EuroWire November 2022

Technology News

Nano crystalline diamond dies Ajex & Turner has been engaged in the manufacture of a variety of wire drawing and compacting dies and tools for the wire and cable industries since 1962. The VNT nano dies can be used to draw copper/aluminium for stranding, compacting, bunching, rod break down (RBD), etc.

Groep are required for producing high performance chips using an innovative process. The Kabelschlepp conveying system is also modern and innovative. “We created a unique and absolutely individual system for several machines and materials, which also ensures cutting fluid processing and smooth container loading,” explained Michael Diebel, COO of Kabelschlepp GmbH-Hünsborn. “Our approach was to consider the waste removal and the recycling loop as key components of the complete recycling value chain.” Another focus was placed on achieving a balance between the processes and the machine controllers in close coordination with the customer. The degree of automation of the interfac es makes it possible to remove containers for each truck without specific tools. Using the same modules in multiple ways also reduces the complexity of operation and maintenance. A spokesperson for VDL said, “The system has proven to be ideal in operation. Kabelschlepp have designed and implemented a system that fully meets our high requirements.” Tsubaki Kabelschlepp GmbH www.kabelschlepp.com VDL Groep www.vdlgroep.com Ajex & Turner states that the advantages of VNT nano dies for wire drawing and compacting include lower friction, for better copper and aluminium utilisation; better surface quality – high and bright surface finish; an improvement of 3-4 per cent in raw material utilisation and bet ter life than PCD and tungsten carbide dies; zero per cent tolerance for the entire working life for any metal; and no die pol ishing/re-cutting required for any metal. For aluminium/copper RBD, nano dies are claimed to be better for a continuous process with no metal loss and tolerance breakage or scratches on the wire. To avoid rust, the casings are made from stainless steel grade 304. Ajex &TurnerWireTechnologies Pvt Ltd www.ajexturner.com

They can also be used to draw aluminium alloy wire, nickel silver wire, brass, copper tubes or any metal, and to draw stainless steel, and high- and low-carbon steel wire up to 0.6%C, welding wire or any hard/soft wire of any size and hardness.

VNT nano dies are made with multi-layer coatings of nano crystalline diamond through vapour deposition, which pro- vides a smooth surface with low friction. The dies can be made in sizes from 0.5 to 100mm for drawing, compacting, TW, sector and Z-shapes.

TW die, compacting/ stranding/ bunching die, trolley wire die and sector die

Intelligent waste removal with closed-loop recycling

to use their know-how and experience to devise a clever concept for removing the waste for recycling. VDL consulted the manufacturer at an early phase, during the planning of the workshop, so it was possible to include the removal system in the layout. This avoided subsequent interventions and interfering systems in the production area. After a detailed planning phase, a com plex central chip removal system includ ing container management was built. With intelligent control, it contributes to the safety and functionality of the production plant.

Turning 20 tons of aluminium into a workpiece with a weight of “only” two tons produces a lot of chips, which have to be removed as quickly and reliably as possible to prevent jams and to meet the required production cycle times. The sorted recycling process for 18 tons of material also saves 252,000kWh of en ergy and corresponds to 92,000kg of CO 2 per workpiece, compared to producing it from primary aluminium. Kabelschlepp GmbH-Hünsborn took on this technically complex challenge on behalf of its Dutch customer VDL Groep. The very high figure of 95 per cent swarf volume required Kabelschlepp’s experts

The workpieces manufactured by VDL

The intelligent waste removal enables a sorted recycling loop, despite the high machining volume

Photo credit: Tsubaki Kabelschlepp

32

www.read-eurowire.com

November 2022