JP7612271B1 - Manufacturing method of plated special shaped wire - Google Patents

Abstract

The present disclosure aims to provide a method for manufacturing a plated deformed wire that can effectively suppress peeling of the plating layer. The method for manufacturing a plated deformed wire of the present disclosure includes a plastic processing step in which a metallic material wire 30 having a circular cross section is passed through an opening 20 of a die 2 that rotates around a central axis, and the material wire 30 is drawn and twisted to form a deformed wire 31, and a plating step in which the deformed wire 31 is passed through a tank 14 that stores a plating solution containing at least molten zinc, and immersed in the plating solution, thereby forming a zinc-containing plating layer 32 on the surface of the deformed wire 31.

Description

The present disclosure relates to a method for manufacturing plated shaped wire.

Deformed wire is a metal wire whose cross section is a polygonal shape such as a square and whose both ends are gripped and twisted. Deformed wire is also called, for example, a twist bar or a screw bar.

Wire mesh made with deformed wire is lighter than wire mesh made with metal wire (round bar) that has a circular cross section, and the addition of a twist improves its tensile strength. Therefore, wire mesh made with deformed wire has the advantages of being inexpensive, durable, and easy to install when used for fences and barriers. Another advantage of wire mesh made with deformed wire is that it has a high adhesion rate to concrete, making it suitable for use as reinforcing bars, etc.

When wire mesh using deformed wire is used for, for example, fences or railings to prevent damage from animals, the wire mesh is left outdoors and therefore must be rust-resistant. The applicant has previously proposed a method for producing rust-resistant plated deformed wire by passing plated material wire with a circular cross section through a die and drawing and twisting the material wire (see, for example, Patent Document 1).

JP 2018-094560 A

The method described in Patent Document 1 makes it possible to manufacture plated deformed wire in which peeling of the plating layer during and after processing is suppressed. In response to this, the applicant conducted intensive research to manufacture a plated deformed wire in which peeling of the plating layer can be further suppressed than in conventional plated deformed wires, and as a result, completed the manufacturing method of the plated deformed wire disclosed herein.

The present disclosure aims to provide a method for manufacturing plated shaped wire that can effectively suppress peeling of the plating layer.

The method for manufacturing plated deformed wire according to the present disclosure includes a plastic processing step in which a metallic material wire having a circular cross section is drawn and twisted through an opening of a die rotating around a central axis to convert the material wire into a deformed wire, and a plating step in which the deformed wire is passed through a tank that stores a plating solution containing at least molten zinc and immersed in the plating solution to form a zinc-containing plating layer on the surface of the deformed wire.

The method for manufacturing plated irregular shaped wire according to the present disclosure can produce plated irregular shaped wire that can effectively suppress peeling of the plating layer.

FIG. 1 is a diagram showing the steps of a method for manufacturing a plated shaped wire according to the present disclosure. FIG. 2 is a schematic diagram of the wire drawing machine. FIG. 3 is a schematic diagram of a plating apparatus. FIG. 4 is a perspective view of the die. FIG. 5A is an enlarged front view showing openings in the approach portion and the bearing portion of the die. FIG. 5B is an enlarged view of a portion of FIG. 5A. FIG. 6 is a side view of a portion of a plated shaped wire. FIG. 7 is a cross-sectional view of a plated shaped wire.

[Outline of the manufacturing method of plated deformed wire according to the present disclosure]
A method for manufacturing plated deformed wire according to the present disclosure includes, in this order, a plastic processing step in which a metal material wire having a circular cross section is passed through an opening of a die rotating around a central axis and subjected to wire drawing and twisting processes to convert the material wire into a deformed wire, and a plating step in which the deformed wire is passed through a tank containing a plating liquid containing at least molten zinc and immersed in the plating liquid to form a zinc-containing plating layer on the surface of the deformed wire.

