Industry Standards by Wire Journal International, Inc.

WIRE JOURNAL AUGUST 2014

INTERNATIONAL www.wirenet.org

Industry



wire China preview

OFFICIAL PUBLICATION OF THE WIRE ASSOCIATION INTERNATIONAL

WIRE JOURNAL AUGUST 2014

INTERNATIONAL www.wirenet.org

Editorial . . . . . . . . . . . . . . . . . 6

F EATURES

Calendar . . . . . . . . . . . . . . . . . 8 Industry News. . . . . . . . . . . . 10 Asian Focus . . . . . . . . . . . . . 20

Industry

People. . . . . . . . . . . . . . . . . . 22 Fiber Watch . . . . . . . . . . . . . 24 Fastener Update . . . . . . . . . . 27 WAI News . . . . . . . . . . . . . . . 28 Chapter Corner . . . . . . . . . . . 38 Technical Papers . . . . . . 60-75 Products . . . . . . . . . . . . . . . . 76 Classified . . . . . . . . . . . . . . . 81 Career Opportunities . . . . . . 81 Advertisers’ Index . . . . . . . . 83

Next issue September 2014 • Lubrication and Filtration • Preview: wire & Cable India

Preview: wire China . . . . . . . . . . 40 Expectations are high for wire China, to be held Sept. 24-27 at the Shanghai New International Expo Centre in Shanghai, China. 

wire China preview

Industry Standards . . . . . . . . . . . 48 This feature presents a WIRE Q&A “primer” with a NEMA OFFICIAL PUBLICATION OF THE ASSOCIATION INTERNATIONAL official, the perspective of a longtime member of standard committees, participation by one cable manufacturer, a historical look at how the need for standards led to the formation of ASTM, and more.

T ECHNICAL PAPERS Mordica Lecture, Part 1: Trends in drawing technology for bars and wires Motoo Asakawa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Analysis of wire-clamped joints by FEM Janusz Juraszek . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Processing technology of high dimensional accuracy shaped wire drawing for spring wire Kazunari Yoshida, Kenta Suga, Keita Nakazima, Kotaro Watanabe and Koji Umezu . . . . . . . . . . . . . . . . . . . . . . . 72

Cover: Standards ﬁguratively set the cogs for the manufacturing process to carry out. As a sidenote, the cover image, while eye-catching, does appear to display multiple OSHA violations for working with equipment. For the record, WJI does not endorse such an approach on the shop ﬂoor. AUGUST 2014 | 3

CONTENTS

Volume 47 | Number 8 | August 2014

INSIDE THIS ISSUE CONTENTS

wire

China remains a solution . . . . . . 40

wire China organizers note that the effects of the global recession continue to hamper manufacturing, but they say that Chinaâ&#x20AC;&#x2122;s policies for economic transformation, new urbanization development and bolstering of manufacturing industries will continue to offer promise for the wire industry. The wire China venue, they say, will offer attendees the technical solutions to meet future needs. .

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Award-winning

details

. . . . . . . . .60

The 2014 Mordica Memorial Award winner, Motoo Askawa, shares the expertise he derived over 40 years of research into bar and wire processing. The Waseda University professor has won numerous awards, including the Okochi Memorial Prize, the Society for Technology of Plasticity Prize, and the Iron & Steel Institute Prize in Japan, as well as WAIâ&#x20AC;&#x2122;s Allan B. Dove Memorial Award.

EDITORIAL WIRE JOURNAL ®

EDITORIAL

I N T E R N A T I O N A L

Standards an essential part of industry Whatever field you can think of, there’s likely a standard that covers it, from amusement parks (ASTM) and cloud computing (NIST) to fire control (NFPA) and electronics (IEEE). So where do they come from? Per the American National Standards Institute (ANSI), the government is the single largest creator of standards, with some 44,000, while the private sector has some 49,000 standards. ANSI notes at its website that there are nearly 700 standards organizations in the U.S., and that doesn’t include de facto industry standards that are established not through formal procedures, but through widespread acceptance in the free market. Perhaps the best known developer of standards is ISO (International Organization for Standardization). Since it began in 1947, the organization has published more than 19,500 international standards. ISO 9000, launched in 1987, saw its list of certified companies top one million by its 25th anniversary, and its latest numbers claim 1.5 million organizations in 191 countries. The feature that starts on p. 48 in this issue covers a tiny sliver of a topic that covers a truly massive scope. There are hundreds of “traditional” standards developing organizations in the U.S. that rely on individual committees of expert members who address the technical requirements of standards within their specific area. Standards abound, and the vast majority of them carry out their designed purposes, but a watchdog approach is still well advised. A few years ago, a defilibrator lead was pulled from the market when a cable that connected the heart to the implantable defibrillators had its insulation break through from the inside out. Deaths were reported. A subsequent investigation found that the cable met the applicable standard. That would seem to raise the question that if the cables had met the specs, then the governing standard would seem to have been inappropriate, or that maybe the human body is such an invasive environment that it cannot easily be quantified. There is more than a little gray in life, yet without a base of guides to turn to it would be far grayer.

Mark Marselli Editor-in-chief

WIRE JOURNAL INTERNATIONAL (ISSN-0277-4275) published monthly by The Wire Journal, Inc., is a wholly owned subsidiary of The Wire Association International, Inc., which is located at 1570 Boston Post Road, P.O. Box 578, Guilford, CT 06437-0578, USA, and can be contacted at tel. 203-453-2777; fax 203-453-8384; Internet wirenet.org; e-mail editorial@wirenet.org. Address all correspondence concerning advertising production, editorial and circulation to the above address. WJI is printed in USA. Subscription rates: $110 per year, USA; $120 per year, Canada and Mexico; other countries, $140 per year (includes air mail). Back copies: $10 WAI members, $15 non-members. Periodicals postage paid at Guilford, CT 06437, USA, and at additional offices. Wire Journal International grants photocopy permission to libraries and others registered with Copyright Clearance Center (CCC), 21 Congress St., Salem, MA 01970, USA, for a fee of $0.50 per article. Payments should be sent directly to the CCC. Requests for bulk orders or reprints should be sent to the Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA. © 2014 by Wire Journal, Inc. All rights reserved. The Publisher of WJI assumes no responsibility for the validity of manufacturers’ claims made herein. Back issues of WJI are on microfilm and available from University Microfilm, 300 North Zeeb Road, Ann Arbor, MI 48106, USA. Phone: 313-761-4700. POSTMASTER: Send address changes to Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA.

6 | WIRE JOURNAL INTERNATIONAL

CALENDAR

CALENDAR Sept. 24-27, 2014: wire China 2014 Shanghai, China. See p. 40. Oct. 8-10, 2014: SpringWorld Rosemont, Illinois.China. To be held at the Donald E. Stephens Convention Center. Contact: Tom Renk, CASMI, tel. 847-447-1705, tom@casmi-springworld.org or tomr@ewald.com, www.casmi-springworld.org. Oct. 28-30, 2014: Wire & Cable India Mumbai, India. To be held at the Bombay Convention & Exhibition Centre. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com. Nov. 9-12, 2014: 63rd IWCS ConferenceTM Providence, Rhode Island, USA. To be held at the Rhode Island Convention Center. Contact: Pat Hudak, IWCS, tel. 717-993-9500, phudak@iwcs.org, www.iwcs.org. Nov. 26-28, 2014: MFSH 2014 Shanghai, China. This event includes bar, wire, steel rope and more. Contact: Shanghai Aoya Exhibition Co., at 86-21-3351 8138, ayexpo@vip.163.com.

April 28-30, 2015: Interwire 2015 & WAI’s 85th Annual Convention Atlanta, Georgia, USA. WAI returns to the Georgia World Congress Center to stage its biennial trade show, technical programs and 85th Annual Convention. Contact: WAI, USA. Tel. 001-203-453-2777; fax 001-203-453-8384; www.wirenet.org. April 4-8, 2016: wire Düsseldorf Düsseldorf, Germany. This biennial event will be held at the Messe fairgrounds. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com. June 8-9, 2016: WAI Operations Summit & Wire Expo Uncasville, Connecticut, USA. This WAI event, which will be held at the Mohegan Sun Resort Center, will include its trade show, technical programs and WAI’s 86th Annual Convention. WAI, USA. Tel. 001-203-4532777; fax 001-203-453-8384; www.wirenet.org.

WIRE ASSOCIATION INTERNATIONAL EVENTS For more information, contact the WAI, USA. Tel. 001-203-453-2777; fax 001-203-453-8384; www.wirenet.org. Sept. 8, 2014: New England Chapter 20th Annual Golf Tournament Ellington, Connecticut, USA. The New England Chapter will return to the Ellington Ridge Country Club. Contact: WAI’s Anna Bzowski, tel. 203-453-2777, ext. 126, abzowski@wirenet.org. Oct. 2, 2014: The Vannais Southeast Chapter’s 13th Annual Golf Tournament Conover, North Carolina, USA. The Southeast Chapter will return to the Rock Barn Golf and Spa. Contact: Art Deming, tel. 252-955-9451, art.deming@nexans.com.

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Oct. 20, 2014: Western Chapter’s 14th Annual Golf Tournament Fontana, California, USA. The Western Chapter will return to the Sierra Lakes Golf Course. Contact: John Stevens, tel. 905-851-5633, jstevens@emc-wire.com. April 28-30, 2015: Interwire 2015 & WAI’s 85th Annual Convention Atlanta, Georgia, USA. See main listing. June 8-9, 2016: WAI Operations Summit & Wire Expo Uncasville, Connecticut, USA. See main listing.

INDUSTRY NEWS

INDUSTRY NEWS Capsized barge results in loss of $38 million of power cable Prysmian reports that on July 3, a chartered barge that was transporting power cables capsized, resulting in the loss of some US$38 million of cable it had made for Deutsche Bucht and Butendiek offshore wind farms in Germany.

The AMT Explorer loaded with cables. Photo Global Marine Systems/Flickr. A press release said that the barge, the AMT Explorer, had been chartered to ship the cables from Arco Felice in Naples, Italy, to Bremerhaven, Germany. “As a consequence, the cargo and the rotating platform have most likely sunk.” The event took place in international waters, some 50 nautical miles southwest of Sardinia, where it was being pulled by a tug boat when it capsized. Per Wikipedia, the Mediterranean Sea has an average depth of 1,500 m (4,900 ft). An article in World Maritime News said that Smit Salvage is handling the wreck of the 92-meter-long barge, which was built in 1984. Asked by WJI if there was any chance of recovering the cable, a Prysmian company spokesman replied that no details could be provided beyond what was in the press release, which noted that the cables were insured. It added that “Prysmian and TenneT are working at their best capabilities to avoid consequences that may affect the project execution timetable.”

General Cable announces restructuring, plans to lay off 7% of its workforce General Cable Corporation announced that it will implement a restructuring program designed to improve profitability and return on invested capital in each of its three reportable segments, a plan of action that will see the company’s global workforce trimmed by 7%.

