Heavy Fabrication and Machinery Job Work

We, at Vivek Enterprises, are committed towards providing excellence in our heavy fabrication and machinery job works. Our years of experience allow us to offer a wide variety of custom precision wires to our manufacturing clients. Our strength comes from our engineers and workers who develop precision wire forms for a large variety of applications. Features Corrosion resistant Superior strength Easy fabrication Low maintenance Low thermal conductivity High load capacity Resistant to chipping and cracking Vivek Enterprises is capable of undertaking Heavy Fabrication and Machinery Job Work of upto 1.50- 4.5meter length. We can take up turning jobs of 2.5 meters 0 x 600 mm. and of 1.5 meters x 4.5 meters. We are well known in the industry for our quality and time bound-working style.

Features Capability: As per the buyer's specifications Place of origin: India

Wire Straightening and Cutting Machines

Wire Straightening and Cutting Machines are widely used to extend wires from a roll or coil in order to cut them. For straightening the wires, wire straightners are used that extend the wires and straighten them as required for the desired purpose. These machines are offered with extensive features requiring diverse applications. Some machines are configured for straightening and cutting all kinds of cold drawing wires and other nonferrous metal wires. They may cut the wire automatically in the required dimension and thereafter, work continuously. These machines are available with various features such as different diameter size wires for straightening, different cutting lengths and standard multi-power motor both for straightening and cutting of wires. These machines are available in automatic versions for convenience, ease and to increase productivity. These automatic machines are particularly used for drawl wires and are particularly fit to straighten mild steel wires. Features These machines are available with various features such as different diameter size wires for straightening, different cutting lengths and standard multi-power motor both for straightening and cutting of wires. These Machines are designed for straightening and cutting any kind of metal wire/bar or non - metal wire/bar such as, steel bar for construction, welding rods, netting - wire, fan netting hanger, refrigerator netting, shopping basket, shoes rack, book stand, domestic fowls cage, record stand and the other kinds of steel wire etc. These machines are easy to operate. Moreover, it rotates smoothly and noiselessly, precise in its measure and strong in its structure. During the operation, the shifting of a cutter cooperatively ceaselessly continues the feeding of wire/bar and the cutting action. Our machines are known for their high speed and high precision. They are designed in such a way so as to give out a high output, high precision and a fast changeover.

Features Capability: As per the buyer's specifications Place of origin: India

Wire Drawing Machinery

The Wire Drawing Machinery is of two types, namely the Dry Wire Drawing Machine and the Wet Wire Drawing Machine. We manufacture multi spindle and multi dies as 13 die, 17die and 21die machines with spoolers or with vertical drum attachments for coiling the finished wire sizes at a fixed speed or variable speed with A.C. drives and D.C. drives. Features High efficiency circulation pumps for lubricating the dies. Hardened and helical teeth ground gears submerged in lubrication oil. High Carbon high chromium/tungsten carbide made cone rings as per customer's choice. Final Speeds: 400 to 800 meters/minute. All rotating parts dynamic balanced. Variable A.C. drives and D.C. drives (Optional) Material Drawn: Stainless Steel Wire, Mild Steel Wire, Galvanised Wire, Nichrome Wire, Copper & Aluminium Wire Main body with base, drawing drum and drawing die box of close grain Cast Iron Water-cooling arrangement provided inside the Drawing Drum and the Die Box Phosphorous bronze gears with high carbon axle steel worms Suitable for making Nail Wire from 8 mm or 6 mm input rods up to 2 mm Also suitable for making Wire used to make Barbed Wire, Wire Mesh, etc. Wet / Slip type Fine Wire Drawing Machine also available - Details on request Wire Pointing Machines This machine is suitable for pointing different types of materials like Mild Steel, High Carbon Steel, Aluminium, Copper, etc. The pointing rolls are made of EN-31 material and are ground finished. They are driven by power as well as by hand. The machine is mounted on 4 wheels, thereby making it mobile and useful to serve several drawing machines. The machine is of a swiveling type with12mm-0.8mm thickness of wires. Descaling Attachments This attachment is designed in such a way so that it is suitable to fit with the first block of the wire drawing machines in order to remove the scales from the inlet wire rod. Die Polishing Machine is also supplied with 1HP/3 Phase Electric Motors.

Features Capability: As per the buyer's specifications Place of origin: India

Wet Wire Drawing Machine

Multi Spindle and multi dies as 13 die,
17die, 21die machines with spooler or
with vertical drum attachment for
coiling the finish wire sizes at a fix
speed or variable speed with A.C.
drives and D.C. drives.

