Wireworks

Wire drawing is a metalworking process used to reduce the cross-section of a wire by pulling the wire through a single, or series of, drawing die(s). There are many applications for wire drawing, including electrical wiring, cables, tension-loaded structural components, springs, paper clips, spokes for wheels, and stringed musical instruments. Although similar in process, drawing is different from extrusion, because in drawing the wire is pulled, rather than pushed, through the die. Drawing is usually performed at room temperature, thus classified as a cold working process, but it may be performed at elevated temperatures for large wires to reduce forces.

The wire drawing process is quite simple in concept. The wire is prepared by shrinking the beginning of it, by hammering, filing, rolling or swaging, so that it will fit through the die; the wire is then pulled through the die. As the wire is pulled through the die, its volume remains the same, so as the diameter decreases, the length increases. Usually the wire will require more than one draw, through successively smaller dies, to reach the desired size. The American wire gauge scale is based on this. This can be done on a small scale with a draw plate, or on a large commercial scale using automated machinery. The process of wire drawing changes material properties due to cold working.

The area reduction in small wires is generally 15–25% and in larger wires is 20–45%. The exact die sequence for a particular job is a function of area reduction, input wire size and output wire size. As the area reduction changes, so does the die sequence.

Very fine wires are usually drawn in bundles. In a bundle, the wires are separated by a metal with similar properties, but with lower chemical resistance so that it can be removed after drawing. If the reduction in area is greater than 50%, the process may require an intermediate step of annealing before it can be redrawn.

Commercial wire drawing usually starts with a coil of hot rolled 9 mm (0.35 in) diameter wire. The surface is first treated to remove scales. It is then fed into a wire drawing machine which may have one or more blocks in series.

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