Five common problems of copper wire drawing liquid

Copper Wire drawing liquid, also known as copper Drawing Oil or copper Stretching Oil, is an indispensable and important lubricant in the copper wire drawing process. The quality and performance of the drawing liquid are directly related to the quality and production efficiency of the copper wire. However, during use, the copper wire drawing liquid will encounter a series of common problems. This article will explore the five common problems of copper wire drawing liquid in depth and propose corresponding solutions.

1. Insufficient lubricity leads to wire breakage

The wire breakage problem is one of the most common faults in the copper wire drawing process, and insufficient lubricity is one of the main causes of wire breakage. The lubricity of the drawing liquid depends on its formula and the use of the emulsion, including concentration, emulsification uniformity, emulsification stability and component content. If the lubricity of the drawing liquid is insufficient, the friction between the copper wire and the die will increase, making the copper wire easy to break during the drawing process.

Solution:

Optimize the formula of the drawing liquid to ensure that it can form a stable and uniform oil film during the drawing process.

Check the concentration and emulsification state of the drawing liquid regularly to ensure that it is in the best use state.

Choose high-quality wire drawing liquid to ensure its excellent lubrication performance.

2. Bacterial growth causes emulsion deterioration

Water is the carrier of bacteria, and the emulsifier and some natural ingredients in the emulsion provide a suitable environment for bacterial growth. Bacteria will corrode the emulsifier, turning it into an acidic component, causing the pH value of the emulsion to drop, causing the emulsion to be unstable, demulsified, and accompanied by a special odor. This not only affects the surface quality of the copper wire, but also reduces the lubricity of the emulsion.

Solution:

Regularly monitor the bacterial growth of the emulsion, and use bactericides to control it when the bacterial growth is large.

The best preventive measure is to aerate the emulsion, usually by circulating air into the emulsion to stop the growth of anaerobic bacteria.

Keep the emulsion clean and fresh to avoid contamination and deterioration.

3. Oxidation causes the surface quality of the copper wire to deteriorate

Oxygen and sulfur can easily corrode copper to form compounds such as black CuO, Cu2O and red Cu2S. These reactions may be caused by factors such as anaerobic bacteria, humidity on the copper wire after annealing, and the presence of oxygen during the annealing process. Oxidation will cause the surface quality of the copper wire to deteriorate, affecting the appearance and performance of the product.

Solution:

Antioxidants should be contained in the wire drawing liquid to prevent the copper wire from being completely or partially blackened.

During the annealing process, take effective protective measures to avoid exposing the copper wire to oxygen.

Check the antioxidant content in the wire drawing liquid regularly to ensure that it is within the effective concentration range.

4. Improper fat content affects the thickness of the oil film

The fat content of the copper wire drawing liquid can be simply understood as the thickness of the oil film formed in the deformation zone during the copper wire drawing process. Too high or too low fat content will affect the thickness of the oil film, thereby affecting the wire drawing effect of the copper wire. Too high fat content will cause the oil film to be too thick, causing the copper wire to lose its surface gloss and even produce oil spots; too low fat content will not form a complete oil film, resulting in increased friction and easy wire breakage.

Solution:

Precisely control the fat content of the wire drawing liquid to ensure that it is within the optimal range.

Check the fat content of the wire drawing liquid regularly, and adjust and replenish it in time.

According to different wire drawing process requirements, choose the appropriate wire drawing liquid type and formula.

5. Improper emulsion temperature control affects performance

The normal operating temperature of the emulsion is about 36 degrees Celsius to 45 degrees Celsius. Too high temperature will cause the effective ingredients to volatilize, resulting in large losses and lubrication failure; at the same time, the grease in the emulsion forms a colloid with the copper powder, blocking the die eye and causing wire breakage. Too low temperature will affect the fluidity of the emulsion and reduce its lubrication performance.

Solution:

Install a cooling tower or heat exchanger to reduce the temperature of the emulsion and keep it within the optimal use range.

Regularly check the cooling system of the emulsion to ensure its normal operation.

According to different production environments and process requirements, reasonably adjust the temperature of the emulsion.

Copper wire drawing liquid plays a vital role in the copper wire drawing process. However, during use, five common problems such as insufficient lubricity, bacterial growth, oxidation, improper fat content and improper emulsion temperature control will be encountered. These problems can be effectively solved and the quality and production efficiency of copper wire can be improved by optimizing the drawing liquid formula, regularly monitoring bacterial growth, adding antioxidants, accurately controlling the fat content and reasonably adjusting the emulsion temperature. At the same time, the daily maintenance and management of the drawing liquid should be strengthened to ensure that it is in the best use state and provide reliable protection for the copper wire drawing process.