Features:
High efficiency circulation pump for lubricating the dies.
Hardened and helical teeth ground gears submerged in lubrication oil.
High Carbon high chromium/tungsten carbide made cone rings as per customer's choice.
Final Speeds: 400 to 800 meters/minute.
All rotating parts dynamic balanced.
Variable A.C. drives and D.C. drives (Optional)

Material Drawn: Stainless Steel Wire, Mild Steel Wire, Galvanised Wire, Nichrome Wire, Copper & Aluminium Wire

Wire Galvanizing Plant

10 line to 40 line Cold Dip/Hot Dip Galvanising
Feeding - Continuos Annealing/Pre Annealed Wire
Fumeless Pickling/Conventional Pickling
Horizontal Takeup/Vertical Drop Coiler
Customised Coil Weight (15 Kg. to 500 Kg.)
Size Range: 6mm to 1.6mm / 1.4mm to 0.8mm / 0.7mm to 0.2mm

Wire Drawing Machine (BB.Block Type)

Input Size : 4.0mm to 2.7mm
Finish Size : 1.2mm to 0.8mm
Final Speeds : 400 to 700 meters/minute

MIG Wire Plant

Drawing, Copper Coating and Spooling Line for Welding wire, working on only one vertical plane, with no torsion of the wire. Independent pulling capstan, after the treatment tank with variable drive.
Maximum Speed: 10 Meter/second
Maximum Production Per Day: 2500 Kgs. (Size: 1.0mm)
Feeding Size: 2.5mm to 2.0mm
Finish Size: 1.6mm to 0.8mm
Machine Combination: Dry Blocks / Wet Wire Drawing Machine

8 Blocker Binding Wire Machine

Input Size: 2.6mm to 2mm
Finish Size: 1mm to 0.8mm
Speeds: 300 meters to 425 meters per minute
Feeding Material: Mild Steel Annealed Wire
Production Per Day: 2400 Kgs. (Size: 0.9mm)

Wire Annealing Furnaces

Material Handling Equipments
Electric Operated Wire Rope Hoists
E.O.T. Cranes

WET WIRE DRAWING MACHINES

Wet wire drawing machines are suitable to draw low, high carbon and stainless steel wire. For certain applications like CO2 welding wire and steel cord wire for automotive tires special machines types have been developed.

The machines are generally designed and built to draw intermediate size wire from about Max 3.5 mm to 2.0mm to a finish size of 1.2mm - 0.6mm. and are generally of the so called wet slip type.

There are 2 basic wet slip machine types.

A)

The machine where the elongation is compensated for by increasing the draw race rpm via the transmission gear ratios. These machines are generally designed to accommodate anywhere from 6-19 dies.

B)

The cone type machine where the the elongation is compensated for by increasing the draw race diameters sequentially, are generally designed to accommodate anywhere from 12 dies to in some cases as many as 32 dies. This is done by using different machines executions with 2 or 4 or 6 and exceptionally 8 couples of drawing cones each with 5-6 draw races per shaft.

Both machine types as an inherent result of the design have fixed elongation ratio between each die. As a result the die sizes has to be selected so that the area reduction through each die is slightly higher then the theoretical area reduction that would match the fixed elongation. This way the draw race for the second die will pull through more wire than is called for by the 3rd and subsequent drawraces and as a result the wire will constantly slip on the draw races. The slip factor is normally 1-3 %. While the finish diameter can be determined and adjusted by varying the inlet diameter and the reduction taken through the inlet die plus the number of draw races used the slip factor can to a degree also be used to fine tune a draft serie.

Below is a number photos of various machine types.

Steel making a brief introduction

For some steel wire products the wire rod represents more than 80% of the variable cost of the production. It therefore seems appropriate to dedicate a chapter to the process of steel making and the various techniques employed in producing the wire rod. This way the viewer gets a better understanding of the up-stream process steps that are neccessary to provide a wire rod that meets the specific requirements of the end product of various wire products.

Process flow chart

Electroplating

Electroplating is the process of producing a metallic coating on a surface by electrodeposition - i.e., by the action of an electric current. Such coatings may perform a mainly protective function, to prevent corrosion of the metal on which they are deposited: e.g., plating with zinc (electrogalvanizing) or with tin; or a decorative function: e.g., gold and silver plating; or both functions: e.g. chromium plating. The principle of electroplating is that the coating metal is deposited from an electrolyte - an aqueous acid or alkaline solution - on to the base: i.e., the metal to be coated. The latter forms the cathode (negative electrode). A low-voltage direct current is used; the anode is gradually consumed. Various substances (addition agents) are added to the electroplating bath to obtain a smooth and bright metal deposit. These are principally organic compounds, usually colloidal. Sometimes the objects to be plated are coated with two or more layers of different metals; for example, chromium plating cannot suitably be applied directly to a zinc-sprayed base; a coating of copper followed by a coating of nickel must be applied intermediately before the chromium is deposited.

