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Interwire 2009 Courses: Fundamentals of Wire Manufacturing Saturday and Sunday, April 25 and 26 Get back to the basics on Saturday and Sunday with WAI's two-day course, "Fundamentals of Manufacturing." You’ll learn the central practices of wire manufacturing as shared by a team of eight instructors who are experts in their respective disciplines. Four general topics (two hours each) will be covered on the first day that apply to everyone in the wire and cable industry. On the second day, instructors will cover sector-specific topics in ferrous and nonferrous/electrical disciplines (four hours each), and then the entire group will reassemble in the afternoon for a combined session featuring general discussion and a question-and-answer forum with all presenters on hand. 8:30 a.m. to 5:30 p.m. General Topics | Instructors • 10:30 a.m. - Cold Rolling of Bar and Wire, Dale Olp, American Spring Wire Corp. 8:30 a.m. to 12:30 p.m. Ferrous Track | Instructors
S u n d a y 8:30 a.m. to 12:30 p.m. Nonferrous/Electrical Track | Instructors
Wire Breaks and Surface Damage 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. A detailed analysis of central bursting (cuppy wire) will include both causes, prevention, and correction. The effects of wiredrawing speed and lubrication will be discussed with respect to generation of fines, shaving, galling, and other surface defects. 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 joined Superior Essex in 1972. He founded the company’s corporate metals laboratory. 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 1992-93. He is the sole or co-holder of 10 patents. Many of his papers have been published in leading technical journals. Dale Olp, American Spring Wire Corp.
There is a trend toward increased cold-roll shaping of steel bar and wire for two key reasons. First, if a part can be rolled, i.e., embodies close to one continuos profile its full length … then this technique can be the lowest cost of all metal parts-making processes. Secondly, this process increases tensile and yield strengths over the normal starting material; surface finishes down to 6 RMS are feasible, particularly in any alloy grades; and standard tolerances are +/- .0015 in. thickness and +/- .002 in width, all of which can reduce material and secondary operation costs. This course provides fundamental information on the manufacture of flat and shaped wire. Topics include common terminology and machine types, configurations, and capabilities including basic tooling types, design and manufacture, along with some general operating techniques. Dale D. Olp is currently the plant and tooling manager for American Spring Wire Corp., Bedford, Ohio, USA. He has spent 39 years in the wire industry, starting his wire career at the age of 12 when his father co-foundered Contours Incorporated in Orrville, Ohio, now a Bekaert company. He worked his way up from the production floor and was the VP of operations when he left. In 1994, he joined Fenn Manufacturing as district sales manager for the machinery division, and in 1996 joined Pittsburgh Tool Steel as the VP of Operations. In 2000, he joined Hoskins MFG as VP of Operations. Throughout his career, he has been active in shaped and flat wire machine selection, design, and operation, along with the design and manufacturing of shaped tooling, and has been instrumental in the conversion of machined parts to near net rolled or drawn shapes. Douglas B. Relyea, Quality Principle Associates
The purpose of Statistical Process Control (SPC) is to understand and reduce all forms of variation in order to solve problems and/or improve productivity. Interactions exist between raw materials and specific pieces of equipment that might cause significantly different productivity metrics between two or more “identical” processes. Once a productivity concern such as low yield, high scrap rate, or low quality is identified, efforts such as sample selection, data collection and analysis are launched. This presentation addresses these steps with examples for wire and cable applications. Author of “The Practical Application of SPC in the Wire & Cable Industry,” Douglas B. Relyea is the founder and senior partner of Quality Principle Associates, LLC, a New England-based consulting firm that specializes in the education and application of data analysis techniques to industrial problem solving. He worked for 20 years at General Dynamics and a Division of Rogers Corporation. He has served as a first line supervisor, quality assurance manager, engineering manager, manufacturing manager, and sales and marketing product manager. In 1987 he left the industry and formed Quality Principle Associates. Rick Gordon, Gerdau Ameristeel
Wire and cable manufacturing involves many processes that must function reliably within given operating specifications. Deviation results in products that are not suited for subsequent operations or delivery to customers. Problems result from many causes including operators, equipment, materials, work methods, measurements, and environment. This presentation examines many problems commonly found in a wire mill and outlines problem solving methodologies for identifying the root causes and implementing appropriate solutions. Specific problems from attendees will be discussed. C. Richard Gordon is technical service metallurgist at Gerdau Ameristeel. He has over 30 years’ experience in the steel and wire industries. He previously worked with the National Standard Company managing groups working in the areas of R&D, quality, and process technology for carbon steel and stainless steel wire products. He is a graduate of the Illinois Institute of Technology with master’s and B.S. degrees in metallurgical and materials engineering. He serves on the Board of Directors for the ASM International’s Notre Dame Chapter and is also a member of ASTM, TMS, and WAI. Joseph Bahadrian
