SUNConferences, Southern African Institute of Industrial Engineering 2013

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Investigation of the Effects of Lubricant Fat Content on Drawing Copper Wires
Annanciater Chiduwa, Lungile Nyanga, Samson Mhlanga, André van der Merwe, Givemore kanyemba

Last modified: 2013-06-18

Abstract


The drive towards Lean Manufacturing by manufacturing companies has made it a necessity to reduce defects and produce good quality products first time. In the cable manufacturing industry one way of achieving this is by optimising the wire drawing process. One way to meet the desired quality of the drawn wires is to improve lubricant efficiency through installation of an automatic continuous lubricant fat content control system on the drawing machine. The paper shows a method of finding the optimum lubricant concentration for producing good quality copper wires using Taguchi experiments to analyse the effects of different lubricant fat content levels on the wire surface finish, tensile strength and surface temperature of the wire. The results from the experiments indicate that the surface finish and tensile strength of the wire is affected by low lubricant fat content. The optimum lubricant emulsion strength obtained from the experiments for running a 2.55mm copper wire is 7.5%. When lubricant emulsion strength is below the stipulated minimum 6% the tensile strength decreases by an average of 5% resulting in numerous wire breaks during wire drawing. The proposed design of an automatic continuous lubricant fat content control system is also given.


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