Photo courtesey of Outokumpu WTT AB

To obtain a good and firmly adhering coating it is necessary to subject the objects or components to a thorough cleaning.. This may be achieved by by degreasing with organic solvents; or by chemical methods such as pickling with acid or degreasing by the action of alkalizes (saponification); or by electrocleaning, which is a method of cleaning by electrolytic action (more particularly the scrubbing action exercised by the evolution of gas at the surface of the metal). Wetting agents or emulsifiers may be added. The vats for electroplating baths differ greatly in size, shape and lining material (glass, lead, etc.), depending on the size and shape of the components to be plated and on the chemical character of the bath. Electroplating is normally done with direct current. However, particularly with cyanide copper baths, improved smoothness and uniformity of the coating can be obtained by means of the so-called periodic-reverse process, in which the polarity is periodically reversed, so that the metal is alternatively plated and deplated.

Wire is plated with zinc or with tin in continuous and largely automated high-speed processes. The electrolytic zink-plating process illustrated schematically above and in the picture below comprises the following operations: electrolytic cleaning in dilute sulfuric acid, pickling, electrodeposition of zink, so called progressive rinse and air wipe drying after which the wire is taken up on a carrier or spool.

Multi-wire and single-wire Electroplating plants like the one shown in the above picture are available for all types of electroplating and are designed in accordance with the customer's specification. The modern equipment offered includes a newly developed systems for plating at higher speeds (higher current densities) of zinc and copper, with acidic electrolytes. Wires of different diameters can be plated in the same plant. Typical applications include nickel and copper on stainless steel, tin and nickel on steel or copper alloys, silver on copper alloys, zinc on steel (staple wire) and brass on steel (tire cord).

Salt bath furnaces

Modern Salt bath furnaces are used for a number of heat treatment applications such as: Preheating • Austenitizing • Martempering • Neutral Hardening • High-Speed Tool Hardening • Tempering Nitriding • Carburizing • Solution Heat Treating • Dip Brazing

Modern systems offer quick ramp-up and high heating uniformity with temperatures maintained to within 5 degrees throughout the bath providing high and uniform processing results

Today's furnaces are heated by electricity, oil or gas. In procuring Salt Bath Furnaces special attention should be given so operator safety standards and local environmental requirements are met and that waste treatment technologies involved meet government regulations and provide for a comprehensive and cost-effective waste management such as effective sludge removal systems.

Modern systems included modular stages in order to accomodate pre- and post-treatments that are combined with fully programmable controls that offer precise in-line processing capabilities.

Typical wire and wire rod applications include: Annealing •Nitriding •Melting •Tempering •Hardening •Brazing •Galvanizing •Aluminizing as well as Surface treatment of various metals & alloys

Typical processing tempratures for wire applications are 500°C to 1100°C (900°F to 2000+°F)

The electrically heated furnaces are equipped with either resistance or silicon carbide heating elements, mounted externally to either a square or round metal pot holding molten media.

At elevated temperatures silicon carbide heating elements are prefered. The elements are made in one piece from high-density, high-purity, self-bonded silicon carbide.

For a round pot furnace helically-wound wire heaters are a common configuration.

Schematic view of Furnace with over - the - top mounted electrodes
Features include: 6" thick tile walls make the pot last for years. The removable electrodes can be changed without emptying furnace.
The use of large cross section electrodes assure long heater life and provides electrodynamic circulation for uniform temperature.

Furnace with submerged electrodes Operating temprature 850&degC to 1260&degC (1550°F to 2300°F) for Austenitizing

Submerged electrodes provides long life & trouble free service with periodic maintenance. Electrodes, embedded in the wall, below the salt line,are sealed against corrosive attack at the air-salt interface. The submerged electrode design also lends itself to economical 3 phase operation in deeper furnaces when 2 or more tiers of electrodes are utilized.

Isothermal Quench Furnaces
For Austempering & Martempering

Molten salt quenching for austempering or martempering requires a furnace capable of several functions, and the resulting designs are much different from salt bath furnaces employed in heating or austenitizing work.

Four primary factors should be considered for all Quench Furnaces:

1.Bath Temperature Uniformity is essential for consistent metallurgical properties. Internal heating of the bath can be accomplished electrically by using either immersion heaters or electrodes. Gas-fired immersion tubes can also be employed. It is important to automatically dissipate heat from work being quenched by either internal or external cooling means. For light duty, forced air or air/water can be directed to the exterior of the pot. For heavy duty, controlled cooling is provided by internal coils, using water or air/water injection.

2.Proper Agitation of the bath is necessary to remove heat quickly and efficently from the work.mConstant or variable speed propeller agitation provides a uniform flow through the workload being quenched.

3. To achieve optimum hardness and other physical properties, foreign bath contaminants must be removed. In most furnaces this is accomplished by a continuous filtering and automatic dumping. A common system like that supplied by AJAX Electric Company comprises a scoop-shaped filter basket connected to a driving cylinder mounted adjacent to the furnace wall, the basket is automatically raised up and out of the bath - automating chloride removal. Readily installed on new furnaces, the mechanism can also be retrofitted on existing salt baths.

4. For isothermal quenching of heavier sections, water increases quenching power. Small amounts of water added to a nitrate-nitrite salt drives vapor from the bath as hot work enters and gives a faster cooling rate. Both manual and automatic systems are available for adjusting the frequency and duration of water additions.