out among the various individual stretching procedures to provide a wire already stretched at least partially once more with its deformation capacity. Following this preparation, the wire usually has saw teeth in a suitable drill. The saw teeth produced by the drilling process can also be hardened before or after the drilling process. After the drilling procedure, small perforated ridges remain on the surface of the wires with saw teeth. In addition, the impurities caused by the above processing steps can adhere to the surfaces of the wires with saw teeth, such as scabs, i.e., oxide residues, or dirt residues produced during the heat treatment. These residues in sawtooth wires are dangerous when sawtooth wires are then used to process textile fibers, in particular when using high capacity machines, since individual fibers can adhere to the teeth of the carcass lining. , and this, as a result, increases the tendency to fill with fibers and impurities, such as, for example, steel parts or the like. To avoid these disadvantages, the saw-tooth wires intended for manufacturing steel wire cuttings with all-steel saw teeth, in addition to common saw, are cleaned and polished after the drilling or hardening process. For this purpose, an electrolytic polishing plant is usually used. In the electropolishing process carried out with said electrolytic polishing plant, the material is removed from the surface of the intermediate product in the form of anodically changed wire, like the wire already provided with saw teeth and / or hardened wire, by the use of a electrolyte selected from common specific material and an external direct current source. This material is dissolved by the electrolyte, where the elimination occurs without a mechanical load that acts on the piece to machine, that is to say, the intermediate product in wire form, and produces a smoothing or flattening of the surface of the piece. Consequently, the electropolishing process is in principle the opposite of the electroplating process. In contrast to mechanical removal methods, the flattening achieved in this respect starts at the microscopic scale and, with the increase in the duration of the operation, includes larger structures that are rounded and flattened on the surface. As a result, the electropolished surface is characterized by smoothing and closed structure in the micro scale and a residual ripple in the macro scale that depends on the initial state, the duration of the electropolishing and the structure of the material. When manufacturing sawtooth wires for all-steel sawtooth wire card liners, said electropolishing process is performed by winding the intermediate products in wire form into several layers in a carrier and immersing the intermediates for a time predetermined in an electrolyte bath containing a suitable electrolyte, in which the electropolishing process is carried out. However, it has been found that sawtooth wires obtained with conventional methods have a surface property that varies with the length thereof, so that satisfactory smoothing is not achieved in all areas of the wire surfaces with saw teeth. In view of these problems in the prior art, the invention is based on the object of providing further development of the known methods by which a uniform surface property can be achieved, and an apparatus suitable for performing said methods. With respect to the method, this object is fulfilled through a further development of the method explained above which is essentially characterized in that a relative movement occurs between the electrolyte and the intermediate product during the electropolishing process in the electrolyte bath. This solution is based on discovering that, in conventional immersion methods in which the intermediate product in the form of wire wound in a body is immersed in an electrolyte, the electrolyte does not flow uniformly around all the portions of the wire with teeth of Mountain range. This causes that the treatment does not occur uniformly, especially on the surfaces of the teeth, where in particular when the intermediate product in the form of wire is wound in several layers in the carrier, there is not enough contact between the electrolyte and the tips of the teeth inside the resulting "wire ring"; This also causes insufficient tooth polishing. By using the greater development according to the invention of conventional methods, on the other hand, a uniform treatment is achieved for all portions of the intermediate product in the form of wire submerged in the electrolyte bath, because the relative movement between the electrolyte and the intermediate product has the effect that the electrolyte flows uniformly around this intermediate product which, in turn, results in a uniform and homogeneous treatment during the electropolishing process. As can be understood from the previous explanation of the method according to the invention, the apparatus in accordance therewith for performing the method, in essence, is characterized in that it includes a device for producing a relative movement between an electrolyte contained in an electrolyte bath and the intermediate product in the form of wire submerged in the electrolyte bath. With respect to the technology of the method, it has been found particularly convenient if the intermediate product moves in the electrolyte bath during the electropolishing process. In order to achieve a particularly effective continuous method, the electropolishing process is carried out by transporting the intermediate product through the electrolyte bath, preferably by pulling the intermediate product through the electrolyte bath by means of a transportation device placed in the transport direction of the electrolyte. intermediate product behind the electrolyte bath and acting on the intermediate product. For this purpose, the apparatus according to the invention preferably has a conveying device with two conveyor rollers having roller axes extending in a parallel position with one another, wherein the intermediate product in the form of a wire is held between them. Conveyor rolls and is pulled through the electrolyte bath by rotating the conveyor rollers. In performing the continuous electropolishing processes according to the invention, a treatment time that lasts long enough to achieve a satisfactory treatment, while at the same time ensuring a high processing speed in a relatively small electrolyte bath, can be achieved if the intermediate product is diverted into the electrolyte bath with a suitable deflection device to increase the travel path traveled by the intermediate product in the electrolyte bath. As a result, even if the transport speed is relatively high, the residence time of sufficient duration within the electrolyte bath is achieved, without excessively increasing the size of the electrolyte bath for this purpose. It has been found particularly useful if the intermediate product moves essentially helically around a deflection device placed in the electrolyte bath and which has at least one deflection roller. The residence time of the intermediate product in the form of wire in the electrolyte bath can be adjusted depending on the properties of the intermediate product material, such as the surface property after leaving the electrolyte bath, if the transport speed is controlled depending on the These properties of the material.

