Method for manufacturing brass-plated steel wire and apparatus for drawing brass-plated steel wire

Abstract

A wire drawing apparatus (10) is used in a final drawing process to ensure adequate initial performance of adhesion between brass-plated steel wire and rubber without a drop in productivity. At least one of the die (14z) disposed in the most downstream position, the die (14y) disposed in the second most downstream position, and the die (14x) disposed in the third most downstream position is a drawing die having a friction coefficient of 0.12 to 0.41 with the brass-plated steel wire. The other dies (14) are drawing dies each having a friction coefficient of 0.1 or below. By using these drawing dies, brass-plated steel wire (13) is drawn, and a noncrystalline portion of high lattice defect density is formed on the surface of the crystalline portion of the brass-plating layer of the brass-plated steel wire (13).

Claims

1. An apparatus for drawing a brass-plated steel wire, the apparatus comprising a plurality of dies for sequentially drawing a steel wire having a brass plating layer on the surface thereof, the plurality of dies comprising: a most downstream die disposed in the most downstream position of a final drawing process; a second most downstream die disposed in the second most downstream position before the most downstream die; a third most downstream die disposed in the third most downstream position before the second most downstream die; and anterior dies disposed in anterior positions before the third most downstream die; wherein the friction coefficient of the anterior dies with the brass-plated steel wire is below 0.12, wherein the friction coefficient of the most downstream die is 0.21 to 0.41, wherein the most downstream die has a larger friction coefficient than the second most downstream die and the third most downstream die, wherein the friction coefficient of second most downstream die is less than 0.1, and wherein the friction coefficient of third most downstream die is less than 0.1.

2. The apparatus for drawing a brass-plated steel wire according to claim 1, wherein the friction coefficient of the most downstream die is 0.21 to 0.22.

3. A method for manufacturing a brass-plated steel wire, comprising: drawing the brass-plated steel wire using the brass-plated steel wire drawing apparatus as recited in claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic illustration showing a wire drawing apparatus according to a preferred embodiment of the present invention.

(2) FIG. 2 is an illustration for explaining a relationship between the friction coefficient of a die and the drawing conditions for the brass-plated steel wire.

(3) FIG. 3 is a table showing the results of investigation on the friction coefficients of the dies used in Examples and the adhesiveness, die life, and wire breaking of the brass-plated steel wires prepared in them.

REFERENCE NUMERALS

(4) 10 wire drawing apparatus 11 lubricant tank 11m liquid lubricant 12A, 12B drive capstan 14 anterior die 14x third most downstream die 14y second most downstream die 14z most downstream die (final die) 15 drive capstan

BEST MODE FOR CARRYING OUT THE INVENTION

Best Mode (Preferred Embodiments)

(5) Preferred embodiments of the present invention will be described hereinbelow with reference to the accompanying drawings.

(6) FIG. 1 is a schematic illustration showing a multistage slip type wet wire drawing apparatus 10 according to a preferred embodiment of the present invention. This multistage slip type wet wire drawing apparatus 10 is used in a final drawing process in which a steel wire having a brass plating layer on its surface is drawn after the process of patenting heat treatment or the like. The wire drawing apparatus 10 includes a lubricant tank 11 filled with a liquid lubricant 11m, multidtage drive capstans 12A and 12B disposed in the liquid lubricant 11m, a plurality of drawing dies 14, 14x, 14y, and 14z, and a drive capstan 15. Note here that the drawing die 14z is a final die (hereinafter referred to as the most downstream die). The drawing die 14y is a die before the most downstream die 14z (the second most downstream die). The drawing die 14x is a die before the second most downstream die 14y (the third most downstream die). The drawing dies 14 are dies disposed before the third most downstream die 14x (hereinafter referred to as anterior dies).

(7) A description will now be given of a final drawing process by a wire drawing apparatus 10. Firstly, a brass-plated steel wire 13 is alternately passed between and engaged with each stage of two multistage drive capstans 12A and 12B which are disposed opposite to each other in a liquid lubricant 11m in a lubricant tank 11. In doing so, the wire is drawn by drawing dies 14 (14, 14x, 14y) in their respective stages. Then, the brass-plated steel wire 13, having been processed to a predetermined diameter after passage through a most downstream die 14z, is sent to a not-shown winding process by a drive capstan 15. Through the process as described above, the brass-plated steel wire 13 is drawn into a predetermined wire diameter (0.1 to 0.4 mm in diameter) by the use of more than twenty dies.

(8) In the present embodiment, a drawing die whose friction coefficient with the brass-plated steel wire is 0.2 (hereafter representing the friction coefficient of a die) is used as the most downstream die 14z of the above-mentioned dies, and drawing dies whose friction coefficient is 0.1 or below are used as the second most downstream die 14y, the third most downstream die 14x, and the anterior dies 14.

(9) It should be noted that the anterior dies 14 are made of cemented carbide such as tungsten carbide (WC) whereas the downstream dies 14x to 14z are diamond dies. The friction coefficients of the dies 14, 14x to 14z are each adjusted by changing the sectional area A0 of brass-plated steel wire before drawing through the die, the sectional area A1 of brass-plated steel wire after drawing through the die, the die angle , and the drawing force Pz to be applied to the brass-plated steel wire 13 in Siebel's equation in relation to the value of the yield stress Y of the brass-plated steel wire 13 to be drawn.

