FUNDAMENTALS OF WIRE MANUFACTURING
MONDAY, APRIL 22 | 9:00 a.m. - 5:00 p.m.
9:00 a.m. - 10:20 a.m.
Measurement and Controls | Keith Donahue, Zumbach Electronics Corp.
This course examines measurement and controls for hot rod rolling, wiredrawing, extrusion, insulation, and jacketing. It discusses the requirements of each process for measurement of diameter, shape and profile, temperature, eccentricity, capacitance, surface defects, spark faults, wall thickness, and length and line speed. It also describes the technologies available to address these needs, including laser scanning, X-ray systems, multi-axis scanning, infrared "heat flow" sensors, and ultrasonic technology. The course also outlines advantages and disadvantages of these solutions.
Keith Donahue is vice president sales and marketing for Zumbach Electronic Corp. He joined the company in 1987 as a field service engineer which started his 25-year career of traveling extensively in the wire/cable, steel/metal, and extrusion industries to troubleshoot problems and to later consult for new applications. He holds a B.S. degree in electrical engineering from Union College in Schenectady, New York, USA, and an M.B.A. degree from Villanova University, USA.
10:30 a.m. - 11:50 a.m.
Fundamentals of Ferrous Metallurgy | Anand Bhagwat, Minova International
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.
Anand Bhagwat is Mining Bolting System Lead at Minova International, a Ground Support company for the mining industry. Before joining Minova, he was plant manager at FENIX, LLC, a subsidiary of Seneca Wire Group. He was managing director of WAI Wire and Cable Services, Pvt. Ltd., Pune, India from 2006 to 2009. He has experience in wire manufacturing processes, quality, product development and failure analysis, and development of steel rod suppliers. He holds an M.B.A. degree and an M.S. degree in Materials Science, both from Case Western Reserve University, Cleveland, Ohio, USA, and a B.S. degree in metallurgy from the College of Engineering, Pune, India. He also holds six patents in wire and tire reinforcement technology.
10:30 a.m. - 11:50 a.m.
Metallurgy and Technology of Electrical Conductors | Horace Pops, Horace Pops Consulting Inc.
The course covers the technology and metallurgy of copper and aluminum conductors. It addresses topics that include the following: requirements for conductors, magnet wire, metals vs. alloys, processing of electrical conductors, electrical properties, the role of oxygen in copper, effects of impurities, annealing behavior, annealability, thermal mechanical production variables, surface effects, and the properties of copper vs. aluminum.
Horace Pops is president of Horace Pops Consulting, Inc., Ft. Wayne, Indiana, USA. He previously was director, metals laboratory at Superior Essex in Ft. Wayne. He holds an Sc.D. degree from the University of Pittsburgh and an M.Met.E. degree from Lehigh University, and a B.Met.E. degree from Rensselaer Polytechnic Institute. He was president of the Wire Association International from 1992 to 1993. He has received numerous honors from WAI, including its Mordica and Donnellan Memorial Awards as well as 16 paper awards spanning 1976 to 2008. He is the sole or co-holder of 10 patents.
1:00 p.m. - 2:20 p.m.
Mechanics of Wiredrawing | Joseph P. Domblesky, Marquette University
This course covers basic engineering principles and process calculations that are used in wiredrawing processes for metal rods and wires. Topics that will be covered include stress-strain curves, material heat-up during drawing, and friction. Calculating reductions and draw forces for sizing drawing stands using standard engineering formulas will also be considered. Also the effect of alloy chemistry will be considered on drawing performance along with an overview of common die materials.
Joseph P. Domblesky is an associate professor in the mechanical engineering department at Marquette University in Milwaukee, Wisconsin, USA, where he teaches manufacturing processes/enigneering and performs research in mass finishing and metal forming. He also teaches a workshop in die stress analysis for the cold and hot forming industries. He has been with Marquette since 1996. He previously held positions at General Motors and MSW Inc. as a manufacturing engineering and tool room supervisor. He holds B.S. and M.S. degrees in industrial engineering from Penn State University and a Ph.D. in metal forming from Ohio State University. He is a licensed Professional Engineer in Wisconsin.
2:30 p.m. - 3:50 p.m.
Wiredrawing Lubricant Technology | David Gzesh, Blachford Corporation
The wiredrawing process generates significant heat. This heat affects the lubricants' 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, and production equipment. This presentation reviews basic wiredrawing lubrication principles and the lubricants chemistry. A review of basic issues demonstrates the importance of understanding how the lubricant chemistry interacts with other wiredrawing factors.
David Gzesh is an application specialist with Blachford Corporation, USA. He has been developing and servicing metal-working lubricants for over 35 years. During this time, he became a senior product chemist for the various successors of the RH Miller Company beginning with Pennwalt, Elf Atochem, Henkel, and Condat. He holds B.S. and M.S. degrees in chemistry from the University of Pittsburgh. He is a longtime member of the Wire Association International, the Society of Tribologists and Lubrication Engineers, and the American Chemical Society.