Advanced Wire Straightening and Plasma Cutting Methods Used in Custom Metal Fabrication Works

by Patrick Duncan Marketing Manager

For wire straightening from a coil, a sequential operation is used. It is important to select the appropriate straightening die according to the wire to be straightened. The head and tail of the straightening die must be placed on the centerline of the straightening cylinder, while the middle three can be cut off the centerline. The wire straightening and cutting machine should be installed on a solid concrete foundation and its shed should be set up in the outdoor work for piling up materials and semi-finished products next to the machine site.

Before starting the operation, the wire straightening machine should be run in idle condition to check the temperature of the bearing, and proper working of the gear. Wire straightening and cutting machines (WSCM) are often used to extend wires from a coil or roll in order to straighten and cut it. Some machines are configured for straightening and cutting all kinds of cold drawing wires and other nonferrous metal wires. These machines are available with various features such as multi-power motor for straightening and cutting.

Avoidable and unavoidable stresses

The wire straightening process may be divided into avoidable and unavoidable stresses. Stress is the reaction of a material to an external load. There is a fundamental correlation between the condition of stress and the condition of deformation of the wire. By taking steps to prevent avoidable stresses and a constant straightening process, continuously better results from the wire straightening process can be achieved. Wire straightening has been shown to change the internal stresses so that the internal stress conditions that were existing in the material in the un-straightened state are eliminated while leaving the straightened wire in the optimal shape.

A wire with fluctuating initial parameters, such as alternating internal stresses and fluctuating material parameters, will be left with varying final curvatures after straightening. This results in the killing of wire and the final product may not have the desired outcomes.

Resolving the issue of helicites

For wire straightening operations, the product is wound into coils. This entails laying of the wire, and winding it in the direction of its coil axis. If the coil is not rotated simultaneously during the laying by the operator, helicites will be produced with each winding. The product will then behave accordingly when it is pulled off. Helicites are an undesired condition for all follow-up processes if it is not specifically created for the product, but it arises unintentionally due to certain production factors. Inconstant helicites not only impede the process flow but also rule out the final product of any required constancy.

Helicities need to be avoided, and a helix straightener can remove helicites. That’s why, Brisbane Metal Products uses helix straighteners and other wire straightening aids that go a long way in resolving the issue. A correct wire straightening process setup depends on an analysis of the straightened material production process, and also an analysis of the wire to be straightened.

Use of plasma cutting in sheet metal fabrication

When it comes to sheet metal fabrication, the recent advances in plasma cutting in Brisbane are offering high-quality cuts at faster speeds that can help reduce the costs related to defects and overtime. Plasma cutting in Brisbane is capable of speeds twice as fast as oxyfuel cutting. The thinner the metal, the better the speed benefits. Thinner metals can be cut by plasma cutting in Brisbane up to 12 times faster than oxyfuel. This results in the cutting of more parts in less time that translates directly to improved operations and increased productivity.

Workpieces made of electrically conductive materials are cut through by the operators using an accelerated jet of hot plasma. The cutting process offers an effective way to cut thick metal sheets. Typical materials that can be cut with the help of plasma cutting in Brisbane include stainless steel, aluminium, brass, copper and other conductive metals. Due to the high speed and precision offered by plasma cutting in Brisbane, the cutting process is widely used in manufacturing, industrial constructions, and larger industrial CNC applications.

Advanced plasma cutting methods

The process of plasma cutting in Brisbane provides excellent performance in small and medium mild steel thicknesses, and cutting of high-alloy steel and aluminium materials in medium and large thicknesses. Plasma cutting in Brisbane under water is used by Brisbane Metal Products that results in very low heat exposure, and low noise level at the workplace. Mechanical plasma cutting in Brisbane is generally used in thin metal processing, metal service centres, construction and works of art. Mechanised plasma cutters are usually much larger than manual plasma cutters, and used by Brisbane Metal Products in conjunction with cutting tables. These cutters can be integrated into a punching, laser or robot cutting system as per the requirements of a project.

You can approach Brisbane Metal Products (BMP) for all your wire straightening and other metal fabrication requirements, such as metal, aluminium, stainless steel. The leading fabricator has over 50 years of experience in custom metal fabrications with nationwide distribution capabilities.