The manufacturing method of plated deformed wire of the present disclosure produces plated deformed wire by plastically processing a material wire to produce deformed wire and then plating the deformed wire. If plastic processing such as twisting is performed on the plated material wire after plating, there is a risk that the surface of the plated material wire may be scratched during the plastic processing. In harsh outdoor environments, if there are scratches on the surface of the plated deformed wire after processing, these scratches may cause the plating layer to peel off. According to the manufacturing method of plated deformed wire of the present disclosure, the surface of the plated deformed wire is less likely to be scratched during plastic processing, so the plated deformed wire after production is less likely to have the plating layer peel off and can exhibit good rust prevention effects.

The method for manufacturing plated deformed wire according to the present disclosure can be preferably configured such that the cross-sectional shape of the opening in the die is an approximately polygonal shape with the corners of the polygon rounded with a radius of curvature of 0.7 mm or more, and the speed at which the deformed wire is drawn from the opening of the die in the plastic processing step is 50 M/min or more. According to the method for manufacturing plated deformed wire of the present disclosure, since the cross-sectional shape of the opening of the die through which the material wire passes is an approximately polygonal shape with the corners rounded with a radius of curvature of 0.7 mm or more, the material wire can be plastically processed to produce the deformed wire at a high drawing speed. Therefore, the manufacturing efficiency of plated deformed wire can be improved, and plated deformed wire can be produced at low cost.

The method for manufacturing plated deformed wire according to the present disclosure can be preferably configured such that, in the plastic processing step, when the speed at which the deformed wire is drawn out of the opening of the die is 50 M/min or more, the rotation speed of the die is 556 rpm or more, or the axial length required for one rotation of the deformed wire obtained in the plastic processing step is 100 mm or more and 200 mm or less. According to the method for manufacturing plated deformed wire according to the present disclosure, the axial length (twist interval) required for one rotation of the plated deformed wire after production is short, and the twists are densely present in the plated deformed wire, so that the tensile strength of the plated deformed wire can be favorably improved.

In the method for manufacturing plated deformed wire according to the present disclosure, the plating process can preferably be configured to include a first process of passing the deformed wire through a tank containing hot water and immersing it in the hot water, a second process of passing the deformed wire after the first process through a tank containing cold water and immersing it in the cold water, a third process of passing the deformed wire after the second process through a tank containing acid and immersing it in the acid, a fourth process of passing the deformed wire after the third process through a tank containing flux and immersing it in the flux, and a fifth process of immersing the deformed wire after the fourth process in the plating solution.

[Embodiment of the manufacturing method of plated profile wire of the present disclosure]
A specific embodiment of the method for manufacturing a plated profile wire according to the present disclosure will be described with reference to Fig. 1 to Fig. 3. In the drawings, the same or corresponding parts are denoted by the same reference characters, and the description thereof will not be repeated.

The manufacturing method for plated deformed wire includes at least a plastic processing step in which a metallic material wire 30 having a circular cross section is plastically processed into deformed wire 31 having a polygonal or nearly polygonal cross section and a shape in which both ends are grasped and twisted; a plating step in which a zinc-containing plating layer 32 is formed on the surface of the deformed wire 31 to produce plated deformed wire 33; and a coiling step in which the plated deformed wire 33 is wound and coiled. The plating process includes a first step of passing the deformed wire 31 through a first tank 11 in which hot water is stored and immersing it in hot water; a second step of passing the deformed wire 31 after the first step through a second tank 12 in which cold water is stored and immersing it in cold water; a third step of passing the deformed wire 31 after the second step through a third tank 13 in which acid is stored and immersing it in acid; a fourth step of passing the deformed wire 31 after the third step through a fourth tank 14 in which flux is stored and immersing it in flux; and a fifth step of passing the deformed wire 31 after the fourth step through a fifth tank 15 in which a plating solution containing at least molten zinc (referred to as "molten zinc" in this disclosure) is stored and immersed in the plating solution.

The metallic wire material 30 that is the raw material for the plated deformed wire 33 is preferably an iron wire or a steel wire. The wire diameter of the wire material 30 is not particularly limited, but is, for example, 5.5 mm or more and 7.0 mm or less. The wire material 30 is wound into a coil shape on the unwinding machine 4.