Furthermore, the effectiveness of the electropolishing method according to the invention can be increased more if the direct current intensity of the direct current source anodically coupled to the intermediate product that is received in the electrolyte bath is controlled depending on the material properties of the product. intermediate, as the surface properties after leaving the electrolyte bath. With respect to the method, it has been found useful in particular if the intermediate product is pulled by the conveying device from an unwinding reel and, as it moves through the electrolyte bath, it is placed on a winding reel and wound onto it. reel. To increase the efficiency of the electropolishing method of the invention it has also been found useful if the intermediate product is initially mechanically cleaned before performing the electropolishing process; for this purpose, the intermediate product preferably travels through a fixed cleaning device. This mechanical pre-cleaning can be carried out by means of a brush and / or washing discs and results in the elimination of a coarse irregularity, such as notches, scratches and substantial marks or protuberances which can only be removed with great difficulty by means of an electropolishing process which constitutes a treatment fine or very thin. The electropolishing process according to the invention is usually carried out with the use of sulfuric acid and phosphoric acid (35-45%), where chromic acid is avoided as much as possible. The electrolyte bath can also contain various additives or brighteners. In order to ensure a smooth subsequent processing of the intermediate product in the form of a wire after traveling through the electrolyte bath, it is important that the electrolyte residues are completely removed from the intermediate product in the form of a wire. For this purpose, after performing the electropolishing process, the intermediate product is cleaned for convenience; preferably the intermediate product is moved through another fixed cleaning device. This additional fixed cleaning device can have a plurality of cleaning stations, such as water baths, placed one behind the other in the transport direction of the intermediate product, to achieve a complete cleaning of the intermediate product and to prevent the residues of the electrolyte from drag to other stages of processing. It is also conceivable that, after carrying out the electropolishing process and preferably after traveling through the additional cleaning device, the intermediate product has been preserved with a rust protection agent in an appropriate preservation device; for this purpose, the intermediate product is also displaced for convenience through the preservation device, to obtain a continuous operation method. As can be understood from the above explanation of the invention, it is useful in particular if to carry out this method, the sawtooth wire is pulled continuously from an unwinding reel; then it is first moved through a cleaning device designed to perform mechanical cleaning; it is subsequently displaced through the electrolyte bath, where the intermediate product essentially rotates helically through the electrolyte bath to achieve a prolonged residence time; the intermediate product moves after leaving the electrolyte bath through another cleaning device to remove the residues of the electrolyte; then it moves through a conservation device; and then it is placed and wound on a winding reel, wherein the transportation device necessary for this purpose is placed for convenience between the conservation device and the winding reel and includes two conveyor rollers between which the intermediate product is held. Then, the invention will be explained with the aid of the drawing, wherein express reference is made to the drawing with respect to all the details that are essential to the invention and are not set forth in detail in the specification. Figure 1 of the drawing shows a schematic illustration of an apparatus according to the invention that serves to perform the method according to this invention. The apparatus illustrated in the drawing consists essentially of an unwinding reel 10 in which an intermediate product with wire figure is wound in the shape of a wire that already has saw