(10) Since the most downstream die 14z has a larger friction coefficient than those of the preceding dies 14y, 14x, and 14, the extreme surface of the drawn brass-plated steel wire 13 is subjected to a heavy-working. As a result, a noncrystalline portion consisting of crystal grains of 20 nm or less in grain size is formed on the surface side of the crystalline portion of the brass plating layer. Therefore, the brass-plated steel wire 13 manufactured in this way has a noncrystalline portion of high lattice defect density on the surface of the brass plating layer, so that heating the brass-plated steel wire 13 in contact with rubber will cause a quick progress of adhesive reaction between the brass-plated steel wire and the rubber. Thus, the initial adhesion performance improves as an adhesion layer is formed quickly between the brass-plated steel wire 13 and the rubber.

(11) When the friction coefficient of the most downstream die 14z is below 0.12, the surface of the brass plating layer remains crystalline without being fully heavy-worked and therefore the progress of adhesive reaction between the brass plating layer and the rubber will be slow. Consequently, it is difficult to improve the initial adhesion performance. On the other hand, when the friction coefficient of the most downstream die 14z exceeds 0.41, the friction between the die and the brass-plated steel wire becomes too large while although the initial adhesion performance may improve. This may accelerate the wear of the die, which will not only shorten the die life but also cause frequent breaking of wire. Therefore, it is necessary that the friction coefficient of the most downstream die 14z be in the range of 0.12 to 0.41.

(12) Note that in the present embodiment drawing dies whose friction coefficient is 0.1 or below are used as the second most downstream die 14y, the third most downstream die 14x, and the anterior dies 14. As a result, no unnecessary processing other than the heavy-working by the most downstream die 14z is done on the brass-plated steel wire 13, so that there results no loss in the performance of the brass-plated steel wire 13. Also, since the friction coefficient of the dies 14, 14x, and 14y is 0.1 or below, the service life of those dies will be long.

(13) Thus, according to the preferred embodiments of the present invention, the wire drawing apparatus used in the final drawing process is such that a drawing die whose friction coefficient with the brass-plated steel wire is 0.2 is used as the most downstream die 14z while drawing dies whose friction coefficient is 0.1 or below are used as the second most downstream die 14y, the third most downstream die 14x, and the anterior dies 14. And a brass-plated steel wire 13 is drawn using these dies, so that a noncrystalline portion of high lattice defect density is formed on the surface side of the crystalline portion of the brass plating layer of the brass-plated steel wire 13. This will not only improve the adhesion performance of the brass-plated steel wire 13 while retaining the die life but also can sufficiently reduce the frequency of wire breaking.

(14) It should be appreciated, however, that although the friction coefficient of the most downstream die 14z is 0.2 in the preferred embodiments, the friction coefficient is acceptable if its value is in the range of 0.12 to 0.41. Also, in those embodiments, the most downstream die 14z only among the dies used in the final drawing process is the drawing die whose friction coefficient is 0.2, but this condition should not be binding. The arrangement may be such that at least one of three dies, namely, the most downstream die 14z, the second most downstream die 14y, and the third most downstream die 14x, is used as a drawing die whose friction coefficient is 0.12 to 0.41. In other words, there may even be two or three drawing dies whose friction coefficient is 0.12 to 0.41. Even in such a case, it should be noted that the friction coefficient of the die or dies other than the one or ones whose friction coefficient is 0.12 to 0.41 is preferably below 0.12, and more preferably 0.1 or below.

(15) Also, as the at least one drawing die out of the three dies 14x, 14y, and 14z, it is preferable to use a drawing die whose friction coefficient is 0.12 to 0.41, more preferable to use one whose friction coefficient is 0.18 to 0.22, and most preferable to use one whose friction coefficient is in the range of 0.18 to 0.21.

EXAMPLES

(16) In the final drawing process, a brass-plated steel wire was drawn with at least one of three dies, namely, the most downstream die, the second most downstream die, and the third most downstream die, used as a drawing die whose friction coefficient was 0.12 to 0.41. The results of investigations on the adhesiveness, die life, and breaking of wire are shown in the table of FIG. 3.

(17) The brass-plated steel wire of Example 1 was drawn with the most downstream die only used as a drawing die whose friction coefficient was 0.20 and the other dies used as drawing dies whose friction coefficient was 0.1 or below.

(18) The brass-plated steel wire of Example 2 was drawn with the most downstream die only used as a drawing die whose friction coefficient was 0.22 and the other dies used as drawing dies whose friction coefficient was 0.1 or below.

(19) The brass-plated steel wire of Example 3 was drawn with the most downstream die only used as a drawing die whose friction coefficient was 0.41 and the other dies used as drawing dies whose friction coefficient was 0.1 or below.

(20) The brass-plated steel wire of Example 4 was drawn with the second most downstream die only used as a drawing die whose friction coefficient was 0.21 and the other dies used as drawing dies whose friction coefficient was 0.1 or below.

