Fixed Cutting and Straightening Machine: The Secret of Ensuring Scratch-free Steel Wire Processing

The straightening rolls of the fixed cutting and straightening machine are not ordinary cylindrical surfaces. Their surfaces are carefully designed, usually adopting a combination of multi-segmented curved surfaces. The radian and angle of these curved surfaces are optimized according to the straightening requirements of steel wires of different specifications. For example, for thin steel wires, the curved surface of the straightening roll is smoother and more conforming to the radian of the steel wire to reduce the contact stress concentration points. During the straightening process, this design makes the contact area between the steel wire and the straightening roll increase uniformly, avoiding local overextrusion and scratches. The multi-segmented curved surface can also be adaptively adjusted according to the bending degree of the steel wire, effectively straightening the wire while minimizing damage to the steel wire surface.

The material of the straightening roll plays a vital role in preventing scratches on the steel wire surface. Generally, alloy materials with high hardness, high wear resistance and good surface finish are selected, such as chromium-molybdenum alloy steel after special heat treatment. This material can not only ensure the shape stability of the straightening roll under long-term high-intensity work, but also reduce its own wear, thereby reducing the risk of the steel wire being scratched by particles generated by roll surface wear. At the same time, the roll surface will be finely polished to make its surface roughness reach an extremely low level, usually between Ra0.01 - Ra0.05μm, ensuring that no micro-scratches will be caused on the steel wire surface when in contact with it.

The fixed cutting and straightening machine is equipped with advanced tension sensors to monitor the tension changes of the steel wire in real time during the straightening and cutting process. Once the tension fluctuates, the control system will quickly respond by adjusting the operation parameters of the traction device and the tensioning device to restore the tension to the set stable value. For example, when a sudden increase in tension is detected, the control system will automatically reduce the traction speed or fine-tune the pressure of the tensioning wheel to avoid scratches on the steel wire surface caused by friction between the steel wire and equipment components due to excessive tension. This real-time monitoring and dynamic adjustment mechanism ensures that the steel wire is always in the best tension state throughout the processing process, providing a strong guarantee for scratch-free processing.

In order to further guarantee the surface quality of the steel wire, the fixed cutting and straightening machine adopts closed-loop control technology to achieve a constant output of steel wire tension. By precisely controlling the speed and torque of the motor, the traction device and the tensioning device work together to maintain the tension of the steel wire constant in each processing stage. Compared with the traditional open-loop control, the closed-loop control can effectively eliminate the tension changes caused by factors such as equipment operation fluctuations and uneven steel wire materials, greatly reducing the problem of steel wire surface scratches caused by tension instability. With the cooperation of a high-precision electronic control system and high-performance drive equipment, the fixed cutting and straightening machine can control the fluctuation range of the steel wire tension within a very small range, usually within ±0.5N, meeting the application scenarios with extremely high requirements for steel wire surface quality.

The traditional cutting method often generates a large impact force at the moment of cutting, which is likely to cause slight deformation and scratches on the steel wire near the cut. The fixed cutting and straightening machine adopts advanced shock-free cutting technology to achieve smooth cutting of the steel wire through a specially designed cutting mechanism and motion control method. For example, a rotary cutting tool is used, and the contact between the tool and the steel wire during the cutting process is gradual, avoiding the instantaneous impact. At the same time, by precisely controlling the cutting speed and the cutting angle of the tool, the cutting force is evenly distributed on the cross-section of the steel wire, effectively reducing the stress concentration and surface damage near the cut.

The material and sharpness of the cutting tool directly affect the cutting quality and the integrity of the steel wire surface. The fixed cutting and straightening machine selects hard alloy tools with high hardness and high toughness, such as YG series hard alloys with a high cobalt content. These tools have excellent wear resistance and sharpness, and can maintain good cutting performance during long-term continuous cutting. When cutting the steel wire, the sharp tool can cut the steel wire quickly and cleanly, reducing the friction and pulling between the tool and the steel wire, thereby avoiding scratches and burrs generated during the cutting process. In addition, the edge of the tool is finely ground and polished to make its surface roughness reach the nanometer level, further reducing the risk of damage to the steel wire surface.

During the steel wire processing process, any tiny impurities may become a hidden danger of scratching the steel wire surface. The fixed cutting and straightening machine is equipped with a complete cleaning system. Before the steel wire enters the straightening machine, its surface dust, debris and other impurities will be removed by an efficient dust suction device and brush. During the straightening and cutting process, there will also be special cleaning components to clean the steel wire surface in real time to ensure that there is no foreign matter adhering to the steel wire. At the same time, the working area inside the equipment will be regularly cleaned to prevent the steel wire from being contaminated by wear particles generated by the equipment itself. For example, sealing covers and dust suction pipes are set around the straightening rolls and cutting tools to timely collect the tiny particles generated by the equipment operation and avoid their contact with the steel wire.

Lubrication is an important means to reduce the friction between equipment components and steel wires and prevent surface scratches. The fixed cutting and straightening machine adopts an intelligent lubrication system, which automatically controls the spraying amount and spraying time of the lubricant according to the running state of the equipment and the processing parameters of the steel wire. The selected lubricant has good lubrication performance and anti-corrosion performance, which can form a uniform protective film on the steel wire surface, effectively reducing the friction coefficient between the steel wire and the straightening roll, cutting tool and other equipment components. At the same time, the lubricant can also play a cooling role, reducing the heat generated by friction and further protecting the surface quality of the steel wire. Under the action of the lubrication system, the friction coefficient of the steel wire during the processing process can be reduced to between 0.05 and 0.1, greatly reducing the possibility of surface scratches.

Through the synergistic effect of the design of high-precision straightening rolls, precise tension control, optimized cutting mechanism and complete cleaning and lubrication system, the fixed cutting and straightening machine successfully ensures that there are no scratches on the steel wire during the processing process, laying a solid foundation for the production of high-quality steel wire products. With the continuous progress of technology, the fixed cutting and straightening machine will continue to innovate and improve in ensuring the surface quality of steel wires to meet the strict requirements of more high-end application fields for steel wire quality.