teeth, a cleaning device 20 designed to perform a mechanical cleaning of the intermediate product, an electrolyte bath 30, an additional cleaning device 40 designed to rinse the intermediate product leaving the electrolyte bath, a conservation device 50, a transportation device 60 and a winding reel 70. transport device 60 includes two conveyor rollers 62 and 64 that have roller axes that extend parallel to each other; the intermediate product is clamped between the conveyor rollers 62 and 64. With the rotation of the conveyor rollers 62 and 64 in the directions indicated in the drawing by the arrows P, the sawtooth wire 5 is pulled from the unwinding spool 10. in the direction indicated by the arrow P '. After leaving the unwinding reel 10, the saw-toothed wire 5 is in principle diverted by a deflection roller 12 in a path that essentially extends horizontally and is then conducted in the cleaning device 20. In this device of cleaning 20, the sawtooth wire is cleaned mechanically by two cleaning rollers 22 and 24, where the brushes and / or washing discs can also be used in place of the cleaning rollers. After leaving the cleaning device 20, the sawtooth wire 5 which continues to be transported by the transportation device 60 is driven in the electrolyte bath 30 placed in the transport direction behind the cleaning device 20. Within the electrolyte bath 30, the sawtooth wire 5 travels in a helical manner, in essence, around two deflecting rollers 33 and 34 having roller axes extending parallel to each other and placed inside the bath of electrolyte 30. As the transport device 60 continues to transport the wire with saw teeth 5, the sawtooth wire 5 leaves the electrolyte bath in a horizontal path and enters the additional cleaning device 40 placed in the transportation direction behind the electrolyte bath 30. This additional cleaning device 40 is comp of four water baths placed one behind the other in the direction of transportation in which the wire is rinsed with saw teeth to eliminate waste electrolyte, where the contamination of the individual water baths decreases in the direction of transportation, so that a particularly effective cascade cleaning is achieved with the additional cleaning device 40. After leaving the additional cleaning device 40, the sawtooth wire 5 which continues to be transported by the transportation device 60 is carried to the preservation device 50, where it is preserved with a rust protection agent. Followed by this conservation device 50, the sawtooth wire is moved through the conveying device 60 and then wound onto the winding reel 70. Within the electrolyte bath 30, the sawtooth wire 5 is coupled anodically to a direct current source that is controlled from the outside (not illustrated), where the intensity of the direct current in the electrolyte bath is controlled depending on the surface properties of the wire with saw teeth to ensure optimal treatment of the wire with saw teeth inside the electrolyte bath. The working temperature of the bath is approximately 70 ° C to 580 ° C during the electropolishing process. Prepared as the electrolyte is an aqueous solution without chromic acid of sulfuric acid and phosphoric acid (35-45%) which may contain additional additives, in particular brighteners. The volume of the bath is 600 liters. The control of the electrolyte bath is carried out through a density determination, where the density monitored for convenience by means of a density spindle, preferably is around 1.78 kg / l, where an iron content of 3 g / l already taken into consideration. To control the properties of the electrolyte bath, the electrolyte can be added to the bath or the bath can be diluted with water. In a conventional production process, 10 to 20 liters of water are added to the electrolyte per week, where a partial exchange of the bath takes place from 30 to 40 liters once a week. The invention is not limited to the embodiment explained with the aid of the drawing, but the electrolyte bath can also have a different type of deflection device. In addition, the additional cleaning device may have more or less than four cleaning baths. It is also conceivable to transport the wire with saw teeth along a different extension path through the apparatus according to the invention.