A press release said that the restructuring plan, which furthers existing productivity and optimization plans, calls for “the closure of certain underperforming assets as well as the consolidation and realignment of other facilities.” There will also be global reductions in selling, general and administrative expenses. The collective efforts, which could take up to a year to complete, are projected to result in $10 million savings this year. Most of the costs for the restructuring will be in 2014, and going forward the annual savings are expected to be $75 million, with full realization starting in 2016. The global workforce cuts equal nearly a thousand jobs, it said. “While we strongly believe our business is well positioned for the long-term, we are continuing to face ongoing challenges in certain end markets and persistently uneven global demand and pricing,” said General Cable President and CEO Gregory B. Kenny. “While these are difficult decisions that affect the lives of our employees, we believe these actions are essential to improving both the near-term performance as well as assuring the long-term success of the company. … As we move forward, we remain confident in our strategy, competitiveness and ability to create shareholder value. Over a business cycle, our operating model continues to support substantial incremental earnings as we further strengthen the alignment of our portfolio with the long-term fundamental growth prospects for energy, infrastructure and construction investments in our key end markets around the world.” Looking at the current operating income for 2014, the company lowered its guidance from $230 million to $200 million. “Aside from typical seasonality, global demand and pricing remains uneven as the tepid pace of the recovery continues to hamper growth in key end markets. As a result, management is tempering its expectations for the second half of the year principally due to the lack of consistent momentum in utility and construction spending in North America and Latin America as well as ongoing headwinds expected in Spain and Thailand. The company also anticipates that certain assets are unlikely to meet key performance improvement milestones in the second half of the year.” Speaking to investors in a conference call, Kenny said that slow global recovery from the Great Recession was the cause for its recently announced restructuring and jobs cuts. Reports said that he cited weak market demand, especially in Thailand, which he noted is an important market for the company. General Cable Spokeswoman Lisa Lawson was cited in the Cincinnati Business Courier as saying that none of the 400 positions at the company’s headquarters in Northern Kentucky would be impacted by the restructuring. That

Does your company have news that belongs here? E-mail it to the WJI at editorial@wirenet.org. 10 | WIRE JOURNAL INTERNATIONAL

its sales and distribution operation from Connecticut to New Mexico, it said, adding that the project is pending approval from the State Board of Finance regarding industrial revenue bonds and tax breaks.

Swiss company acquires Northwire

CN Wire to open first manufacturing plant, will relocate from Connecticut CN Wire has announced plans to open its first manufacturing plant in North America, locating it in Santa Teresa, New Mexico, and moving its headquarters there from Connecticut. A report in Albuquerque Business First said that CN Wire, which was founded in 1998 as a distributor of products from Turkey’s ER-BAKIR Elektrolitik Bakir Mamulleri A.S., supplied its parent company’s single wire, multiwire, bunched and stranded wire, tin-plated copper and braid wire. CN Wire, it said, will begin limited production this year, will full operations to start in early 2015, at which time it could have some 300 jobs. The report said that CN Wire will invest $42 million to purchase and renovate a 256,000 sq-ft building in the Santa Teresa Business Center. It added that CN Wire has been approved for $537,626 in Job Training Incentive Program (JTIP) funds to hire and train 79 New Mexico workers. As part of the plans, CN Wire will also relocate

LEMO, a Swiss designer and manufacturer of precision custom connectors, announced that it has acquired Northwire, Inc. (NWI) a U.S. manufacturer of copper wire, multi-conductor cable and retractile cords for the medical, aerospace and defense, energy and industrial markets. “The acquisition of Northwire will enlarge the LEMO offering, providing a complete cable-connector solution to our valued customers,” said LEMO Group President and CEO Alexandre Pesci. He emphasized “that the Northwire and LEMO existing structures will remain unaltered. The additional processes that we plan to implement will enable Northwire’s integration into the Group and promote our cooperation and services provided to our mutual customers.” In related news, the Northwire facility in Merrill, Wisconsin, was damaged by an early morning fire on July 13 that caused damages estimated to be around $2 million. Per multiple media reports, fire crews responded to the report of smoke coming from the roof around 1:30 Sunday

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AUGUST 2014 | 11

INDUSTRY NEWS

initiative, a later release said, at this point includes the closure of three company production facilities, one each in North America, Peru and in India. The markets for both those latter countries, it said, will be served by production from other General Cable facilities.

INDUSTRY NEWS

morning. The majority of the fire was found in the metal plating area of the factory. Crews were able to put out the fire, which was said to be centered in the metal plating area. The majority of the building was not affected by the fire.

Ducab will supply cabling for update for well-known pilgrim destination Ducab reports that it has been chosen to supply cables and accessories to the Saudi Arabian authorities responsible for the expansion and enhancement of the Mataf area beside Al Masjed Al Haram, within the Holy Site at Mecca.

LS Cable wins $8 million cable contract that it notes is first such deal in Italy LS Cable and System, Korea’s largest cablemaker, reports that it has become the first non-European company to supply cables to Italy after securing a deal worth US$8 million. Koreajoongangdaily.com reports that the affiliate of LS Group said that it will supply transmission cables to Terna, an Italian electricity transmission system operator. The aerial cable product, it said, enables the transmission of double the electricity compared to old cables without replacing transmission towers. “Industry insiders said that this is significant because it shows that Korean companies are able to enter the electricity market’s so-called European mecca,” said the report, noting that Italy is home to Prysmian, the world’s largest cablemaker. LS Cable, it said, first entered the European market after opening a sales unit in the U.K. in 2008.

U.S. body’s initial finding goes against imported steel wire rod from China

Ducab was selected for the project at the Holy Site in Mecca. A press release said that the expansion project in Saudi Arabia “aims to strengthen infrastructure and increase capacity in this area from 50,000 pilgrims per hour to 130,000 pilgrims per hour.” It said that as millions of visitors come during the year for Hajj and Umrah, the Holy Site sees one of the largest annual gatherings of people in the world, and assuring safety for all pilgrims is a prime consideration. “As a consequence, Ducab has been selected to supply products from its internationally certified Low Smoke Zero Halogen (LSZH) cables & wires in addition to the FlamBICC Range of fire retardant cables,” it said. Ducab Chairman Jamal Salem Al Dhaheri said in the release that the company welcomes the project. “We have been given an opportunity to work closely with the most iconic symbol of the Middle East, and as a UAEbased firm, it is a matter of pride – and a sign of our commitment to our culture and community – that we are playing a role in the expansion and strengthening of facilities at the Holy Site. It is an honor to be chosen to help ensure the safety of our brothers and sisters while they carry out their pilgrimage and sacred duties at Al Masjed Al Haram.” Ducab has a history of success in the Kingdom, having supplied cables and accessories for the King Abdullah Financial District, Riyadh, and the Ras Al Khair project in the Eastern province of the Kingdom, the release said. 12 | WIRE JOURNAL INTERNATIONAL

The U.S. Commerce Department has set preliminary subsidy rates on imported steel wire rod from China. China’s Xinhua reported that the department made its preliminary affirmative determination that Chinese producers and exporters of carbon and certain alloy steel wire rod received countervailing subsidy rates ranging from 10.3% to 81.36%. Punitive duties would be imposed after both the Commerce Department and the U.S. International Trade Commission made affirmative final rulings, which are scheduled on November 12 and December 27, respectively. If the ITC makes a negative determination, the investigations will be terminated, the story said. The investigations are in response to the petition filed by ArcelorMittal USA and five other U.S. companies, the story said. It noted that the companies claimed that the products from China were sold below the fair value of the products in the U.S. market, while Chinese producers and exporters also received improper government subsidies.

Davis-Standard workhorse extruder produces 20 billion ft of cable Talk about return-on-investment: Davis-Standard reports that one of its extruders at Southwire Company’s building wire plant in Carrollton, Georgia, has been estimated to have produced 20 billion feet of two-conductor NMB wire since it first entered operation there in 1966. With the earth’s circumference roughly 132,000,000 feet, that works out to enough cable to circle the planet 152 times. A press release said that the extruder, #0750-02, was bought used by Southwire, having been sold new to a competitor six years earlier. It was run continuously by its first

INDUSTRY NEWS

owner and Southwire has run it virtually 24-7 since it acquired the equipment, it said. The line was one of the first extruders installed in the plant, and its 20 billion ft of cable production has a market value of over $5 billion based on today’s NMB prices, it said. “This extruder is an iron horse; there’s no other way to describe it,” Southwire Process Engineering Support Manger Scotty Ledbetter said in the release. He observed that the extruder performs as well as the newest machine in the building in terms of efficiency and production. The only thing it has required is barrel and feed screw replacement several times throughout the years. We have never rebuilt or replaced the gearbox, which is rare. It is one of two machines (at the plant) with the old-style, round-top gearbox.” To put the extruder’s longevity in context, the release said that the company has one employee, Patsy Lambert, who was working in the plant when the extruder was installed and commissioned. The release said that Southwire’s appreciation and confidence in Davis-Standard’s extruders can be seen by their deployment. Ledbetter said that his group has approximately 130 Davis-Standard extruders, and for Southwire as a whole, he estimated that 90% of all its extrusion equipment is from the Connecticutbased supplier. Southwire, it said, ships multiple tractor-trailer loads of finished product daily, which is destined for big box retailers and other customers throughout the U.S. “Davis-Standard has played an integral role in our success,’’ said Ledbetter. “We like that they consistently make great equipment that we’ve relied on to grow our business over the past four decades. It’s heavy-duty, reliable and built to last. … I have never heard of anyone else possessing an extruder that has a record like this machine’s.”

Scottish project for 100 plus miles of power cable gets regulator job A £1.2 billion underwater cable project requiring more than a hundred miles of subsea and underground cables to be laid in the Moray Firth area of northern Scottland, has been approved by energy regulator Ofgem. A press release said that the subsea cable will connect 1.2 gigawatts of renewable energy, enough to power almost 640,000 homes, with the grid. The project, which is due to be completed in 2018, represents the largest investment in the region’s electricity network since the hydro era of the 1950s, it said. Work on the project is being led by SSE subsidiary Scottish Hydro Electricity Transmission. Asked by WJI about which cable company will provide the cables, a spokesman said that the supplier has not been chosen yet. The project includes a cable route running from Spittal in central Caithness, underground to the coast, 14 | WIRE JOURNAL INTERNATIONAL

A view of the area where a subsea cable network will transmit renewable energy. and then subsea to a landfall near Portgordon in Moray. A further underground section runs inland to Blackhillock substation, near Keith, in Moray. The main component of the project is the HVDC system with converters at either end, but there are also a number of associated AC network upgrades, including new and upgraded AC substations, overhead line and cable, the spokesman said. “subsea cable laying will begin in early 2017. However onshore cable works are due to start in 2016.”

Prysmian Group acquires the remainder of Estonia cable company The Prysmian Group reports that it has acquired the remaining 34% interest in AS Draka Keila Cables, making it the sole owner of the Estonian cable company that it initially entered into through its acquisition of Draka in 2011. A press release said that the acquisition amounts to €6.2 million and “takes into consideration a positive net financial position (cash) of approximately €4.9 million at the end of 2013.” It said that Draka Keila Cables reported sales of about €53.8 million in 2013 and was expected to top that this year because of “favorable development of market demand in the reference market of Baltic republics and Nordic countries.” The release said that the Prysmian Group has “a prominent presence in the Nordic region” with six plants in Finland, Sweden, Norway, Denmark and Estonia. Collectively, they offer a wide range of products, from submarine and underground high and medium voltage cable systems to special cable solutions for the oil and gas, the marine industry, the renewable energy sector, telecom and cablings for the construction sector, it said. “The investment in Keila Cables will allow the Group to further speed up the development of its growth strategy in this high-potential region,” it said.