The material wire 30 is subjected to plastic processing such as wire drawing and twisting to become the deformed wire 31. Wire drawing is a plastic processing to thin the material wire 30, and the material wire 30 is gradually thinned to a predetermined wire diameter by the wire drawing. Twisting is a plastic processing to twist the material wire 30 around its axis along the axial direction, and as shown in Figure 6, twisting forms twists at predetermined intervals in the deformed wire 31 and plated deformed wire 33 that are plastically deformed from the material wire 30.

The material wire 30 is drawn and twisted, for example, by passing it through a die 2 installed in a wire drawing machine 1. Figure 2 is a schematic diagram of the wire drawing machine 1 that produces the deformed wire 31.

The wire drawing machine 1 comprises at least a die 2, a die holder 3, a payout machine 4, a winding machine 5, a motor 6, a power transmission mechanism 7, and a box 8.

The unwinding machine 4 and the winding machine 5 are, for example, equipped with cylindrical bodies 41, 51 that can rotate around central axes 40 and 50, respectively. The winding machine 5 is configured so that the cylindrical body 51 rotates due to the rotational driving force from a motor, and winds up the deformed wire 31 after plastic processing. The unwinding machine 4 is configured so that the cylindrical body 41 rotates due to the force of winding up the deformed wire 31 due to the rotation of the cylindrical body 51 of the winding machine 5, and unwinds the material wire 30 from the cylindrical body 41.

The die 2 is placed in the die holder 3 to perform drawing and twisting on the material wire 30. As shown in Figure 4, the die 2 has a cylindrical shape with a circular outer shape in cross section, for example, and has an opening 20 that passes through the die 2 in the direction of its central axis. After being passed through the opening 20 of the die 2, the material wire 30 is plastically deformed while being pulled out of the opening 20, becoming a deformed wire 31.

As shown in Figures 4, 5A and 5B, the opening 20 is formed in the die 2 so as to extend along the central axis of the die 2, centered on the central axis of the die 2. The cross-sectional shape of the opening 20 in the die 2 determines the cross-sectional shape of the deformed wire 31. The cross-sectional shape of the opening 20 is polygonal or approximately polygonal.

The polygon may be a triangle, a rectangle, a pentagon, a hexagon, or any other shape, but is preferably a rectangle. The term "approximately polygonal" refers to a shape in which at least one corner of the polygonal cross-sectional shape of the opening 20 is rounded. Here, rounding the corners does not refer to the inevitable rounding that occurs when wire-cut electric discharge machining is used to form the opening 20 with a polygonal cross-sectional shape in the die 2, but rather refers to performing a process to round the corners of the polygon to, for example, a radius of curvature of 0.7 mm or more, preferably 0.8 mm or more, and more preferably 1.0 mm or more. In other words, a shape in which at least one corner of the polygonal cross-sectional shape of the opening 20 is replaced with an arc with a radius of curvature R of 0.7 mm or more is called an approximately polygonal shape. The substantially polygonal shape is preferably a shape in which all corners of the polygon are rounded, that is, a shape in which all corners of the polygon are replaced with arcs having a curvature radius R of 0.7 mm or more. In this embodiment, the cross-sectional shape of the opening 20 of the die 2 is a substantially quadrilateral shape in which all corners of the quadrilateral are rounded.

The die 2 has an approach section 21, a bearing section 22, and a back relief section in the order that the wire material 30 passes through along the central axis. The approach section 21 is a section in the die 2 for gradually narrowing the wire diameter of the wire material 30. The bearing section 22 is a section in the die 2 for determining the dimensions of the deformed wire 31. In the opening 20 of the die 2, which has a substantially rectangular cross section, the dimension S of the opening 20a in the bearing section, which has the narrowest cross section, is expressed as the distance between two opposing sides of the substantially rectangular cross section (opposite side dimension S) as shown in FIG. 5A. The opposite side dimension S of the opening 20a is not particularly limited, but is, for example, 4 mm or more and 6 mm or less. The back relief section is a section in the die 2 that is tapered away from the deformed wire 31 in order not to damage the surface of the deformed wire 31 drawn through the opening 20 of the die 2.

