Manufacturing
Process
Cold Draw: One cold draw pass produces a cold drawn
tube of close dimensions, good surface, and mechanical
properties within the usual limits of cold-worked steel.
Additional passes may be necessary to secure: 1) better
surface finishes, 2) smaller diameters, or 3) longer lengths.
Redrawing:
While a large proportion of tubes receive only one cold
draw pass, many require a number of passes for the reasons
mentioned in the previous section. Because cold drawing
hardens and reduces the ductility of tubes, it is necessary
to anneal them after each cold drawing operation. Before
further cold drawing, the annealed tubes must be cleaned
as mentioned earlier. All tubes receive a final anneal
or heat treatment after the last cold draw pass.
Straightening:
The removal of sweep and camber is performed by a gag
press. The gag press is a straightening device that
can straighten tubes to very tight tolerances. All tubes
are carefully measured for outside diameter, size, and
wall thickness. A protective coat of oil, or rust preventative
can be applied before shipment.
Sink
Drawing: The process consists of pulling the tube
through a die, the hole of which is smaller than the
outside diameter of the tube being drawn. The resistance
of the metal to passage through this restricted space
exceeds the yield strength of the metal at this section,
resulting in a plastic flow. The metal passing through
the die is subjected to stress almost up to its breaking
strength and is thus given a test of its physical fitness
to withstand high stress in its ultimate service. Any
flaw or defect of consequence is brought to light under
this severe treatment.
Chain
speed is automatically controlled so that the tube is
started through the die at a slow speed, and, as soon
as it is fairly started, the speed increases to predetermined
drawing rate. Dies are made with a conical outer surface
which fits in a holder mounted at a die head. Dies are
made with either tungsten-carbide inserts or hardened
tool steel.
The
operation starts when shot blasted tubes are delivered
to the draw bench. A draw bench is a heavy steel frame
or bench on which is located a die head for holding
a die. Louisiana Steel utilizes four draw benches rated
from 50,000 to 1,000,000 pounds of draw capacity. These
benches produce a finished size range of .750 inch to
16 inch outside diameter on rounds, and .750 inch to
12 inch on square and rectangular products.
At
one end of the bench is located a holder to anchor the
die. At the other end a shaft is mounted carrying a
sprocket wheel over which passes a heavy, endless, square
linked chain. This chain lies in a trough on top of
the bench, which extends from the sprocket wheel to
the die head, where the chain passes around an idler
and returns underneath the bench to the sprocket wheel.
The sprocket wheel is driven by a variable motor through
suitable reduction gearing. A carriage called a "plyer"
runs on tracks on top of the bench and over the chain
that lies in the trough between the tracks. The plyer
is equipped on one end with the jaws to grip the tube
and on the other end with a hook to engage a link of
the draw chain. The plyer is connected by cable to a
motor actuated drum by which means it is returned to
the die head after drawing the tube. The jaws grip the
end of the tube, which projects through the die about
6 inches. The material is then pulled through the die
thus reducing the OD. Such a reduction results in a
thickening of the tube wall, which is uniform and predictable;
however, the inside diameter cannot be held to the close
tolerances produced with the use of a mandrel support.
All controls for the draw benches are grouped at the
operator's position near the head so he does not have
to move away from the position when operating the bench.
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