INDUSTRY NEWS

Europacable reports new leaders Following its General Assembly on June 24, Europacable, which represents approximately 85% of the European wire and cable industry, announced changes in its leadership. Per its release, Prysmian Group CEO Valerio Battista was elected the new Europacable president, succeeding Nexans Chairman and CEO Frédéric Vincent. Nexans Senior Corporate Executive VP Pascal Portevin was elected the new chairman of the Europacable Executive Board, succeeding Prysmian Group Chief Strategy Officer Fabio Romeo, who has lead the Executive Board since its foundation. Speaking at the Europacable General Assembly, Battista applauded the achievements brought about by his predecessor. “Mr. Vincent took on the challenge to establish what we like to call ‘Europacable New’: the direct representation of Europe´s leading wire and cable manufacturers through our team in Brussels. Four years on, and thanks to his guidance, we are today well connected to our key EU partners. I look forward to even further increasing our visibility.” Portevin observed that the organization’s members serve an important role, contributing to the infrastructure of Europe, a key basis for competitiveness. “This is true for the energy infrastructure (the grids) where interconnections will ensure a real European electricity market for the benefit of society and an industry which has to compete on a global level. This is also true for the telecommunication and data infrastructures that will give Europe the competitive edge for the future. Under my leadership, the Executive Board of Europacable will ensure that our industry is heard by the European decisions makers who need to better understand that a European manufacturing basis for wires and cables is vital for our economies.” Eurocable’s members include both the world’s largest cablemakers as well as more than 200 highly specialized small and medium-sized businesses, the release said.

ABB reports $400 million contract Swiss-based ABB Ltd. (ABBN) reports that it has won a $400 million contract to supply 106 miles of subsea transmission cables for use in the first electricity link between Newfoundland and the North American power grid. A press release said that the order from Emera Inc., a Canadian power company, is for the Maritime Link Project, a 500-megawatt high-voltage line that will bring renewable power mainly from hydroelectric dams in Newfoundland and Labrador to Nova Scotia. The undersea line will allow Nova Scotia to import power from the 824-megawatt Muskrat Falls hydro project in Labrador being developed by Nalcor Energy Corp. Nova Scotia is already connected to the Canadian and U.S. power grids, it said. “This is an important new chapter in the power transmission industry for Canada and North America,” Anders Hultberg, senior vice president of power systems for ABB in Canada, said in a statement.

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A ship deploys ABB power cable. ABB photo. A Bloomberg article said that Nalcor raised $4.7 billion for Muskrat Falls. The transmission line and its two converter stations and two substations are scheduled to be in operation in 2017. Muskrat Falls is expected to open late in 2017. Emera, which gets 59% of its power from coal, is procuring renewable energy to meet Nova Scotia’s mandate for 40% green power by 2030, up from 17% now. The project includes a total of 106 miles of subsea transmission cables under the Cabot Strait, and overhead lines in Newfoundland, Labrador and Nova Scotia.

UAE’s Ducab plans to build a cable plant in the Abu Dhabi industrial zone UAE-based Ducab plans to build a cable plant in Abu Dhabi’s Khalifa Industrial Zone (Kizad), where it plans to invest approximately US$60 million. A press release from Kizad said that Ducab Aluminum has an agreement for a tract over 50,000 sq m in Kizad’s aluminum cluster. The plant will be Ducab’s sixth in the UAE, alongside its three facilities in Musaffah and two in Dubai. Ducab also owns AEI Cables in the U.K. which was purchased earlier this year. The new plant, it said, will produce aluminum rod and conductors for overhead transmission lines, and will focus on supplying the cable manufacturing industry and utility sectors. The plant is expected to be operational in 2015. The release said that Ducab joins Kizad’s more than 50 “national and international high-profile investors.” Ducab’s manufacturing facility, it said, “will integrate perfectly into our aluminum cluster and function as a downstream producer next to Emirates Aluminum (EMAL), one of the world’s largest single-site aluminum smelters and Kizad’s anchor tenant in the cluster.” “Kizad has emerged as an exponentially growing industrial zone recently,” said the release, citing advantages for both logistics and manufacturing. “Proximity to EMAL for molten metal supplies is one of the most critical reasons, as is proximity to Khalifa Port for an unparalleled logistics infrastructure,” it said.

Beta LaserMike merges with its sister company to form NDC Technologies Beta LaserMike reports that it has merged with its sister company, NDC Infrared Engineering, to form a new company called NDC Technologies, which will be based in Irwindale, California. A press release said that both companies are owned by Spectris PLC, a U.K.-based supplier of productivity enhancing instrumentation and controls. “The combination strengthens the new company’s position in the

marketplace by offering a more comprehensive portfolio of gauging solutions with enhanced cross-selling opportunities. In addition, the new operating model expands the company’s reach to better serve its growing global base of customers.” “We are confident that the combined company, NDC Technologies, will increase our competitive advantage in products, sales distribution, and technical support, while enhancing our relationships with customers and partners,” said Ken Wright, former President of Beta LaserMike and now President of Global Engineering and Marketing for NDC Technologies. A spokesman for Beta LaserMike said that the company “will use the new NDC Technologies company name, but will still retain the Beta LaserMike line of products brand in all of our communications, including advertising and PR.”

Mid-South Wire buys warehouse for possible company expansion Mid-South Wire recently bought the 190,000-square-foot former Ajax Turner Co. warehouse for $3.7 million with plans to expand the steel wire manufacturer. John T. Johnson Jr., CEO of Mid-South Wire, said that the beverage distributor’s former home, which sat

AUGUST 2014 | 17

INDUSTRY NEWS

Ducab noted in the release that it currently exports copper rod, cable and wire to clients in the GCC and MENA region, as well as to clients on the Indian Subcontinent, in Africa and Europe. Founded in 1979, the company is owned, in equal shares, by the Investment Corporation of Dubai (ICD) and Senaat (General Holding Company, private investment of the government of Abu Dhabi). The company supplies a wide range of power cables and accessories to customers in over 40 countries across the globe. Ducab has provided cable and wire solutions to numerous landmark projects in the UAE and worldwide, including Burj Khalifa, Burj Al Arab, Emirates Palace, the Al Maktoum International Airport, and the Central Bank of Oman.

INDUSTRY NEWS

vacant since a flood in May 2010, is ideal for the company’s future expansion because it sits across the street from his company’s headquarters at 1070 Visco Drive in Nashville,Tennessee. “We’re just going to expand our current operations and add some product lines we think are opportunities for us,” he said. “It made more sense to acquire this across the street to eliminate duplication of management, maintenance and transportation costs, than to go somewhere else.”

Joe Snee Associates reports that it will now represent AW Machinery Joe Snee Associates, Inc., reports that it has been named the New England representative for AW Machinery (AWM), which is based in Fairfield, New Jersey. Founded in 2003 by Art Watson and company President Ed Gener, AWM is a manufacturer and integrator of machinery and control systems that also provides technical service and spare parts for its equipment as well as Viteck equipment. AWM supplies complete extrusion lines and systems for use in producing: telephone and LAN cables, power cable-CV lines, optical fiber coating, building wire, automotive wire, appliance wire, special cables and medical tubing. The company also designs and fabricates electrical control systems used in its machines, with digital touch screen control system design and fabrication a specialty. Joe Snee Associates also represents PWM cold pressure welders, dies and spares, and Beta LaserMike measurement technology and control systems. Joe Snee can be contacted at tel. 774-991-0504 or joe@jsnee.com.

METALUBE opens office in Shanghai U.K.-based lubricants manufacturer, METALUBE has expanded its Asian capabilities with its new office in Shanghai, China. The company notes that it now has four offices in the Asia Pacific region: one each in Shanghai and Dongguan, in China, one in Hong Kong, and one in Kuala Lumpur, Malaysia. “It is so positive to be part of a company such as METALUBE that understands the importance of having a real and physical presence in the countries to where it exports to,” said Maurice Ngai, general manager, Asia Pacific, said. “The investment is certainly paying off. We have witnessed year on year growth in this important and fast growing region and this year alone, we expect to see a further 40% increase in sales.” Ngai said that the company has “big plans to launch a host of new product ranges in to the region over the coming year.” He added that the local presence is a plus for the company. “Our customers are comforted by the knowledge that we have industry experts, who speak their language, on hand, to ensure a seamless operation.” n 18 | WIRE JOURNAL INTERNATIONAL

ASIAN FOCUS

ASIAN FOCUS BRICS form development bank

The LA Times report observed that as developing countries began playing a larger role in the world economy, The five BRICS (Brazil, Russia, India, China and South their leaders repeatedly complained that they have not Africa) nations recently signed an agreement to form an been given correspondingly larger voices. international development bank, an entity that will presThe U.S. typically appoints the World Bank president, ent an alternative to the World Bank and the International and European countries appoint the IMF chief. Monetary Fund, which has been seen by some as favoring Russian Foreign Minister Sergey Lavrov told the Western interests. The following details were excerpted Russian news agency ITAR-Tass that the decision “confrom multiple media reports on the announcement, which firmed that BRICS members, while speaking against unihas long been anticipated. lateral actions in the world economy and politics, are not seeking confrontation but propose working out collective On July 15, the leaders of Brazil, Russia, India, China approaches toward the resolution of any problems.” and South Africa said that the BRICS will start out with There are questions as to how the NDB will operate. $50 billion and have a $100 billion currency reserve pool Germany’s DE reported that a key question is how the called the Contingent Reserve Arrangement (CRA) to CRA’s lending conditions provide emergency cash will differ from the IMF’s. to BRICS countries faced For decades, IMF emergenwith short-term currency cy loans have been extendcrises or balance-of-payed to developing countries ments problems. Of the only if they have agreed to initial $100 billion, China limit public spending, open will contribute $41 billion, their economies to foreign Brazil, Russia and India investment, abolish tariffs, will each contribute $18 deregulate markets, privatbillion, and South Africa ize state-owned firms, and $5 billion. take other measures consisThe new bank is expecttent with the so-called “ecoed to make loans for BRICS leaders sign the NDB agreement, from l-r, Russia President nomic policy agenda.” development and infraVladimir Putin, India Prime Minister Narendra Modi, Brazil The NDB is to be more structure projects as well President Dilma Rousseff, China’s President Xi Jinping and South than just a bank as there as help foster developare political aspects as well ment expertise from other Africa President Jacob Zuma. AP Photo/Silvia Izquierdo. that are related to the world emerging economies. order. Brazil and India have long wished to see changes Further, other countries, such as Indonesia, Mexico or to the United Nations Security Council as they have no Turkey, could eventually join the bank. standing there. China and Russia are two of five permaBrazilian President Dilma Rousseff, Russian President nent members with veto power. Vladimir Putin, Indian Prime Minister Narendra Modi, “International governance structures designed within a Chinese President Xi Jinping and South African President different power configuration show increasingly evident Jacob Zuma signed the agreement. The NBD will be based signs of losing legitimacy and effectiveness,” said the offiin Shanghai, China. The first president will be from India cial statement signed by the BRICS leaders. “We believe and the position will rotate every five years among Brazil, the BRICS are an important force for incremental change Russia, India, China and South Africa. and reform of current institutions toward more representaMarcos Troyjo, professor of international and public tive and equitable governance.” affairs at Columbia University and co-director of the The lengthy joint statement covered many topics but BRICLab Center, told the LA Times that the BRICS counavoided directly addressing troublesome political issues, tries have seen their growth slow over the last few years such as the conflict in Ukraine between pro-government from the peak of international investor interest in emergand pro-Russia factions. That sharp divide was essentially ing market countries. “The only thing they may have in side-stepped by noting “deep concern” and “desire for common is the use of some kind of state capitalism in comprehensive dialogue.” their growth,” he said. “The BRICS are needing to reinThe BRICs acronym was coined by Goldman Sachs vent themselves, and it’s unlikely their route forward can Group Inc. economist Jim O’Neill in 2001 to describe the be the same route that got them here.” four large emerging markets—Brazil, Russia, India and An ABC report said that the new bank is seen as a China—that could play a large role in global economic strong push by the BRICS against the World Bank and the growth. They began meeting for periodic summits in 2009, International Monetary Fund, which the developing world and were later joined by South Africa. has long complained is far too U.S.- and European-centric. 20 | WIRE JOURNAL INTERNATIONAL

