Production process of various steel wire ropes
2021-02-26
Production process of various steel wire ropes
Wire rope is an important metal product frequently used in lifting machinery and other transmission parts. According to its surface condition, it can be divided into bright wire rope, galvanized wire rope, and phosphatized wire rope.
1. Bright wire rope
Bright wire rope refers to wire rope that is not galvanized on the surface. The steel wire is drawn from 6.5mm high wire into a thin wire, first twisted into small strands, and then the small strands are twisted into a rope. In 1834, European Orubert invented the world's first wire rope (bright wire rope). In 1939, the Tianjin No. 1 Wire Rope Factory, established in 1939, was China's first metal products enterprise. So far, China has produced and used bright wire rope for more than 70 years.
Its process flow is:
Coil → Pickling → Washing → Zinc Phosphate → Washing → Drying → Cold Drawing → Heat Treatment → Pickling → Washing → Zinc Phosphate → Washing → Drying → Cold Drawing → Wire for rope making → Stranding and steel core → Roping → Inspection → Packaging.
2. Galvanized wire rope
Galvanized steel wire is made by drawing high-quality carbon structural steel such as 45#, 65#, 70#, and then galvanizing (electroplating or hot-dip galvanizing). The surface of galvanized steel wire is smooth, clean, free of cracks, knots, burrs, scratches, and rust. The galvanized layer is uniform, has strong adhesion, and has long-lasting corrosion resistance. It has excellent toughness and elasticity.
The process flow is:
Online → Heat treatment → Lead quenching head → Shelling device → Cold water washing → Hydrochloric acid pickling → Cold water washing → Sulfuric acid electrolytic activation → Cold water washing → Electroplating zinc → Cold water washing → Hot water washing → Drying dehydrogenation → Wire collection and bundling → Inspection and testing → Warehousing.
3. Phosphated coated wire rope
According to the classification of steel wire surface state, there were only bright wire rope and galvanized wire rope in the past. Phosphated coated wire rope is a patented technology that has emerged in recent years. The wire rope making wire is phosphatized, and manganese-based or zinc-manganese-based phosphating is preferentially used. The steel wire is phosphated without any drawing processing, and the phosphatized steel wire is directly used to twist the wire rope. Because the phosphated coating makes the steel wire surface more wear-resistant, the service life of the phosphated wire rope is 2-3 times that of the bright wire rope, and the fatigue resistance of the wire rope is greatly improved.
The process flow is:
Coil → Pickling → Washing → Zinc Phosphate → Washing → Drying → Cold Drawing → Heat Treatment → Pickling → Washing → Zinc Phosphate → Washing → Drying → Cold Drawing → Wire for rope making → Alkali washing → Water washing → Acid washing → Water washing → Manganese-based wear-resistant phosphating → Water washing → Drying → Stranding and steel core → Roping → Inspection → Packaging.
Currently, bright wire rope accounts for about 80% of the total output of wire rope, galvanized wire rope accounts for about 10%, and the rest are plastic-coated wire rope and stainless steel wire rope.
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