As shown in Figure 2, the die 2 is fixed in the die holder 3. To twist the material wire 30, the material wire 30 is passed through the rotating die 2, and since the die 2 is integrated with the die holder 3, the die 2 rotates together with the die holder 3.

The die holder 3 is rotatably attached to the box 8. The die holder 3 is a member for holding the die 2 in the box 8 without succumbing to the force of the winding machine 5 pulling the deformed wire 31 out of the die 2. It is also a member for rotating the die 2 as a unit to impart a twist to the material wire 30. The die holder 3 is cylindrical, and the die 2 can be inserted into the die holder 3. The die 2 is inserted into the die holder 3 and fixed in the die holder 3 using a plurality of die fixing bolts or the like.

The die 2 rotates together with the die holder 3 around the central axis of the die 2 as a result of the rotational driving force being transmitted from the motor 6 to the die holder 3 via the power transmission mechanism 7. As long as the rotational driving force from the motor 6 can be transmitted to the die holder 3 to rotate it, the mechanism of the power transmission mechanism 7 is not particularly limited and various conventionally known configurations can be adopted. The power transmission mechanism 7 can be, for example, a combination of a timing belt and a sprocket.

It is preferable that the die 2 rotates at a constant speed in a constant direction during the plastic processing of the material wire 30. At that time, it is preferable that the speed at which the winder 5 pulls out the irregular wire 31 from the opening 20 of the die 2 (the winding speed of the winder 5) is also constant.

When performing the wire drawing and twisting of the material wire 30, the speed at which the deformed wire 31 is drawn from the opening 20 of the die 2 is not particularly limited, but is, for example, 50 M/min to 200 M/min, preferably 80 M/min or more, more preferably 90 M/min or more, and more preferably 100 M/min or more. When performing the wire drawing and twisting of the material wire 30 with the die 2, if the cross-sectional shape of the opening 20 of the die 2 (especially the opening 20a in the bearing portion) is polygonal and the corners of the polygon are not rounded (including the case where there is unavoidable roundness), it is difficult to draw the deformed wire 31 at a high speed of 80 M/min or more, and drawing the deformed wire 31 at a high speed causes problems such as wire breakage. On the other hand, if the cross-sectional shape of the opening 20 of the die 2 (particularly the opening 20a in the bearing portion) is approximately polygonal and the corners of the polygon are rounded, it is possible to draw out the deformed wire 31 at a high speed of 80 M/min or more, thereby improving the manufacturing efficiency of the final plated deformed wire 33 and enabling the plated deformed wire 33 to be manufactured inexpensively.

The number of rotations of the die 2 when drawing and twisting the material wire 30 is not particularly limited, but is preferably 556 rpm or more and 834 rpm or less when the above-mentioned drawing speed is 50 M/min or more. By rotating the die 2 at a high speed within the above-mentioned range, the amount of twist per unit length of the deformed wire 31 can be increased. For example, as shown in FIG. 6, the axial length L required for one rotation of the deformed wire 31 can be set to 100 mm or more and 200 mm or less, preferably 120 mm or more and 180 mm or less, and most preferably 150 mm. In other words, it is preferable to rotate the material wire 30 once at a length of 120 mm or more and 180 mm or less. By setting the interval of the "twists" formed in the deformed wire 31 within the above-mentioned range, the final plated deformed wire 33 has dense twists, and the tensile strength of the plated deformed wire 33 can be improved.

In addition, the wire drawing machine 1 also includes a removal device that physically or chemically removes scale and other particles adhering to the material wire 30 before it is sent to the die 2, and a box containing a lubricant to be applied to the material wire 30 before it is sent to the die 2.

The deformed wire 31 plastically processed by the wire drawing machine 1 described above is plated by being immersed in molten zinc in the plating device 10. The deformed wire 31 is plated to produce a plated deformed wire 33. Figure 3 is a schematic diagram of the plating device 10. The deformed wire 31 is wound on the unwinding machine 16. The plated deformed wire 33 is wound on the winding machine 17.