Closed steel mill in China to reopen with support from local government Last year, the Longhai Steel Group was forced to close its steel mill in Xingtai and lay off some 3,000 employees when it lost its $177 million of bank funding due to efforts by the central government to streamline production, cutting overproduction and reduce pollution. Per a report in The Wall Street Journal, the company, whose overall operations include wire production, is scheduled to start again. The bankers have not returned but it does have new support: the city of Xingtai, which was said to be arranging a merger to put the owner back in business. “The local government is trying to help us resume production as soon as possible,” Longhai Steel Group ChairmanWang Chaojun was quoted as saying. The story said that China’s senior leaders were serious about reducing steel production and pollution, and want mills to operate at high capacity rates that are more efficient. Local government officials, who get the bulk of their industrial taxes from factory production, have an incentive to keep companies operating no matter what. “While a tug of war between local officials and China’s regimes isn’t as unusual as some Westerners might think, this one has already featured a rare public scolding from Beijing as well as the televised spectacle of a province

blowing up furnaces without really reducing production. The stakes behind this battle are high: economists and Chinese officials (must) ... convince localities that are more concerned about protecting jobs and businesses.” “Don’t think just of the central government” when considering Chinese economic policy, said John Zhao, chief executive of Hony Capital, a private-equity firm in Beijing. “China has 30-some provinces and powerful cities and they all run their own economic policies.” The WSJ report said that Premier Li Keqiang criticized the lack of support in carrying out orders. “Some [local] government officials hold the belief that doing nothing is better than doing something wrong,” he said, per an account posted on the Chinese government’s website. A key issue is efficiency, the story said. The more a factory uses its machinery, the more efficiently it runs, with costs for rent, power, and other overhead spread across more products. A good target is 85% capacity utilization, but China’s rate across all industries barely tops 70% according to the International Monetary Fund. When China’s mills were growing at double-digit rates, capacity was not an issue, but as the economy slowed to closer to 7.5%, mills ran into problems. “You can’t overstate the urgency to tackle the overcapacity problem now,” observed Li Xinchuang, chairman of China Metallurgical Industry Planning and Research Institute, a state think tank that helped draft Beijing’s policy to shrink the steel industry. 

AUGUST 2014 | 21

ASIAN FOCUS

ASIAN NEWS BRIEF

PEOPLE PEOPLE

PEOPLE

RSCC Wire & Cable LLC, has promoted Christopher Venice from vice president of sales and marketing to vice president and general manager of the company’s Down Hole Metal Clad segment, reporting to company President Steve Bonnell. In January 2014, he became vice president of sales and marketing for the company segment, which manufactures the PermaTEC ™ lines of specialized downhole Venice instrument cables used globally in the oil and gas industry. He previously held several positions within the Marmon Engineered Wire & Cable Group, most recently as Vice President of New Operations & Supply Chain Infrastructure. He previously served five years as Vice President/GM for Kerite Pump Cable. He holds an MBA degree from the University of New Haven. Based in East Granby, Connecticut, USA, and a business of the Marmon Engineered Wire & Cable Group, RSCC manufactures specialty power cables for the energy, nuclear utility, transit, oil and gas, and other industrial markets. Tony Dolce, the founder of T & T Marketing, Inc., has retired after 26 years with the company that he founded in 1988. He has spent more than 60 years working in the wire and cable industry, including a prior position as vice president of sales at BP in Hackettstown, New Jersey. He established T & T as a consulting firm in 1988, and in 1991 it evolved into Dolce a sales representation and distribution company. Today, the business has 23 employees and distributes products internationally. During his years with T & T, he served as president and CEO, CFO and, most recently, as an advisor. Company President and CEO Tom Jordan said that Dolce “brought a sense of passion and excellence to his work over these many years and has been instrumental in helping to build the business into what it is today.” Dolce, who lives in New Jersey, plans to remain active, pursuing other interests. Based in Allamuchy, New Jersey, T & T Marketing supplies a wide range of products to the wire and cable industry. Sharon Martin has joined Teknor Apex Company as its corporate marketing communications manager, responsible for advertising, public relations, trade show coordination, marketing collateral and digital marketing for all Teknor Apex business units worldwide. She previously held marketing communications positions with Helicos BioSciences

22 | WIRE JOURNAL INTERNATIONAL

Martin

Conneaut Industries, Inc., has named John Mancinelli to fill a new national sales manager position. An industrial engineer, he most recently worked for 15 years at AGY as a product engineer and regional sales manager. Prior to that, he worked for 11 years at Owens-Corning as a production supervisor. In addition to his new sales assignment, he brings excellent engineering skills, yarn processing expertise and customer support experience. He will work closely with company President John Santos. Based in West Greenwich, Rhode Island, USA, Conneaut Industries is a leading supplier of specialty fibers used for sectors that include the wire and cable industry. Alysse Koch has joined Metro Wire and Cable-Iowa City as a sales consultant. She previously held marketing and sales roles for Cumulus Media and Centriq Training. She holds a B.S. degree in business management from Colorado State University. She will work with electrical contractors, fire and security companies, utilities, OEMs and other customer bases in Koch the greater Midwest. Based in Sterling Heights, Michigan, USA, Metro Wire & Cable distributes electrical products.

WHO WE ARE - WHAT WE OFFER We are a german company with generations of experience in manufacturing machines for the cable and rope industry. We develop and manufacture according to our customers‘ requirements and are the world‘s leading manufacturer for machines for CTC (continuous transposed conductors). Further we offer used or reconditioned cable and rope making machines. Please take a look at our currently available used equipment at www.queins.com

PEOPLE

QUEINS Machines GmbH

PEOPLE

Corporation. She holds a B.A. degree from James Madison University, Harrisonburg, Virginia. Andrea M. Barish has joined the company’s Vinyl Division as a sales representative, responsible for sales management and account development in Arkansas, Kansas, Missouri, Nebraska and western Tennessee. She previously was senior national accounts manager for RockTenn Corporation, focusing on resin sales, and prior to that worked for Jamplast, Inc., a resin distributor. She holds an M.S. degree in industrial Barish safety from Central Missouri State University and a B.S. degree in business administration from the University of Missouri. Based in Pawtucket, Rhode Island, USA, Teknor Apex Company is an international supplier of polymer technology for sectors that include wire and cable.

MANUFACTURING RANGE Pay-offs and take-ups, all Tubular stranders designs Rigid stranders Belt-type caterpillar capstans Planetary stranders Single- and double disc Power cable drumtwisters capstans Armouring lines Rotating caterpillar capstans Bow/Skip stranders Single/Double twist bunchers Taping heads for plastic- and steel tapes Transposed wire machines

NEW ARRIVALS - PRE-OWNED • Queins - FLR 30+36/630 mm, (24.8"), fast loading rigid stranding/screening for up to 66 wires • Pourtier - complete line with 320 pads paper lapping heads • Outokumpu UPCAST - 12 x 8mm (0.3") Cu rods 10,000 t/year

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Meghan Buisson is Loos & Co’s new marketing assistant, responsible for contributing to the overall marketing strategy. She holds a degree in communications from Bryant University. Based in Pomfret, Connecticut, USA, Loos & Co. manufactures a wide variety of wire, aircraft cable, and wire rope.

Hans-Georg-Weiss-Str. 12 52156 Monschau GERMANY Tel.: +49 2472 8080 Fax: +49 2472 3014 info@queins.com www.queins.com

Buisson

Your best partner for new and reconditioned machines JULY 2014 | 23 1_2 engl. 2014-08 fbg wire journal vertical.indd 1

25.07.2014 18:18:50

FIBER WATCH

FIBER WATCH Project calls for apartment site in Dublin suburb to get super-fast fiber

Alcatel-Lucent says 10 Gbps capacity has been achieved over copper network

Some 120 apartments in the Dublin suburb of Stillorgan will get gigabit fiber-optic broadband as part of a test to see what happens when people get such capacity. An article in Lightwave said that Magnet Networks, an Internet service provider with operations in the U.K. and Ireland, has equipped the apartments with a 1 Gbps fiber connection that will provide 10 times faster service than the current fastest connection available in the majority of Ireland. Users, it said, would be able to access gigabit speeds for both uploads and downloads. The test, part of Project Leap, will monitor broadband use in the connected homes to determine the impact of ultra-fast speed and connectivity on Irish consumers’ use of devices and applications, the Lightwave article said. The expectation is that average household broadband usage will accelerate rapidly in a gigabit environment from the current average of 22.7 GB of data per month, it said. It noted that the current mix of reported usage is 68% web browsing; 10% Netflix; 7% Google, including YouTube; 5% Torrents; 0.6% RTE; and 9.4% other types of traffic, the operator says.

Alcatel-Lucent reports that it has set a world record for broadband speed over traditional copper telephone lines, attaining 10 Gbps for data transmission. Alcatel’s research arm, Bell Labs, used prototype technology called XG-FAST to demonstrate how existing copper networks can be used to deliver ultra-broadband services, as well as 1 Gbps symmetrical services. “By pushing broadband technology to its limits, operators can ... deliver gigabit services over their existing networks, ensuring the availability of ultra-broadband access as widely and as economically as possible.” The 1 Gbps symmetrical services achieved involved splitting bandwidth to provide simultaneous upload and download speeds of 1 Gbps; a breakthrough for copper broadband, said a report in Capacity Magazine. “It is expected to enable operators to deliver internet connectivity speeds over copper, that appear identical to fiber-to-the-home (FTTH) services; benefitting homes and businesses in locations that cannot lay new fiber. Fiber will instead be brought into the pavement nearby, or basement of, a building, and copper used for the final few meters.” n

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Company plans to open plant for titanium products including fasteners

million to $100 million to build the factory. It would cost about $3 million to just set up shop, he said, noting that even that can be difficult. “It’s frustrating, because I can walk into any car dealership—any car dealership—and walk out with a new car,” Greimes said. “But trying to get a machine that will actually make something, essentially spit out money, is like pulling teeth. We really want to get up and running, because the basic moral of this story is until we start making money manufacturing, no bank’s going to give us money to manufacture products.”

Allied Titanium, Inc., a seven-year-old Delaware titanium manufacturing company, plans to open a factory in Sequim, Washington, that it said would be capable of manufacturing 75% of the products that it now produces in China. Reports in the Peninsula Daily News said that Allied Titanium CEO Christopher Greimes plans for the facility to produce many of the 93,000 titanium products, which include a range of fasteners—from bolts and screws to threaded rod and pins—that it now makes at eight plants in China. The exact size of the proposed Sequim plant has not been finalITC votes to expedite 5-year review ized, but the facility would have between 50 to 150 people. of anti-dumping penalties for China “We know that we can manufacture parts cost-effectively in Sequim,” Greimes said in one article. “The land and the The U.S. International Trade Commission (USITC) has taxes and the power (costs) are less than they are in China.” voted to expedite its five-year (sunset) review concerning The company hopes to operate the Sequim plant around the the antidumping duty (AD) order on certain steel threaded clock. rod from China. Greimes said that the plant should be a plus for the Sequim As a result of this vote, the Commission will conduct an region as there would be no smoke stacks or industrial polluexpedited review to determine whether revocation of this tion and there would be good jobs for local workers. order would be likely to lead to continuation or recurrence As of press time, the company had not filed for a buildof material injury within a reasonably foreseeable time, a ing permit. Further, finding a strategic partner and bank press release said. It noted that it is required to perform a financing to help finance the project has not been easy. Micro-WJI-Ad-August-2014 7/25/14 10:04 AM Page 1 review after five years to determine whether the existing Greimes estimated that the company will need to raise $10 order should be revoked or continued. n

Butt Welders For Continuous Processing of Wire, Rod or Cable

Booth W1/G10 Shanghai Sept 24-27

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Mumbai, India October 28-30

AUGUST 2014 | 27

FASTENER UPDATE

WAI NEWS

August 2014

WAI MEMBERSHIP

SPOTLIGHT This section introduces a new WAI member each issue.