The recent downturn in the world economy will be putting more pressure on North American manufacturers as global competition will become fierce for a strong supply and a weak demand for their products. This presentation emphasizes the interdependency of the different manufacturing activities of fasteners in general and steel fasteners in particular in a cost optimization condition. The effect of raw material selection, forming methods and sequence on the heat treatment and surface finishing of fasteners. The design of new fasteners and coatings in the context of higher energy costs and environmental constraints is also discussed. Joseph Bahadrian was vice president of Ifastgroupe, a division of Ivaco of Montreal, Canada. Ivaco became part of the Heico Group, a holding company headquartered in Chicago, USA, in 2004. Ifastgroupe included Infasco and Galvano in Quebec and Infasco Nut and Ingersoll Fasteners in Ontario. Bahadrian has more than 30 years of experience in the ferrous industry. In 1977 he joined Sivaco (Ivaco) as chief metallurgist of the wire mills. In 1979 he became plant manager at Galvano, Ivaco’s fasteners surface finishing division. In 1998 he became the general manager of Infasco. In 2005 he became the vice president of the Ifastgroupe until he left in 2007. He has published articles on wire and fasteners and is an active member of ASTM. He has been active also in the ISO technical committees pertaining to fasteners. He has a BS in metallurgy and an MBA from McGill University. Anand Bhagwat, WAI Wire & Cable Services
This course discusses critical aspects of spring manufacture that include: types of springs; definitions of key terms and fundamentals of spring design; processing details such as hard drawn structure and oil tempering; properties and tests important for material selection; specifications; and root cause analysis of common spring failures related to steel quality, wire processing, coiling, and design and applications. Anand Bhagwat is managing director of WAI Wire and Cable Services, Pvt. Ltd., Pune, India. Most recently, he was vice president, quality and technology at Seneca Wire & Manufacturing Co., Fostoria, Ohio, USA. Prior to that he was principal metallurgist at the Goodyear Tire & Rubber Company. He has experience in wire manufacturing processes, product development and design, product 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 holds five patents in wire and tire reinforcement technology. Tony Irujo, OFS
This course addresses a number of aspects related to fiber optics. Topics include fiber optics basics, such as fiber’s advantages and fundamental components; fiber as a transmission medium, including construction, multimode vs. single-mode types, manufacturing, and critical parameters; testing, both during manufacture and in the field; fiber designs and uses; basic network architectures; and the evolution of industry standards. Tony Irujo is a sales engineer and customer technical support manager for optical fiber at OFS, the former Optical Fiber Solutions division of Lucent Technologies. Based out of OFS’s multi-mode manufacturing center in Sturbridge, Massachusetts (the former SpecTran fiber manufacturing facility), he provides technical sales and marketing support for multimode and single-mode optical fiber manufacturing, testing, and applications. He started with SpecTran in 1993 as a quality and process engineer and transitioned to more customer-focused roles with Lucent and OFS. He represents OFS in the Fiber Optic LAN Section (FOLS) of the TIA, has authored several papers on fiber technology and applications, and is a frequent speaker at industry events. He holds a BS degree in mechanical engineering from Western New England College in Springfield, Massachusetts. Ron Beeckman, Superior Essex
Magnet wire—or winding wire, as it is known internationally—is an insulated conductor that when wound into a coil and energized creates or uses a magnetic field that is used to transform energy from one state to another. This course covers different types and uses of magnet wire, specifications, materials, manufacturing, and testing. It addresses conductors, terms, definitions, conformance, and periodic testing requirements. Thermal classes—how they are derived and how to use them—is also discussed, along with common wire problems and application issues. Mechanical properties and conformability of magnet wire are dictated primarily by the behavior of the conductor, which is affected by its thermal and mechanical processing history. This course discusses the importance of those properties by addressing essential requirements of the bare wire for subsequent coating, and describing relevant manufacturing schedules and metallurgical controls necessary to process the conductor into a product with suitable properties and which will serve well its purpose in its ultimate application. Ronald J. Beeckman is manager of product applications for Essex Group Inc., Ft. Wayne, Indiana, USA. He has been in the magnet wire industry for the past 35 years. He has held many assignments in process engineering, quality, metals engineering, product development, R&D, and manufacturing for three different magnet wire companies. He has worked in many magnet wire plants and has authored several technical papers for IEEE, NEMA, and Wire Journal International. He is a co-inventor on two US patents on magnet wire. He is a graduate of Western Michigan University. |
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