The plating device 10 is a device that forms a zinc-containing plating layer 32 on the surface of the deformed wire 31 by passing the deformed wire 31 through the fifth tank 15, which is a tank that stores at least molten zinc, and immersing it in the molten zinc. The plating device 10 includes a first tank 11 that stores hot water, a second tank 12 that stores cold water, a third tank 13 that stores acid, a fourth tank 14 that stores flux, a fifth tank 15 that stores at least molten zinc, and a transport device that transports the deformed wire 31 from the first to the fourth layers 11 to 14 in order.

The first layer 11 stores hot water. Hot water is high-temperature water heated to 60°C or higher. The second layer 12 stores cold water, for example at about 20°C. The deformed wire 31 is passed through the first tank 11 and immersed in hot water to raise the temperature of the deformed wire 31, and then passed through the second tank 12 and immersed in cold water to rapidly cool the deformed wire 31, thereby quenching the deformed wire 31.

The third tank 13 stores acid. The acid is a surface cleaning agent that removes rust, oil, and the like adhering to the surface of the deformed wire 31. The acid is not particularly limited, but hydrochloric acid, sulfuric acid, nitric acid, and the like are used. The temperature of the acid is not particularly limited, but is, for example, 50°C or higher and 70°C or lower. By passing the deformed wire 31 through the fourth tank 14 and immersing it in the acid, the rust, oil, and the like adhering to the surface of the deformed wire 31 are removed, making it easier to form the plating layer 32 described below on the surface of the deformed wire 31.

The fourth tank 14 stores flux. The flux is a surface cleaning agent that removes oxides and the like adhering to the surface of the deformed wire 31. An appropriate flux is used depending on the material of the deformed wire 31. The temperature of the flux is not particularly limited, but is, for example, 50°C or higher and 70°C or lower. By passing the deformed wire 31 through the fourth tank 14 and immersing it in the flux, oxides and the like adhering to the surface of the deformed wire 31 are removed, making it easier to form a plating layer 32 (described later) on the surface of the deformed wire 31. The flux-treated deformed wire 31 is then dried, for example, in a drying oven, and then transported to the fifth tank 15.

The fifth tank 15 stores a plating liquid containing at least molten zinc. In addition to molten zinc, the plating liquid may contain small amounts of other molten metals such as molten iron and molten aluminum. The temperature of the plating liquid is not particularly limited, but is, for example, 450°C to 480°C. The plating liquid stored in the fifth tank 15 is heated by a heater to adjust to a predetermined temperature. The deformed wire 31 is passed through the fifth tank 15 and immersed in the plating liquid, so that the plating liquid is attached to the surface of the deformed wire 31. The time for which the deformed wire 31 is immersed in the plating liquid is not particularly limited, but is, for example, 1 second or less. By immersing the deformed wire 31 in the plating liquid at the above-mentioned temperature and time, sufficient plating liquid can be attached to the surface of the deformed wire 31, and a plated deformed wire 33 having a plating layer 32 of sufficient thickness can be manufactured.

The plating liquid adhered to the surface of the deformed wire 31 is wiped off by a wiping device disposed above the fifth tank 15, for example, to control the adhesion of the plating liquid. As a result, as shown in Fig. 7, a plating layer 32 with a predetermined amount of plating liquid adhered thereto is formed almost uniformly on the surface of the deformed wire 31. The amount of the plating layer 32 adhered to the surface of the deformed wire 31 is not particularly limited, but is, for example, 40 g/m2 or ^more , and preferably 155 g/m2 or ^more .

The deformed wire 31 with the plating layer 32 formed thereon, i.e., the plated deformed wire 33, is cooled to room temperature and then wound into a coil on the winding machine 17.

The conveying device is not particularly limited, but for example, conveys the deformed wire 31 to the plating device 10 by roll conveying, and includes at least a payout machine 16, a winding machine 17, and a plurality of rollers 18.

