Copper flat wire is the main material used in the manufacture of electromagnetic wire for transformers. Its conductivity, tensile strength, ductility, and surface quality directly affect the performance and quality of transformer windings.
The traditional copper flat wire processing is rolling-drawing-annealing, which has multiple process steps, long cycle, high cost. The raw material size is related to the product specifications, which is difficult to the produce multi variety and small batch production with different size. The changing product specification needs a lot of time.
The copper flat wire produced by the "upward continuous casting-continuous extrusion" process has fine grain structure with uniform grain distribution, and its performance indicators fully meet the requirements. The elimination of the annealing process not only saves energy but also completely avoids product performance variations caused by uneven furnace temperature during the annealing process. It ensures that the product's performance remains uniform along its entire length, possesses good surface quality, and significantly enhances production efficiency, reduce production cost.
Advantages of continuous extrusion process compared to traditional process
Process and efficiency advantage:
1. Process simplification: Only one continuous extrusion process is needed to directly shape copper rod into copper flat wire, eliminating multiple steps such as drawing and annealing.
2. No need for annealing: As the continuous extrusion process is hot forming, the metal undergoes recrystallization under high temperature and high pressure, and the finished product meets the performance standards without additional annealing, saving energy and avoiding performance fluctuations caused by uneven annealing.
3. High production efficiency: The continuous extrusion machine (such as TLJ300 Continuous extrusion machine) can achieve a production efficiency of up to 480 kg/h.
Quality and performance advantage
1. Dense organization and refined grain size: During the extrusion process, three-dimensional compressive stress promotes dynamic recrystallization, and the grain size can be refined to below 25 μ m .
2. Excellent surface quality: no defects such as burrs, no scratches, etc., high surface smoothness, which is conducive to subsequent insulation paint coating and stable electrical performance.
3. High dimensional accuracy: By controlling the cross-sectional shape through a mold, the dimensional consistency is good.
Economic and environmental advantage
1. High material utilization rate: up to 95% or more, with minimal waste. .
2. Low energy consumption: Compared to traditional multi process processes, the comprehensive energy consumption is reduced by more than 30%.
3. Strong flexible production capacity: quickly switch product specifications (TLJ300 Continuous extrusion machine, width 1-40mm, cross-sectional area 5-200mm ²) by changing molds, suitable for small batch and multi variety production.
The TLJ300 continuous extrusion machine is manufactured by Dalian Konform and mainly used for producing copper&aluminum flat wire. They has been exported to 54 countries and regions. Dalian Konform is the leading company in the continuous extrusion industry, continuously develop new technology to meet customer ‘s demands.