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Straightening Tips-1 10-5-16

This document discusses wire straightening theory and practices. It describes the two main methods for straightening wire - roll straighteners and rotary straighteners. Roll straighteners bend the wire around rolling bearings while rotary straighteners rotate dies around the wire as it is pulled through. The document provides tips for achieving the best straightening results, including maintaining a straight wire path, consistent back tension, lubrication, and using rotary straighteners for higher tensile wires.

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62 views1 page

Straightening Tips-1 10-5-16

This document discusses wire straightening theory and practices. It describes the two main methods for straightening wire - roll straighteners and rotary straighteners. Roll straighteners bend the wire around rolling bearings while rotary straighteners rotate dies around the wire as it is pulled through. The document provides tips for achieving the best straightening results, including maintaining a straight wire path, consistent back tension, lubrication, and using rotary straighteners for higher tensile wires.

Uploaded by

Triều Nguyễn Ngọc
Copyright
© © All Rights Reserved
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www.novoprecision.

com

Wire Straightening Theory & Practice


Over the years there have been several approaches taken to straighten wire with each in its own way resolving certain
issues or problems that were encountered when trying to form something from the wire. Many of these approaches
continue to be used even though the necessities of modern wire forming applications have evolved beyond the point
were they can achieve success. This document will address the theory and practices to consider when trying to
straighten common materials and special wire alloys produced for more modern applications.

Typically wire is straightened by manipulation. The two widely used methods are the “roll” style straightener and the
“rotary” style. The basic approaches that each style employs is illustrated below. The rotary method will generally deliver
the best results, but is very expensive to implement, is slow, and can leave marks on the wire called “barber poling”
which appear spiral in nature if not set up correctly. In the case of the roll straightener, the wire is maneuvered or
forced to traverse a course around roll bearings like a skier running a slalom course. The wire is bent past its elastic
point and then redirected to a straightened state. In the case of the rotary style, the straightening dies are rotated
around the wire as it is pulled through the device. The rotational speed and direction of the dies as well as the feed
speed and tension value applied to the wire must all be carefully controlled in order to obtain good results. Roll
straighteners, on the other hand, can be configured with multiple planes that can produce similar results of a rotary
straightener but are less expensive, easier to set up and, depending on bearing selection, can be operated at speeds into
the thousands of feet per minute.

The two lists below provide “tips” on how to get the best straightening results possible. The first list will give you “tips”
that should be applied regardless of style selected. The second list will provide “tips” that relate to the two basic machine
styles available in the market place. The more of these featured “tips” a product offers or can work with the better
performance will be.

Typical 2-Plane roll style approach. Roll style straighteners can be


Good for breaking “cast” and general configured to do other shapes. Hex,
straightening of low tensile wire and triangle, rectangle, oval, diamond,
strip “D” shape, square, “I” shape, etc.

4 Plane roll approach – emulates the Rotary approach – The rotating items
“rotary” approach. Works very well on are called “dies” and are made from,
higher tensile wires and more critical ceramic (typ), brass, carbide, bronze,
straightness requirements. etc. based on application.

General Considerations
Wire Line The wire should travel in as straight a line as possible when being “paid off” from the
spool, coil, or reel and though the straightening device.

Back Tension The wire should always be “pulled” through the straightening device with consistent back
tension or resistance.

Pulling Force The pulling force applied should be as consistent as possible. Avoid “herky – jerky” pulling
action at all times.

Lubrication Try to use a lubricant on all applications. This will result in a more consistent friction value
for the straightening device to deal with. There are many evaporating lubricants available
with several being FDA approved.

Tensile Value As the wire tensile value approaches 300 ksi a “roll” style straightening device is less
effective.

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