Seth A. Young Buyer Southwire Company

Q: What does your company do? A: Southwire is North America’s leading manufacturer of wire and cable used to distribute and transmit electricity. We have six corporate divisions: energy, electrical, OEM, industrial, engineered products and international. Each area focuses on specific products and customers. Q: What is your role there? A: I am a buyer at the rod and cable mill in Hawesville, Kentucky. I help procure the materials used at the plant, maintaining information records on materials and vendors, finding ways to cut cost, and ensuring materials are delivered and vendors are paid on time. Q: What do you like best about your position? A: I enjoy the day-to-day interactions with employees and vendors. Working with all our plant departments allows me to learn firsthand about our business and processes. Working with different vendors keeps me informed of new materials or items used in the industry. Q: How has the industry most changed? A: The wire industry’s technology and communication has improved dramatically over the past few decades. We have systems that allow for real-time reports, technology that has immensely improved the quality of wire, and new processes to reduce waste. Improvements in communication and transportation have expanded the market from a national perspective to a global scale. Q: How does your company remain competitive? A: Innovation. We continually work on improving our processes, products, and services, which improves our efficiency while cutting costs. Southwire ensures customer satisfaction by meeting customer requirements and needs. Q: Why did you recently join WAI? A: After attending the WAI convention in Indianapolis, I found that WAI is a valuable tool to keep up with industry trends. It helps connect companies, people, and ideas to grow innovation in the industry.

28 | WIRE JOURNAL INTERNATIONAL

The following individuals either recently joined WAI or became Platinum Members through their companies.

Jorge J Ruiz Sls Eng Sikora International Corp

Michael Dalal VP Reg Sls Niehoff Endex North America Inc

Jacob Safier Metallia USA LLC

Kendal A Deep Sls Trainee Sonoco Reels Gene DeFraties, Jr Sls Mgr Midwest Plastics Co Inc Camille Drake ExxonMobil Patrick Harper Acct Mgr T & T Marketing, Inc.

Sam Santiago Fort Wayne Wire Die (Philippines)

Rolf D Wurmbach Gen Mgr Niehoff Endex North America Inc

WAI NEWS

Lonnie Brett Berkley Eng Mgr Nexans Energy USA Inc

Seth A Young Buyer Southwire Co Farid Zeroug Sarl Steel Consulting

Steve C Schultz OEM Mfg Mgr Lake Cable LLC Daniel Spence Proc Eng Southwire Margie Thacker Op Mgr Sikora International Corp

Marcel Levitre Sr Prod Dev Eng Southwire Co

Edmond T Torbey VP Reg Sls Niehoff Endex North America Inc

Fernando Pereira VP Eng Niehoff Endex North America Inc

Robert Wild CEO Niehoff Endex North America Inc

WAI Platinum Membership Companies Industry leaders can contact WAI Executive Director Steve Fetteroll at sfetteroll@wirenet. org or 203-453-2777, ext. 115, to learn more about this special membership program. Such organizations actively support the Association by participating as exhibitors, advertisers, sponsors or content providers for WAI-organized events, publications and educational programs. section continued on p. 32.

AUGUST 2014 | 29

WIRE & CABLE MAKING MACHINERY PLANT OPERATIONS SESSIONS SPEAKING OPPORTUNITIES NEW TRENDS & PRODUCTS SUPPLIES & EQUIPMENT GLOBAL NETWORKING SPONSORSHIPS

INTERWIRE 2015 | THE LARGEST WIRE AND CABLE MARKETPLACE IN THE AMERICAS. GEORGIA WORLD CONGRESS CENTER | ATLANTA, GEORGIA, USA

SAVE THE DATE EXPOSITION: APRIL 28-30, 2015 CONVENTION: APRIL 27-30, 2015 ALSO WITH: WAI’s 2nd Global Continuous Casting Forum

www.interwire15.com The Wire Association International, Inc. 1570 Boston Post Road | P.O. Box 578 | Guilford, CT 06437-0578 USA Telephone: (001) 203-453-2777 | Fax: (001) 203-453-8384 | www.wirenet.org

PARTICIPATING EXHIBITORS Ace Metal Inc. ADVARIS GmbH Agape Industry Inc. AIM Inc. All Forming Machinery Inc. Amacoil Inc. American & Efird Inc. American Kuhne Inc. Anbao Wire & Mesh Co. Ltd. Assomac Machines Ltd. AW Machinery LLC Aztech Lubricants LLC B & H Tool Co. Inc. B & Z Galvanized Wire Ind. Balloffet Die Corp. Baum’s Castorine Co. Inc. Bechem Lubrication Technology LLC Beijing Orient PengSheng Tech Co. Ltd. Bergandi Machinery Co. Beta LaserMike Blachford Corp. BLM Group USA Corp. Breen Color Concentrates Inc. Brookfield Wire Co. Butt Welders USA Caballe SA Cable Consultants Corp. Canterbury Engineering Co. Inc. Carris Reels Inc. Ceeco Bartell Products, Bartell Machinery Systems Cemanco LC CERSA-MCI Chase Wire & Cable Materials Chemetall Chengdu Centran Industrial Co. Ltd. China Ruijin Fairs International Cimteq Clinton Instrument Co. CM Furnaces Inc CMEC International Exhibition Ltd. CN Wire Corp. Collins & Jewell Co. Inc. Commission Brokers Inc. Condat Conneaut Industries Inc. Davis-Standard LLC Die Quip Corp. Domeks Makine Ltd. Sti Dynamex Corp. Ebner Furnaces Inc. Electron Beam Technologies Inc. Enercon Industries Engineered Machinery Group Inc. Enkotec Co. Inc. ERA Wire Inc. Esteves Group USA Etna Products Inc. Eurobend SA Eurolls Group Srl George Evans Corp. EVG Inc. Evolution Products Fabritex Inc. Fil-Tec Inc. Filtertech Inc. Fine International Corp. Fisk Alloy Wire Inc. FMS USA Inc. Foerster Instruments Inc. Fort Wayne Wire Die Inc. Frigeco USA Inc./ MFL USA Service Corp.

Frontier Composites & Castings Inc. FSP-One Fuhr GmbH & Co. Kg Gavlick Machinery Corp. GCR Eurodraw SpA Gem Gravure Co Inc. W. Gillies Technologies LLC GMP Slovakia s.r.o Guill Tool & Engineering Co. Hangzhou JR Exhibition Co. Ltd. Heany Industries Inc. Heatbath Corp. Henrich Maschinenfabrik GmbH Heritage Wire Die Inc. Holland Colours Americas Inc. Houghton International Inc. Howar Equipment Inc. Huestis Industrial ICE Wire Line Equipment Inc. IDEAL Welding Systems INHOL LLC InnoVites International Wire & Cable Machinery Association Isotek Corp. IWG High Performance Conductors Inc. Joe Snee Associates, Inc. Joe-Tools Jouhsen-Bundgens Inc. Kablosan Turkey-FBC Yayincilik Ltd. sti Kalmark Intergrated Systems Ltd. KEIR Manufacturing Inc. Keystone Steel & Wire Co. Kinrei of America Lamnea Bruk AB LaserLinc Inc. Leggett & Platt Wire Group Leoni Wire Inc. Lesmo Machinery America Inc. Lloyd & Bouvier Inc. Madison Steel Inc. Magnetic Technologies Ltd. Maillefer Extrusion Oy Mathiasen Machinery Inc. Messe Düsseldorf North America Metal Resource Solutions Inc. Metallurgical Council of China MGS Manufacturing Inc. Micro Products Co. Microdia USA Mid-South Wire Morgan-Koch Corp. Mossberg Associates Inc. Mossberg Industries Inc. Niagara Composites Int’l.Inc. Niehoff Endex North America Inc. Nimsco LLC / SB2C Numalliance North America Inc. Oklahoma Steel & Wire OMCG North America Inc. Ozyasar Tel Ve Galvanizleme P & R Specialty Inc. Paramount Die Co. Parkway-Kew Corp. Troester Maschinenfabrik GmbH & Co. KG Pentre Group Ltd.-Hearl Heaton Phifer Wire Inc. PKG Equipment Inc. Plas-Ties Co. PolyOne Polytec Inc. Pourtier & Setic of America Precision Die Technologies Inc. Premier Wire Die PrintSafe

Progressive Machinery Inc. Properzi International Inc. QED Wire Lines Inc. Queins Machines GmbH Raajratna Stainless Wire Inc. RAD-CON Inc. Radyne Corp. Rainbow Rubber & Plastics Refractron Technologies Corp. RichardsApex Inc. Rockford Manufacturing Group Inc. Rosendahl Nextrom Technologies Roteq Machinery Inc. RSD Group USA S&E Specialty Polymers SAMP USA Inc. Sarkuysan SA Schlatter Inc. Shanghai Pudong International Exhibition Co. Sikora International Corp. SIMPACKS Sivaco Wire Group Sjogren Industries Inc. Sonoco Reels Starrett-Bytewise Measurement Systems Stolberger Inc DBA Wardwell Braiding Subec AB T & T Marketing Inc. Tapeformers Ltd. Taubensee Steel & Wire Co. Taymer International Inc. Tecnofil SA Teknikor Teknor Apex Tensor Machinery Ltd. TMS-Specialties Manufacturing Co. Inc. Traxit North America LLC Tubular Products Co. Tulsa Power Inc. United Wire Co. Inc. Vandor Corp. VINSTON US Corp. Vollmer America Inc. W3 Ultrasonics LLC WAFIOS Machinery Corp. Weber & Scher Mfg. Co. Inc. Welding Wire Machineries Windak Inc. Wire & Cable Technology International Wire & Plastic Machinery Corp. Wire Association International, Inc. Wire Journal Interanational Wire Lab Co. Wire Machine Systems (WMS) Wire World Witels Albert USA Ltd. Woodburn Diamond Die Inc. Worth Steel & Machinery Inc. Zumbach Electronics Corp.

HAIW13Sponsors_Layout 1 3/21/2013 11:14 AM Page 1

WAI NEWS

Interwire 2015 update: companies have taken nearly 90% of the exhibit space More than nine months out from WAI’s staging of Interwire 2015 in Atlanta, exhibitors at last count have now accounted for nearly 90% of the floor plan’s 106,100 sq ft at the Georgia World Congress Center. WAI Sales staff reports that a total of 93,300 sq ft of floor space have been taken. “At this time, we’re ahead of where we were two years ago,” said WAI Sales Director Bob Xeller. “There’s a lot of positive momentum.” At this point, all of the larger booths have been taken, with the largest available sizes now being 400 sq ft (20 x 20). If demand continues to stream in, it may be possible to expand the floor plan, he said.

INTERWIRE 2013 | THE LARGEST WIRE AND CABLE MARKETPLACE IN THE AMERICAS.

Thank you to our sponsors for their support of

Platinum Level Sponsor

Gold Level Sponsors

Silver Level Sponsors

A wide range of sponsorships exists for the 2015 staging of Interwire in Atlanta Companies seeking recognition at Interwire 2015 have a wide range of WAI sponsorship opportunities at the Georgia World Congress Center, from the full event to individual elements that are offered on a first-come, first-served basis. Four levels of corporate sponsorships are available to help companies promote their organization in connection with Interwire and WAI’s 85th Annual Convention, to be held April 28-30 in Atlanta, Georgia. All the corporate sponsor-

Bronze Level Sponsors

Supported by:

AMERICAN WIRE PRODUCERS ASSOCIATION

32 | WIRE JOURNAL INTERNATIONAL

Keynote Speaker. This is a chance to provide convention visitors, trade show attendees, and exhibitors with timely information that will set the tone for the biennial event. Cost includes: the speaker fee; the opportunity to introduce the speaker prior to the address; and company name and logo recognition in pre-show coverage (in print and online) and on onsite signs. New! Mobile Website. Make sure your company name is associated with WAI’s convenient new mobile app that visitors will use to check up-to-the-minute show and scheduling details. Ask your sales representative for more information.