(21) The brass-plated steel wire of Example 5 was drawn with the third most downstream die only used as a drawing die whose friction coefficient was 0.20 and the fourth most downstream die used as one whose friction coefficient was 0.11. Note that the friction coefficient of the other dies was 0.1 or below.

(22) The brass-plated steel wire of Example 6 was drawn with the third most downstream die only used as a drawing die whose friction coefficient was 0.20 and the other dies used as drawing dies whose friction coefficient was 0.1 or below.

(23) The brass-plated steel wire of Example 7 was drawn with the most downstream die used as a drawing die whose friction coefficient was 0.18 and the second most downstream die used as drawing die whose friction coefficient was 0.20. Note that the friction coefficient of the other dies was 0.1 or below.

(24) The brass-plated steel wire of Example 8 was drawn with the second most downstream die used as a drawing die whose friction coefficient was 0.21 and the third most downstream die used as drawing die whose friction coefficient was 0.20. Note that the friction coefficient of the other dies was 0.1 or below.

(25) The brass-plated steel wire of Example 9 was drawn with the most downstream die used as a drawing die whose friction coefficient was 0.18, the second most downstream die used as drawing die whose friction coefficient was 0.20, and the third most downstream die used as drawing die whose friction coefficient was 0.21. Note that the friction coefficient of the other dies was 0.1 or below.

(26) Also, for comparison, the brass-plated steel wire (Comparative Example 1) was prepared by drawing it with the dies whose friction coefficient was all 0.1 or below. Also, the brass-plated steel wires (Comparative Examples 2 to 4) were prepared by drawing them with the dies of which at least one of three dies, namely, the most downstream die, the second most downstream die, and the third most downstream die, was a drawing die whose friction coefficient exceeded 0.41. Also, the brass-plated steel wire (Comparative Example 5) was prepared by drawing it with the fourth most downstream die, disposed before the third most downstream die, whose friction coefficient was 0.21, and the most downstream die, the second most downstream die, and the third most downstream die whose friction coefficient was all below 0.12. And the results of investigations on the adhesiveness, die life, and breaking of wire thereof are also shown in the table of FIG. 3.

(27) The adhesion performance was evaluated by the time taken for the brass-plated steel wire to be completely (100%) coated with rubber when it was heated in contact with the rubber. It was represented by an index number relative to that of Comparative Example 1 being 100. The smaller the number is, the better the adhesiveness will be.

(28) The die life was evaluated by the weight of the brass-plated steel wire that can be produced using the die and was represented by an index relative to that of Comparative Example 1 being 100. The larger the number is, the longer the die life and the higher the productivity will be.

(29) The breaking of wire was evaluated by the count of breaking when the brass-plated steel wire was drawn under a tension of 10 tons. It was represented by an index number relative to that of Comparative Example 1 being 100. The smaller the number is, the less frequent the breaking of wire will be.

(30) As is clear from the table of FIG. 3, the brass-plated steel wires of Examples 1 to 9 prepared by a manufacturing method of the present invention show improvements of adhesion performance by 12% to 55% while retaining the die life and frequency of wire breaking equivalent to those of the brass-plated steel wire of Comparative Example 1 drawn with the dies whose friction coefficient was all 0.1 or below. From this, it has been confirmed that the use of the manufacturing method of the present invention can not only improve the performance of adhesion with the rubber without a drop in productivity but also can reduce the frequency of wire breaking sufficiently.

(31) Also, it has been found that the adhesion performance further improves with an increase in the number of drawing dies whose friction coefficient is 0.12 to 0.41.

(32) Also, as indicated by Examples 4 to 6 and Example 8, it has been confirmed that even when the friction coefficient of the most downstream drawing die is 0.1 or below, the adhesion performance improves with the use of the second most downstream and third most downstream drawing dies whose friction coefficient is 0.18 to 0.22.

(33) In contrast to this, when drawing is done with the dies of which at least one of three dies, namely, the most downstream die, the second most downstream die, and the third most downstream die, was a drawing die whose friction coefficient exceeds 0.41, the initial adhesion performance improves in all cases, but the die life becomes shorter, the productivity drops, and the breaking of wire happens frequently. Thus, it has been confirmed that the friction coefficient of dies for heavy-working must be 0.41 or below.

(34) Also, even when the friction coefficient of the fourth most downstream die disposed before the third most downstream die is 0.21, characteristics equivalent only to those of Comparative Example 1 can be obtained if the friction coefficient of three dies, namely, the most downstream die, the second most downstream die, and the third most downstream die, is below 0.12. Thus, it has been confirmed that a die whose friction coefficient is 0.12 to 0.41 must be used as at least one of three dies, namely, the most downstream die, the second most downstream die, and the third most downstream die.

INDUSTRIAL APPLICABILITY

(35) The brass-plated steel wire manufactured according to the present invention features excellent adhesiveness with rubber. Therefore, it can be suitably used not only as steel cords of steel radial tires but also as a reinforcement member for high-pressure hoses, industrial belts, and other rubber articles.