8:30 AM-5:00 PM
Fundamentals of Wire Manufacturing
The popular Fundamentals of Wire Manufacturing is a one-day, pre-conference course designed to give attendees a solid grounding in the essentials of wire and cable manufacturing. Scheduled for the day before the start of Interwire, it includes four general topics in the morning, and four each in a ferrous and nonferrous/electrical track during the afternoon. Lunch is included. It is valuable to those new to the industry, as well as a refresher for seasoned professionals. The course includes a 45-minute question-and-answer session following the end of the last class.
8:30 AM-9:15 AM
“Mechanics of Wiredrawing,” by C. Richard Gordon, C. Richard Gordon Consulting LLC
This course presents fundamental engineering principles and process calculations that are used to design, analyze, and improve metal rod and wiredrawing operations. Topics include a basic overview of wiredrawing mechanics with respect to material behavior and process parameters. Die angle and reduction will be addressed in light of the D-parameter and its practical application. Drawing limits, friction and lubrication, work-piece heating, and temperature effects are also discussed.
9:15 AM-10:00 AM
“Drawing Dies,” by Thomas Maxwell Jr., Die Quip Corp.
This presentation focuses on the die, the most important part of the drawing process. Without it, the best drawing machines, lubricant, and treatment systems cannot reduce the wire diameter. However, with a die, vice pliers, and a hammer, wire can be drawn, albeit slowly, as it has been for over 2,000 years. The intention of this course is to provide an understanding of what makes a die work, how it is designed, causes of failure, and problems with drawing larger sizes.
10:00 AM-10:15 AM
10:15 AM-11:00 AM
“Wiredrawing Lubricant Technology,” by David Gzesh, Blachford Corporation
The wiredrawing process generates significant heat that affects its ability to ensure quality wire production. The amount of generated heat is influenced by the interaction of factors that include the metal composition, surface preparation, production equipment and routine maintenance. This presentation reviews basic lubrication principles, typical lubricant compositions, and routine lubricant maintenance procedures for both ferrous dry drawing and ferrous and nonferrous wet drawing.
11:00 AM-11:45 AM
“Wire Breaks & Surface Damage,” by Horace Pops, Horace Pops Consulting Inc.
This course presents a classification of wire breaks from a perspective that compares material defects to process-related problems. Rod defects will include both casting and rolling issues such as internal voids, foreign contaminants, rolled-in scale, hot cracks, and surface porosity. The effects of wiredrawing speed and lubrication will be discussed with respect to generation of fines, shaving, galling, and other surface defects.
12:00 PM-1:00 PM
1:00 PM-1:45 PM
“Fundamentals of Ferrous Metallurgy,” by Anand Bhagwat, Minova USA Inc.
This introductory course is designed to provide a general understanding of ferrous metallurgical concepts, including phase equilibrium, transformation, strengthening mechanisms, heat treatment, and an overview of steelmaking, and their relevance to the wire technology.
1:45 PM-2:30 PM
“Cleaning and Coating of Rod and Wire,” by Jack McAfee and Rudy Vey, Chemetall US
This course presents the fundamentals of cleaning, pickling, and coating of ferrous wire and rod in preparation for drawing and processing. Proper control and handling in these areas ensures quality of the finished product. The design of these processes impacts the economics of the operation. It is imperative that rather than individual stages, this department should be viewed as a whole as it is critical to success. The course deals with zinc phosphate processes and the advantages and limitations as well as specialty coatings such as salt carriers, lubricants, dry film polymers, and new technologies on the horizon.
2:30 PM-2:45 PM
2:45 PM-3:30 PM
“Ferrous Testing and Properties,” by C. Richard Gordon, C. Richard Gordon Consulting LLC
This course discusses tensile, coiling, wrap, reverse bend, torsion, fatigue, and hardness testing procedures. It illustrates interpretation of test results in terms of sample properties.
3:30 PM-4:15 PM
“Ferrous Heat Treatment,” by C. Richard Gordon, C. Richard Gordon Consulting LLC
This course focuses on heat treatment of ferrous metals. It includes basic heat treating principles applicable to many metals with specific examples related to heat treatment of steel rod and wire.
1:00 PM-1:45 PM
“Stranding & Cabling," by Peter M. Blackford, Cable USA LLC
This presentation documents the stranding process for nonferrous conductors, specifically bare copper and tinned wire, as well as assembly of multi-conductor cables. Different processes that are addressed include bunching and concentric constructions, silicone blocked stranding, as well as cable assembly techniques, and rationale for each type. Specific applications include industrial and energy sectors, electronics and data communications, the automotive industry, consumer products, and appliances.1:45 PM-2:30 PM
“Extrusion,” by Erik A. Macs, Wire & Plastic Machinery Corp.
This course starts with a discussion of the basics of the various polymers used for wire and cable insulation. This is followed by discussion of the construction aspects of rubber and thermoplastic extruders. The remaining components of typical extrusion lines are reviewed and include payoffs, dancers and accumulators, preheaters, crossheads, cooling troughs, capstans, online measurement and testing equipment, online printing, take-ups, and operator control systems.
2:30 PM-2:45 PM
2:45 PM-3:30 PM
“Fundamentals of Electrical Testing,” by Peter M. Blackford, Cable USA LLC
This fundamentals course is geared to providing a general overview of electrical testing. The course highlights key terms, standards, and tests that are common to the wire and cable industry for conductors and insulations, and highlights specific concerns of various industries and product types.3:30 PM-4:15 PM
“Wire and Cable Manufacturing Problem-Solving,” by Stacy Martin, General Cable Corporation
This course is a demonstration of problem-solving techniques used to solve real challenges faced in the wire and cable industry. Actual scenarios are used to challenge attendees to think beyond the obvious symptoms and find the root cause. Lean Six Sigma problem-solving strategies are utilized as the course walks through each problem until the cause is identified. The audience is encouraged to participate in this interactive course.
All the instructors for the Fundamentals courses get together at the end of the program for an open session of questions and answers with the audience. The 45-minute session immediately follows the end of the last class.