Directional Signs. These are four double-sided meter board signs that will be strategically positioned in the convention center to guide visitors to the exhibit area. WAI Member Breakfast. Held Wednesday, April 29th, this invitation-only, one-hour celebratory event welcomes new members to WAI’s network. It will include raffle prizes. The cost includes pre- and post-event coverage; invitations, light refreshments, and logo recognition onsite. Coffee Break. Available for two days. A sponsor’s name and logo will appear on a sign near the coffee station. Juice Bar. Held Wednesday, April 29th, this includes a sponsor’s name and company logo on sign near juice station. Cyber Café. Help participants stay connected at one of two cyber cafés. The sponsor’s name and company logo will be presented at the kiosk area(s). Charging Stations. Up to three device charging stations will be offered onsite. The sponsor’s name and company logo will be seen at the kiosk area(s). Tour Transportation. Provide plant tour transportation. Motor coach can accommodate a customer supplied “infomercial” video.

Sponsors were a key to Interwire 2013.

AUGUST 2014 | 33

WAI NEWS

ships receive exposure on the Interwire website; advertising in Wire Journal International and the Official Show Program; acknowledgment in WAI’s pre-event marketing materials; onsite promotion; recognition at the WAI Member Center; and post-show acknowledgment. Corporate sponsors include: Platinum Level, $9,000; Gold Level, $7,000; Silver Level, $5,000; and Bronze Level, $3,000. For more details on these or the below supporting sponsorships, contact WAI’s Bob Xeller, tel. 203-453-2777, ext. 119, bxeller@wirenet.org; or Anna Bzowski, 203-453-2777, ext. 126, abzowski@wirenet.org.

WAI NEWS

4 WAI members up for consideration for the Association’s board of directors An employee at four companies (a cable manufacturer, a reel supplier, a compounds supplier and a specialty cable manufacturer) are each up for consideration for four slots on WAI’s Board of Directors when the ballots go out in September. Three of the four individuals will be new to the board, with the fourth is now serving his first term. Below are details about the four individuals who are up for a fouryear term on the board. Richard Baker is vice president, manufacturing & process technology for General Cable. He previously worked for Alcan Cable, where he served in a wide range of positions, and was vice president of technology when the company was acquired in 2012 by General Cable. In 20072009, he was the expatriate project director tasked with managing the design, build, commissioning and Richard Baker start-up of a greenfield aluminum power cable facility in Tianjin, China. He has some 37 years of experience, with prior positions including key manager posts at companies that include

Pirelli General Cable, Rodco, Aluminium Wire & Cable and Canada Wire & Cable prior to joining Alcan Cable. He has been a member of the WAI, as well as a Southeast Chapter member, since 1985. He is currently serving a first term on the Board of Directors, and has also served on the Conference Programming Committee. He graduated from the University of Bath, England, with a B.Sc (Hons) degree in materials science. Steven Bonnell is group president of Marmon’s Engineered Wire and Cable’s Specialty Group that includes the RSCC and Dekoron businesses. Marmon Engineered Wire & Cable operates 13 recognized manufacturers of specialty low, medium, and high voltage cables. Marmon Holdings, Inc., a Berkshire Hathaway Company since 2008, is a global, diversified industrial organization comprised of Steven Bonnell three autonomous companies serving four diverse, stand-alone business sectors. Marmon operates over 150 autonomous manufacturing and service businesses with more than 15,000 employees worldwide. Bonnell previously served as president of RSCC and as vice president of the RSCC Exane Business. He joined the wire and cable industry in 2010 with more than 20 years in key leadership positions in the global automotive and aerospace industries. He received his master of science degree in management from Walsh College in Troy, Michigan. He serves on the Board of Junior Achievement of Southwest New England. Jay Munsey is the national sales director at S&E Specialty Polymers in Lunenburg, Massachusetts. He joined S&E in 2011 and is responsible for the national and international sales force, sales forecasting and sales development. Prior to S&E, he worked for AlphaGary Corporation from 1988 to 2011 in a number of different positions, including director of human resources, director of cusJay Munsey tomer service/inside sales, marketing services manager, network safety specialist (AG/DuPont joint venture) and new business coordinator. From 1980 through 1985, he worked at the Wentworth Institute of Technology in Boston, where he was the director of housing, director of student activities and the women’s basketball coach. During that tenure, he served on several national committees and conferences for the National Association of Student Personnel Administrators, the National Association of Campus Activities, the American College Personnel Association, and also chaired a symposium at Bowdoin College focusing on student development theories and practices in higher education. He holds an M.Ed. degree in higher edu-

34 | WIRE JOURNAL INTERNATIONAL

CALL FOR PAPERS

THE LARGEST WIRE AND CABLE MARKETPLACE IN THE AMERICAS. April 28-30, 2015 | Georgia World Congress Center Atlanta, Georgia, USA

id e

ro ll

t at

Inter wire.

AbstrAct DeADline: november 3, 2014 AcceptAnce notificAtion: December 1, 2014 mAnuscript DeADline: februAry 2, 2015

Submit your abstract today! The Wire Association International (WAI), Inc. invites authors to help define its 2015 conference program at Interwire with the latest technical and practical wire and cable industry topics in the world. Accepted authors receive: • complimentary registration with access to conference sessions, exhibit hall, and opening reception; • Conference Proceedings materials; • industry exposure; and • complimentary 1-year WAI membership. See the submission form on the reverse side. The Wire Association International, Inc.

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ABSTRACT SUBMISSION

In order for the Wire Association’s Conference Programming Committee to properly assess the scope and content of your proposed technical article, please submit a 75 word abstract.

PAPERS

Accepted speakers will receive an Author’s Guide with details about manuscript and presentation preparation via e-mail. Only original papers not previously published will be accepted for Wire Association International paper awards and possible publication in Wire Journal International. Please complete the following information. Send to: Marc Murray, Director of Education & Member Services, The Wire Association International, Inc., 1570 Boston Post Rd., P.O. Box 578, Guilford, CT 06437-0578 USA, Tel.: (001) 203-453-2777, Fax: (001) 203-453-8384, E-mail: mmurray@wirenet.org. Check your area of interest: ❏ Operational Presentation ❏ Technical Paper Presentation Check your category: ❏ Ferrous ❏ Nonferrous ❏ Electrical ❏ Fiber Optic ❏ General Author(s) Contact Author (designate one only) Title of Paper Company (affiliations for each author) Address City

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INTERWIRE 2015 The Conference Programming Committee reserves the right to screen all abstracts and reject those abstracts deemed unsuitable or inappropriate for presentation or publication. Everyone who submits an abstract will be notified whether the abstract has been accepted.

business and marketing from Marietta (Ohio) College and has served on its alumni board since 2006. He also sits on several other nonprofit and community service boards.

Jeff Stafford is division vice president and general manager of Sonoco’s reels and spools division, which operates 29 facilities throughout the U.S. He has been a member of WAI and involved in the wire and cable business as a supplier for 14 years. Founded in 1899, Sonoco is a global provider of a variety of consumer packaging, industrial products, protective packaging and packaging Jeff Stafford supply chain services. With annualized net sales of approximately $4.9 billion, the company has more than 19,900 employees working in 335 operations in 33 countries, serving many of the world’s best-known brands in some 85 nations. Stafford has been with Sonoco for 26 years, serving in various capacities and three different divisions. Prior to returning to the reels division in 2013, he was division vice president and general manager of the protective packaging division overseeing operations in the U.S., Mexico, China and Turkey. He holds a B.A. degree in

Platinum members to get 2 exclusive industry bonuses in coming months Companies that hold Platinum membership in WAI will be getting a special report on the wire and cable industry, followed by a webinar providing further details and an opportunity to pose questions. The report will focus on the PLATINUM MEMBER electrical sector this year. The report is being prepared by multiple sources, including U.K.-based Integer Research. All companies that hold Platinum membership will The Wire Association International, Inc. receive the report and an invitation to take part in the webinar. The dates for the report and the website will be noted in a future issue. Next year’s report for Platinum Members will focus on the steel sector. For more information on Platinum membership, contact WAI’s Steve Fetteroll at sfetteroll@wirenet.org. 

AUGUST 2014 | 37

WAI NEWS

cation in student affairs administration from the University of Vermont and a B.S. degree in zoology/marine biology from the University of New Hampshire.

CHAPTER CORNER

CHAPTER CORNER Surprise winner at Midwest golf tourney A total of 45 players competed on June 20 at the 12th Annual WAI Midwest Chapter Golf Tournament, where the winners were, well, the team with the highest score. On what was a deemed an outstanding day for golf, tournament Chairman Kevin Sopczak, Leggett & Platt, explained what happened at the St. Andrews Golf & Country Club in West Chicago, Illinois. The scramble format tournament turned in several low team scores, however, because the team with the overall lowest score departed early, Chairman Sopczak decided to switch things up and awarded the low team award to the highest scoring team. “This decision was greeted with overwhelming support!” he declared. “Perhaps, this is because, everyone now thought they had a chance of winning? The team with the ‘best’ score was the team of: Bud Banks, Robert Bulitta, Denny Brown and Bill Keiler, all from Micro-Weld.” Individual prize winners were: Closest to the Pin: Kurt Breischaft of SDI LaFarga, John Dabbelt of Fort Wayne Wire Die and Steve Schultz of Lake Cable LLC. Longest Drive Contest winners: Don Stephanic of Western Engineered Products, Jerry Jacques of NIMSCO LLC, Doug Hoersten of Shaped Wire and Eric Dorman of Fort Wayne Metals, who won two holes. “The Midwest Chapter outing was a huge success,” said Chapter President Tim Fingeroos of Charter Steel. “After our first rain in 11 years in 2013, this year turned out to have perfect golfing weather.” Fingeroos thanked the following company sponsors, which he said “are the key to making this chapter run and do a great job all year round in support of this industry.” Closest to the Pin sponsors: Southwire/Coleman Cable, D & S Wire, Micro Products and Suzuki Garphyttan; Longest Drive: Charter Steel, Southwire/Coleman Cable (two holes), Illini Wire Works and SDI LaFarga; hole sponsors: Amaral Automation Associates, P & R Specialty, Chicago Area Spring Manufacturers Inc (CASMI), Rubicon Group, Southwire/ Coleman Cable, Sonoco Reels, D & S Wire, Suzuki Garphyttan, Esteves Group USA, Western Engineered Products, Fort Wayne Wire Die, Gem Gravure Co., Krueger Steel & Wire, NIMSCO LLC and Omni Source. The real beneficiary of the tournament is the WAI Midwest Chapter Scholarship Fund, which in conjunction with the Wire Foundation, provides a $1,000 scholarships annually to graduating high school seniors whose parent or guardian is a WAI Midwest Chapter member in good standing. This year’s recipient is Nathan Thomas Palmer, son of Mark Palmer of 3M.