The unwinding machine 16 and the winding machine 17 are provided with, for example, cylindrical bodies 161, 171 that can rotate around a central axis 160 and a central axis 170, respectively. The winding machine 17 is configured so that the cylindrical body 171 rotates by a rotational driving force from a motor, and the cylindrical body 171 winds up the plated deformed wire 33. The plated deformed wire 33 is coiled by the winding machine 17. The coiled plated deformed wire 33 is compressed, bound with a strap, and then packaged. The unwinding machine 16 is configured so that the cylindrical body 161 rotates by the force of winding up the plated deformed wire 33 due to the rotation of the cylindrical body 171 of the winding machine 17, and the deformed wire 31 is unwound from the cylindrical body 161. The multiple rollers 18 are arranged at appropriate positions along the running direction of the deformed wire 31 and the plated deformed wire 33.

According to the above-mentioned manufacturing method of plated deformed wire, the material wire 30 is plastically processed to form the deformed wire 31, and then the deformed wire 31 is plated to manufacture the plated deformed wire 33. If the plated material wire is subjected to plastic processing such as twisting, the surface of the plated material wire may be scratched during the plastic processing. In a harsh outdoor environment, if the surface of the plated deformed wire is scratched after processing, the scratch may cause the plating layer to peel off. According to the above-mentioned manufacturing method of plated deformed wire, the surface of the plated deformed wire 33, which is the finished product after manufacturing, is not scratched by the plastic processing of the material wire 30 during the manufacturing process, so the plated deformed wire 33 is less likely to have the plating layer 32 peeled off, and can exhibit a good appearance and good rust prevention effect. In addition, the plating layer 32 can be formed uniformly on the surface of the deformed wire 31.

As described above, there is a difference in appearance and rust resistance between the conventional method of producing plated deformed wire by plastically processing a material wire that has been plated in advance, and the presently disclosed method of producing plated deformed wire 33 by plastically processing the material wire and then plating the deformed wire. Therefore, by focusing on this difference, it is possible to distinguish between plated deformed wire produced by the conventional manufacturing method and plated deformed wire 33 produced by the manufacturing method of the present disclosure.

The above describes in detail the manufacturing method for plated deformed wire of the present disclosure based on an embodiment, but the manufacturing method for plated deformed wire of the present disclosure is not limited to the above-described embodiment, and various modifications are possible without departing from the gist of the method.

Reference Signs List 1 wire drawing machine 2 die 3 die holder 10 plating device 11 first tank 12 second tank 13 third tank 14 fourth tank 15 fifth tank 20 die opening 30 wire material 31 deformed wire 32 plating layer 33 plated deformed wire

Claims (5)

a plastic processing step of drawing and twisting a metal wire material having a circular cross section through an opening of a die rotating around a central axis to convert the metal wire material into a deformed wire material;
a plating process step of passing the irregular-shaped wire through a tank in which a plating solution containing at least molten zinc is stored and immersing the irregular-shaped wire in the plating solution to form a zinc-containing plating layer on a surface of the irregular-shaped wire;
A method for manufacturing a plated profile wire, comprising: The cross-sectional shape of the opening in the die is a substantially polygonal shape with rounded corners having a radius of curvature of 0.7 mm or more,
2. The method for producing a plated deformed wire according to claim 1, wherein in the plastic working step, the deformed wire is drawn out from the opening of the die at a speed of 50 M/min or more. The method for manufacturing plated shaped wire as described in claim 2, wherein the rotation speed of the die in the plastic processing step is 556 rpm or more. The method for manufacturing plated deformed wire as described in claim 2, wherein the axial length required for the deformed wire obtained in the plastic processing step to be twisted one turn is 100 mm or more and 200 mm or less. The plating process includes:
a first step of passing the deformed wire through a tank containing hot water and immersing the deformed wire in the hot water;
a second step of passing the deformed wire after the first step through a tank containing cold water and immersing the deformed wire in the cold water;
a third step of passing the deformed wire after the second step through a tank containing an acid and immersing the deformed wire in the acid;
A fourth step of passing the deformed wire after the third step through a tank containing flux and immersing the deformed wire in the flux;
a fifth step of immersing the irregular shaped wire after the fourth step in the plating solution;
A method for producing a plated profile wire according to claim 1 , comprising:

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