Simple questions about FCAW manicuring process

admin

Hello guys,I not an expert in this field and thus have some simple questions about the manufacturing process for flux cored wires.#1. I did my research and found out that in the manufacturing process, there are "forming process" and "drawing process" which seem to require two different machines. Can anyone help me to distinguish what are these two different processes? If you can also give me the link (pic) of each machine, I would really appreciate that!!!#2. I'm not sure if this is the drawing machine? (http://www.miyazakijp.com/images/inf...d65w_dd610.jpg) If this is surely one kind of drawing machine, I'm wondering why there are several spools put on the machines? The machines can draw several formed wires into targeted dimension at the same time? Or the wires need to go from the first part to the last part so that it will be drawn to the right dimension?#3. My final question is: in the manufacturing process, there must be "1st drawing" and "2nd drawing"? Is this necessary for all the factories?           And why there are 1st and 2nd drawings? The machine is different from the above one I provided?Thank you so much for helping me out!!!
Reply:If you google your keywords and follow the hypertext links in wikipedia, you'll probably find the information you seek.Simply, "Forming processes" is the generic term for shaping metal: Stamping, pressing, drawing, molding are all forming processes.Drawing is the process of pulling material through a small opening (a die) that causes the material to have a smaller cross section ("diameter" for round materials). The number of drawings is based on how small the finished product is vs. the feedstock. You can only draw out a certain percentage of the feedstock in one drawing. So multiple drawings are used to stage the process.Hope this gets you started.Be wary of The Numbers: Figures don't lie,. but liars can figure.Welders:2008 Lincoln 140 GMAW&FCAW2012 HF 165 'toy' GTAW&SMAW1970's Cobbled together O/A
Reply:Here's a flux core wire making machine in action."USMCPOP" First-born son: KIA  Iraq 1/26/05Syncrowave 250 w/ Coolmate 3Dialarc 250, Idealarc 250SP-175 +Firepower TIG 160S (gave the TA 161 STL to the son)Lincwelder AC180C (1952)Victor & Smith O/A torchesMiller spot welder
Reply:Simple questions about FCAW manicuring process.....
Reply:I was just thinking that if you fed the machine in the second video with a piece of paper strip and put some green, leafy, rope-like filler in the hopper, you might have something.  "USMCPOP" First-born son: KIA  Iraq 1/26/05Syncrowave 250 w/ Coolmate 3Dialarc 250, Idealarc 250SP-175 +Firepower TIG 160S (gave the TA 161 STL to the son)Lincwelder AC180C (1952)Victor & Smith O/A torchesMiller spot welder
Reply:Originally Posted by mike837goIf you google your keywords and follow the hypertext links in wikipedia, you'll probably find the information you seek.Simply, "Forming processes" is the generic term for shaping metal: Stamping, pressing, drawing, molding are all forming processes.Drawing is the process of pulling material through a small opening (a die) that causes the material to have a smaller cross section ("diameter" for round materials). The number of drawings is based on how small the finished product is vs. the feedstock. You can only draw out a certain percentage of the feedstock in one drawing. So multiple drawings are used to stage the process.Hope this gets you started.
Reply:Originally Posted by OldendumHere's a flux core wire making machine in action.
Reply:Originally Posted by kevintangThanks. May I have one more basic question? What is the normal process BEFORE the forming process? That is, what happens before the machines start to form the steel coils?
Reply:Forhire has shown you the slitter video.  I posted the forming video.  YOU posted a picture of a drawing (sizing) machine.  You want me you find you a video of that damn thing pulling wire to make it smaller?  Find your own damn video of the picture you posted."USMCPOP" First-born son: KIA  Iraq 1/26/05Syncrowave 250 w/ Coolmate 3Dialarc 250, Idealarc 250SP-175 +Firepower TIG 160S (gave the TA 161 STL to the son)Lincwelder AC180C (1952)Victor & Smith O/A torchesMiller spot welder
Reply:Originally Posted by OldendumForhire has shown you the slitter video.  I posted the forming video.  YOU posted a picture of a drawing (sizing) machine.  You want me you find you a video of that damn thing pulling wire to make it smaller?  Find your own damn video of the picture you posted.
Reply:Originally Posted by kevintangAbout #2. Within a forming machine, there are also several sets (processes) to complete the forming. Is it the same as drawing process that the coils cannot be formed to perfect U-form only by passing through one set? So it requires the coils to go through several sets?
Reply:Originally Posted by forhireWhen metal is formed it shrinks and stretches... if your dies are too aggressive or you attempt to perform the shape in the single pass the metal will likely rip and/or wrinkle. Progressive dies allow the material to "flow" into the desired shape. The more steps in your forming process the smoother the finished product. Some materials will need to be annealed between forming steps to address work hardening.I think the term you need to search for is "roll forming", stuff like roofing and gutters are roll formed. Here a video showing metal studs being roll formed. Note how the progressive dies change the material shape.