3 WAI Chapter golf tourneys still to be held It’s never too early to sign up for one of the three WAI chapters events that will be held in the coming months. The New England Chapter will hold its 20th Annual Golf Tournament on Sept. 8 at the Ellington Ridge Country Club in Ellington, Connecticut. Contact: Anna Bzowski, tel. 203-453-2777, ext. 126, abzowski@wirenet.org. The Southeast Chapter will once again return on Oct. 2 to the Rock Barn Golf and Spa in Conover, North Carolina, to hold the Vannais Southeast Chapter’s 13th Annual Golf Tournament. Contact Art Deming, tel. 252-955-9451, art.deming@nexans.com. The Western Chapter will stage its 14th annual “Wild West Shootout on Monday, Oct. 20, at the Sierra Lakes Golf Course in Fontana, California. For more details, contact John Stevens at tel. 909-851-5633 or by e-mail at jstevens@ emc-wire.com or WAI’s Steve Fetteroll at tel. 203-453-2777, ext. 115, or sfetteroll@wirenet.org. Each event offers multiple sponsorship opportunities and the chapters welcome donations of items for raffles, held during the awards presentations.  38 | WIRE JOURNAL INTERNATIONAL

EVENT PREVIEW Opening ceremonies at the last staging of wire China. Organizers note that an estimated 1,000 exhbitiors will participate at the 2014 event.

wire China preview The below report was edited from a preview provided by Huned Contracor, the editor of WIRE BULLETIN, WAI’s quarterly publication in India, who will be attending the event. A list of exhibitors is on p. 46. Axel Bartkus

Wu Shimin

The 6th All China International Wire & Cable Industry Trade Fair (wire China 2014), Asia’s premier wire, cable, tube and pipe industry exhibitions, organized by Messe Düsseldorf China Ltd. (MDC), will be held at Shanghai New International Expo Centre (SNIEC) from September 24-27, 2014, and holds the promise of once again getting together hundreds of manufacturers, traders, innovators, suppliers and buyers under one roof. As a preview of what the show has to offer, questions about the event were posed to Axel Bartkus, general manager, Messe Düsseldorf (Shanghai) Co., Ltd., and Wu Shimin, senior engineer engaged in technology and economic information of the wire and cable industry in China for years. He served as Executive Deputy Secretary-General, Electric Cable & Wire Branch

40 | WIRE JOURNAL INTERNATIONAL

of China Electrical Equipment Industry Association (CEEIA); member of Electric Cable & Wire Special Committee of China Electrotechnical Society; and Deputy Director, Convention & Exhibition Center of Shanghai Electric Cable Research Institute (SECRI).

What will the show offer this year? AB: As thousands of exhibitors and trade visitors are going to attend this second-largest trade show of wire and tube industry in the world, wire and Tube China 2014 will be an excellent platform for idea exchanges, networking, cases showing, exhibiting and face-to-face business talk. The special zones featuring raw materials (chemicals and insulation) and springs and fasteners will provide a customized exhibiting occasion to enhance the effectiveness of business matching. Global and Chinese local famous industry players have participated in wire China 2014, including Wafios, Maillefer, SAMP, Niehoff, Furukawa, B & R, Dow Chemical, Elantas, Fupao, Huntsman, Teijin,

Borouge, Suzuki, Kiswire, DSR, Kos Wire, Shanghai Kingstone, Hefei Smarter, Jiangsu Singcheer, Jiangsu Handing, Suzhou Chaur Lung, Baicheng Fujia, Dongguan Liwei, HOSN, Dongguan Jingtie, Jiangsu Xin Hongtai, etc. The international pavilions will display their advanced technologies and solutions in wire China 2014 and these include the pavilions of Germany, U.S., Italy, Austria, U.K., Japan, Taiwan and South Korea.

What will make the wire China show different from the other wire shows? AB: In my opinion, the “similarity” is much more important than the “differences.” As you know, wire China is the second-biggest trade fair for its industry among Messe Düsseldorf’s wire line-up, which consists of six shows in different regions. With the professional organization as well as the strong synergy of this well-known ‘wire’ brand, wire China is always recognized as the most successful international show for customers to tap into the Chinese market or develop their business partnership with Chinese manufacturers.

What is the current status of the wire industry in China?

AB: Over 1,000 exhibitors are estimated to participate in wire China 2014. This show serves the industry as a ‘one-stop’ platform. You can say, we will showcase everything relative to wire and cable manufacturing and processing. Visitors can definitely find those big shots in the sectors they are interested.

WS: ‘China factor’ is a hot topic in the global wire product market and the global basic materials market alike. Since the reform and opening-up policy was adopted over 30 years ago, the Chinese economy has been maintaining an average annual growth rate of nearly 10%. Thanks to swift develop-

ment, the wire industry in China has witnessed tremendous change as its overall scale of wire production ranks No. 1 in the world. Following is the annual output of conductors of the wire industry in China, from SECRI: copper conductors, over 5 million tonnes (mt); aluminum conductors, over 2 mt; and consumption of optical fiber, over 100 million km.

Exhibitor perspectives Maillefer has a long successful history with the wire and cable producers in China. The Chinese wire and cable market continues to grow at a faster pace compared to global markets. We are committed to further strengthen our presence in the market, both as a leading technical supplier of new production capacity, as well as a partner for process improvements, know Fagerholm how, and services. For wire China, we will bring several new innovations and products. To better answer the diverse needs of the market our portfolio now includes three different levels of production solutions, which vary in capacity, cost, automation, �lexibility, product-range and space and maintenance requirements. They match exact needs and provide maximum value for both the high end investments as well as the more affordable requirements. Maillefer CEO Lars Fagerholm. The outlook of Rosendahl Nextrom for the Chinese market continues to be positive. In light of a population of 1.3 billion, the huge territorial expanse, rapid urbanization and the fact that the build-out of the infrastructure is far from being completed, the market demand for wire and cable as well as �iber optics will be huge in the next few decades. The living standard of the Mao Chinese people will rise, and with that, the level of demand for quality and special products will approach that of the industrialized countries. As a global market and technology leader for manufacturing solutions for wire and cable as well as optical �iber, opportunities for us will not diminish as more premium quality and special wires and cables are required. We seek to satisfy the needs of highLuo

end cable-makers and optical �iber-makers in China by offering them high-end equipment together with excellent service. Xingwang Mao, managing director, and David Luo, sales manager, Rosendahl & Nextrom in Shanghai. We have a positive outlook for the Chinese market. Its gross domestic product has been growing for more than 20 years. Simultaneously, the demands of the end-users in regards to product quality are growing too. Thus, wire and cable manufacturers have to improve product quality to stay competitive. We see a lot of Chinese companies becoming more successful due to the use of Chen our measuring and control devices. wire China is a perfect platform to showcase our online technologies, such as the FIBER Series 6000 for quality assurance; the X-RAY 6000 for diameter, eccentricity, ovality and wall thickness; the LASER Series 2000/6000 for professional diameter measurement; the PURITY SCANNER for 100% inspection/ sorting of XLPE pellets; and our PREHEATER 6000 TC. Wanbin Chen, president, SIKORA ASIA. EDER-Austria started to work in China in 1978, resulting in excellent sales of our machines until about 2000, when copying generally started. However, we do have a positive outlook for the Chinese market again, as (it has) come to know the real differences existing between a somehow poorly ef�icient copy and an “original.” In a clearly more wealthy China, most Chinese Eder can now afford to buy “originals” again, claiming that their use creates an even better quality for their own products, which they intend to export abroad and under a better reputation. For us, wire China is supposed to be a good place for discussions and negotiations, but for us it is hardly for direct business and contracting. Dr. Kurt G. Eder, president Eder Engineering.

(continued next page)

AUGUST 2014 | 41

EVENT PREVIEW

How many companies will exhibit? What will they offer?

EVENT PREVIEW

ufacturing industries; and cooperation Secondly, the manufacturing level has with foreign companies while learning considerably improved. In recent years, state-of-the-art technology and managea large quantity of foreign and domestic ment expertise. sophisticated manufacturing equipment Meanwhile, it’s true that the wire have been used in the wire industry industry in China still faces various in China, and the self-initiated R&D challenges, such as: serious excess procapacity of wire companies has been duction capacity and subsequent excesenhanced. The wire industry in China can mass-produce basically all categories of wire products, covering all types and specifications, which greatly satisfy domestic demand. Exported wire products have become even more competitive. Thirdly, the wire industry in China has greatly reinforced the capacity of providing auxiliary parts and components. Domestic wire companies can mass-produce basically all types of U.S. exhibitors continue to have a presence at wire China. wire equipment and materials. sive market competition in mid-range These achievements are attributed to and low-end products; insufficient R&D the following factors: economic vitality capacity, backward technology and weak spurred by China’s economic reform basic research in the manufacturing and opening-up; huge market demand techniques, materials and equipment of generated along with the country’s rapid wire products; and the dependence on economic growth; improved supporting imported high-end products with high efficiency of the industry chain due to added-value. In the wire industry in overall development of China’s man-

China, many small and medium-sized companies remain fragile in sustainable growth, and big companies are plagued by weak international competitiveness. There’s still a long way to go for the wire industry in China, which has much potential of improving self-competitiveness for further development.

Will the industry in China grow in the coming years?

WS: Due to the global economic crisis, China has been facing mounting pressure in the downside of economic growth since 2012. Future economic development will be hindered by increasingly severe problems incurred by break-neck economic growth, including irrational economic structure, low growth efficiency, excess production capacity, unsustainable support of resources and the environment. The Chinese government has realized that both too fast and too low economic growth hurt the domestic economy and potential economic growth shall be sustained with the support of resources and capacity.

(continued from prior page) We indeed have positive outlook for China as this is a huge market. Our market share is still small but we are continuously growing our sales by offering services and technology. Our innovative products are aimed at optimizing production performance with cost effective technologies. Our expectations are to diversify much more and increase Chambellant our commercial network globally. We are growing our sales organization and we are focusing our efforts in south and central China where we expect to �ind agents or distributors. I hope to meet new partners during this Shanghai exhibition. François Chambellant, wire drawing business manager, Condat. 42 | WIRE JOURNAL INTERNATIONAL

Micro Products Company recently entered the Chinese market. We are still in the process of establishing our MicroWeld brand of high-performance butt welders as the ideal choice for wire and cable manufacturers in China. The signs are encouraging and as the Chinese economy recovers this process will receive a further boost. The wire China show provides an Banks excellent platform to showcase our butt welders for quality conscious companies in the wire and cable industry that demand continuous processing of wire, rod or cable without downtime. It’s also an opportunity to meet with our existing and potential customers and reps in the region. Bud Banks, president, Micro Products Company.

The best way to deliver an encore is to add to the cast.

Aluminum joins copper for WAIâ&#x20AC;&#x2122;s second Global Continuous Casting Forum April 27 - 30, 2015 | Atlanta, Georgia, USA | With Interwire 2015 Join a renowned ensemble of continuous casting practitioners, raw material suppliers, and equipment manufacturers on an educational journey from ore to more at WAIâ&#x20AC;&#x2122;s second Global Continuous Casting Forum. Shared sessions. Independent technical tracks. Unalloyed networking. All focused on saving money through performance-based casting technologies. www.castingforum15.com.

April 27 - 30, 2015 | Atlanta, Georgia, USA | With Interwire 2015

2015 SPONSORSHIP PROGRAM PLATINUM

GOLD

SILVER

$6,000

$4,000

$2,000

The Wire Association International, Inc. offers three levels of promotional sponsorship opportunities in support of its Global Continuous Casting Forum 2015. All sponsors will receive recognition in pre-show promotion; on the Continuous Casting website www.castingforum15.com; in Wire Journal International; on conference presentation screens; and on on-site signs. Company names will be listed alphabetically within the appropriate tier (Platinum, Gold, or Silver) and company logos will be accommodated as space permits. Sponsor companies will also be recognized verbally at the opening dinner event and receive a sponsorship plaque to honor participation in the program. Hurry! Pre-show promotion is already underway. For details contact: Gary Spence | gary.spence@encorewire.com | Tel.: 972-562-9473 Richard Baker | rbaker@generalcable.com | Tel.: 770-392-2308 WAIâ&#x20AC;&#x2122;s Steve Fetteroll | sfetteroll@wirenet.org | Tel.: 203-453-2777

Aluminum joins copper for WAIâ&#x20AC;&#x2122;s second Global Continuous Casting Forum! The Wire Association International, Inc. 1570 Boston Post Road | P.O. Box 578 | Guilford, CT 06437-0578 USA | Telephone: (001) 203-453-2777 | Fax: (001) 203-453-8384 | www.wirenet.org

eliminating dependence on highspeed growth, focusing on improving efficiency, enhancing innovation capacity and following a new path for development.