Claims (19)

NOVELTY OF THE INVENTION CLAIMS

1. - A method for manufacturing a wire, in particular a wire with saw teeth for wire card linings with all-steel saw teeth, wherein the surface of an intermediate product in the form of a wire, such as a wire already provided with teeth of saw, is smoothed in an electropolishing process in an electrolyte bath containing an electrolyte, characterized in that a relative movement occurs between the electrolyte and the intermediate product during the electropolishing process.

2. The method according to claim 1, further characterized in that the intermediate product moves in the electrolyte during the electropolishing process.

3. The method according to claim 2, further characterized in that the intermediate product is transported through the electrolyte bath, preferably is pulled through the electrolyte bath by a transport device placed in the direction of transportation of the product intermediate behind the electrolyte bath and acts on the intermediate product.

4. - The methods according to claim 2 or 3, further characterized in that the intermediate product is diverted into the electrolyte bath.

5. The method according to claim 4, further characterized in that the intermediate product moves in a helical shape in essence around a deflection device placed in the electrolyte bath and preferably has at least one deflection roller.

6. The method according to one of claims 3 to 5, further characterized in that the transport speed of the intermediate product and, thus, the residence time of the intermediate product is preferably controlled depending on the material properties of the product. intermediate product, such as the surface property after leaving the electrolyte bath.

7. The method according to one of the preceding claims, further characterized in that the intermediate product is anodically coupled in the electrolyte bath to a direct current source, and the intensity of the direct current is controlled, preferably depending on the material properties of the intermediate product.

8. The method according to one of claims 3 to 7, further characterized in that the intermediate product is pulled from an unwinding reel by the transportation device and, after traveling through the electrolyte bath, is placed on a winding reel.

9. The method according to one of the preceding claims, further characterized in that the intermediate product is mechanically cleaned before the electropolishing process, preferably moving through a fixed cleaning device.

10. The method according to one of the preceding claims, further characterized in that the intermediate product is cleaned after performing the electropolishing process, preferably by moving through an additional fixed cleaning device.

11. The method according to claim 10, further characterized in that the additional cleaning device has a plurality of cleaning stations, such as water baths one behind the other in the direction of transportation of the intermediate product.

12. The method according to one of the preceding claims, further characterized in that the intermediate product is preserved with a rust protection agent after performing the electropolishing process, preferably moving through a preservation device.

13. The apparatus for carrying out a method according to one of the preceding claims, with an electrolyte bath containing an electrolyte to electrolytically smooth an intermediate product in the form of a wire., further characterized by a device for producing a relative movement between the electrolyte and the intermediate product contained in the electrolyte bath.

14. The apparatus according to claim 13, further characterized in that the device for producing the relative movement includes a transport device 60 designed to transport the intermediate product through the electrolyte bath.

15. The apparatus according to claim 14, further characterized in that the transport device 60 is placed in the transport direction behind the electrolyte bath 30 and pulls the intermediate product 5 through the electrolyte bath 30.

16.- The apparatus according to one of the claims 13 to 15, further characterized by a deflection device placed in the electrolyte bath 30 and preferably has at least one deflection roller 32, 34, around which the intermediate product 5 is essentially helically driven.

17. The apparatus according to one of claims 13 to 16, further characterized by a cleaning device 50 for cleaning the intermediate product 5 before performing the electrolytic smoothing.

18. The apparatus according to one of the claims 13 to 17, further characterized by an additional cleaning device 40 for cleaning the intermediate product 5 after performing the electrolytic smoothing.

19. - The apparatus according to one of claims 13 to 18, further characterized by a device for preserving the intermediate product electrolytically smoothed by means of a rust protection agent.