Are Chinese wire companies open to technology sharing? WS: The development of the wire industry in China has been considerably benefited from cooperation with foreign companies and learning and self-improvement for win-win results. Looking forward, it’s imperative for the wire industry in China to strengthen cooperation with foreign companies. Leading Chinese wire companies are raising their awareness of going global. These companies need to strengthen comprehensive cooperation and communication with foreign counterparts in technology, operational management, marketing, etc. Both the wire industry and the wire market in China will be more open-minded to communicating and cooperating

with international counterparts with a view to achieving win-win results.

Will there be seminars?

AB: Yes. Look for details at the official website, www.wirechina.net.

What will exhibitors gain? AB: It was proved that it brought a positive effect to our exhibitors from our earlier shows and there is no doubt the show will lead to many successful business deals. Take the visitors’ comments of wire & Tube China 2012 as an example. From the visitors’ perspective, positive feedbacks were collected as well. Products and services presented were the most advanced compared with previous editions. Furthermore, visitors from different countries worldwide felt very amazed about the wide range of exhibits and considered it a fruitful and resourceful exhibition. Many who came for the first time confirmed their willingness to attend the next exhibition. n

AUGUST 2014 | 45

EVENT PREVIEW

Efforts shall be made to enhance innovation and improve efficiency to further contribute to economic development. Policies keeping moderate investment and stimulating domestic consumption shall be adopted to fuel economic growth. Influenced by domestic economic transformation and slowdown in recent years, the growth rate of China’s wire industry has slumped despite continuous development. Guided by government policies on economic transformation and upgrade, China’s new urbanization development and the transformation and upgrade of manufacturing industries will continue providing broad market space for the country’s wire industry. For instance, since early 2014, China has been stepping up investment in power grids, railways, 4G, etc., while sound momentum has been maintained in the development of clean energy, e.g., wind power and nuclear energy. The wire industry in China will keep relatively stable growth in the next years, thus

EVENT PREVIEW

Alpha list of exhibitors Below is an alpha listing for exhibitors outside mainland China provided by the organizers. For more details, go to www.wirechina.net and see the show program at the event.

• AEI Compounds Ltd • AESA SA • AIM, Inc • Alphagary Corporation • ATE Applicazioni • ATS APPLICAZIONI • Aumann GmbH • Société des Filières • Carl Bechem GmbH • Besel Basim San Tic Ltd Sti • Beta Lasermike • BGH Edelstahlwerke GmbH • Blachford Corporation • Böllinghaus Steel GmbH • Boockmann Engineering GmbH • Dalian Boockmann Co Ltd • burster präzisionsmesstechnik Buss AG • Caballé, SA • Candor Sweden A/B • Ceeco Bartell Products, • CeramTec GmbH • CERSA-MCI • Cimteq Ltd • Clifford Welding Systems (Pty) • CM MANZONI SpA • Condat Lubrifiants • Conductix-Wampfler • Conoptica AS • CONTINUUS-PROPERZI SpA • CONTROLE MESURE SYSTEMES (CMS) • CPT SAR L • Davis-Standard, LLC • Deutsche Nickel GmbH • DWK Drahtwerk Köln GmbH • EBNER Industrieofenbau GmbH

• Eder Engineering GmbH • EJP Maschinen GmbH • Elantas GmbH • Eurolls SpA • FIB BELGIUM SA • Fiber-Line International B.V. • Fisk Alloy Conductors, Inc • Flymca & Flyro • FMS Force Measuring Systems AG • Fort Wayne Wire Die, Inc • FSP-One SAS. • Fuhr GmbH & Co KG • Gauder SA • GCR Eurodraw SpA • GIMAX Srl • HMP Heinrich Müller • Henrich Maschinenfabrik GmbH • H Folke Sandelin AB • HIGHVOLT Prüftechnik • AI HOLDING • ICE - Agenzia per la promozione • IFP SpA • iiM AG • Inductotherm • Intras Limited • IVA / ESSEX SAS. • IVA Electrical Insulation Materials • IWCEA France • IWMA - International Wire & • KBA-Metronic GmbH • KBA-Metronic (Hangzhou) Co • KJM GmbH • Ernst Koch GmbH & Co KG • Lämnea Bruk AB • Landgraf Srl

46 | WIRE JOURNAL INTERNATIONAL

• Lech-Stahlwerke GmbH • Lenzing Plastics GmbH & Co • Leyer & Kiwus Ultraschall- und Lasertech • LUKAS Anlagenbau GmbH • MAG • Maillefer Extrusion Oy • MALI GmbH • Mario Frigerio SpA • Medek & Schörner GmbH • Metalube Ltd • Micro Products Company • Microdia SA • Microstudio Srl • Miltec UV • Maschinenfabrik • OEG Gesellschaft für Optik, Elektronik & • Otomec Srl • Pan Chemicals SpA • Petrofer Chemie • PIETRO GALLIANI SpA • Promostar Srl • Queins Machines GmbH • RAD-CON Inc • Reber Systematic GmbH + Co • RichardsApex, Inc • Rohmann GmbH • Rosendahl Maschinen GmbH • RSD Technik GmbH • Saar-Blankstahl GmbH • Saarstahl AG • SAMP SpA • Sandvik Hyperion • SAS Engineering & Planning • Scapa Cable Solutions • Schlatter Industries AG

• Hans Schmidt & Co GmbH • Schnell SpA • SEI Sistemi Srl • Shanghai Potomer International Trade • Siebe Engineering GmbH • SIKORA AG • Sikora (Fuzhou) Electronic • Simplex Rapid Srl • Sindia Instruments Co Ltd • SKET GmbH • Southwire Company • Spectrum Technologies PLC • Spirka Schnellflechter GmbH • Stolberger GmbH • August Strecker GmbH & Co • Taymer International Inc • TDV SAS • Teknor Apex Company • TKT SpA (Tecnovo Koner Techosider) • TRAXIT International GmbH • Traxit (Tianjin) Chemical Co • Troester GmbH & Co KG • Joachim Uhing GmbH & Co • JSC VNIIKP” • VÖDKM/ WCMA Verband • voestalpine Austria Draht GmbH • WAFIOS AG • WAFIOS (Shanghai) Machinery Co • Weber & Scher Mfg Co Inc • Welding Wire Machineries Srl • Wiedenbach GmbH • Wire & Plastic Machinery Corp. • Wirtschaftskammer Österreich • WiTechs GmbH • WITELS-ALBERT GmbH

FEATURE

Industry Standards This feature presents a range of historical and practical perspectives on standards, including a primer from NEMA about how the process works, a look at the range of one company’s standards activity, a look at how ASTM came to be, the view of a person who was long involved in standards writing committees, technical observations from an industry guru, and more.

You might not have penciled in Oct. 14 as special day, but for the record it is World Standards Day. It was Oct. 14, 1946, when delegates from 25 countries met in London and agreed that the world needed an international organization focusing on facilitating standardization. A year later, ISO, the International Organization for Standardization, was created, and the first World Standards Day was held in 1970. The idea was to honor the efforts of the thousands of experts who develop voluntary standards within standards development organizations such as the International Electrotechnical Commission (IEC), ISO, International Telecommunication Union (ITU), Institute of Electrical and Electronics Engineers (IEEE) and the Internet Engineering Task Force (IETF). With its first meeting held in 1986, IETF is the “new kid” on the standards block, but ISO, IEC and ITU have each issued tens of thousands of standards. At the ISO website, the organization explains, as follows, why the scope and importance of standards, should not be underestimated.

“Today, products that are consumed in one market are no longer made in one country; they are made in the world. Before they get to the end-consumer, they transit through many countries where manpower or parts add value to the final product. “Small and medium enterprises (SMEs) that use international standards will find it easier to get their products certified and are better able to compete and sell anywhere in the world. With international standards SMEs are able to take part in global value chains and benefit from technology transfer. Countries that have mainstreamed international standards in their policies and regulations are able to better protect their populations and give them a bigger choice of quality products. “In a multi-polar world, where the influence and economic weight of emerging economies is shifting the balance of power, international standards stimulate trade, overcome artificial trade barriers and help level the playing field. This makes companies, industries and economies more competitive, making it easier for them to export, and stimulates diversification nationally and internationally.”

For CommScope, activity in industry standards process is not an option How demanding can it be to keep up with all the industry standards? “It takes a serious commitment of resources,” said David Tanis, Strategic Marketing Director, CommScope, who noted that in the last few years more than 30 company staffers with standards expertise have been active participants at 60 different projects around the world.

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The opposite page shows the first of two pages from the company’s quarterly, Standards Advisor, which updates its standards activity. “When you look at all those projects, and remember that you’re looking at just one of two pages, you can appreciate how exacting this is, but it’s something we do it because it’s essential to our business and customers.”

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NEMA primer: the process by which industry standards are created

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Paul Molitor is the assistant vice president of smart grid and strategic initiatives for the National Electrical Manufacturers Association (NEMA), where he is responsible for monitoring the global Smart Grid effort and interfacing with electric utilities, manufacturers, federal agencies, and the U.S. Congress. Below, he explains how the standards-making process works. WJI: How are new standards formed? Has the process member companies and non-members. We drafted and changed much over the years? approved the standard in 90 days and gave it away for free to smart meter manufacturers. This satisfied the regulators Molitor: New standards are usually started because of a and the installation of smart meters went forward. compelling market need. The source of that need could be driven by some form of consumer demand (e.g. the need WJI: Who has standing to ask/press for a new standard? to standardize EV chargers to make things simple for the consumer), or a statutory or regulatory action (e.g. almost Molitor: Anyone can ask for a standard but the everything oriented towards safety). They generally fall challenge in getting it developed depends on the willinto one of two camps: de jure standards written by an ing cohort described above. Because one of the ANSI accredited body like NEMA, or de facto standards written Essential Requirements is consensus, we strive to have by an industry consortium that become commonly used in participants from a healthy, double-digit number of entithe market. Standards ties. (Note that I say from the Internet “entities” and not Engineering Task Force people. Two comare a great example of panies supplying de facto standards. The five people each IETF is not accreditdoes not constitute a ed by any national or standard committee.) international body, but Obviously the more, their standards (called the better. Requests for Comment or RFCs) are widely WJI: Must one adopted around the prove a need for a world. new standard? NEMA is almost Molitor: It’s almost 90 years old and the always the case that process has remained a need exists. I’ve largely consistent over Paul Molitor (speaking) during a panel discussion at heard a rumor that the last several decades. Grid-Interop 2011. someone published an Part of the reason for RFC for running the this is that we are accredited by ANSI, which has very rigid internet protocol over barbed wire, which obviously was rules called the ANSI Essential Requirements for forming a not driven by any form of need. If the need doesn’t exist, standards group to ensure balance, openness, and the other you’re not likely to get people to show up to perform the characteristics that form a consensus body around that stanwork which blows the notion of “consensus” out of the dard. If we don’t follow the ANSI rules, we lose our ability water for us. to write American National Standards. WJI: Does one look to see if there is an existing stanWJI: What impetus is needed to start the process? dard that can be adjusted? If so, can it be used as a base Molitor: The common industry need and a willing cohort or must each new standard start from scratch? are the only two things necessary to start the process. For Molitor: The first thing we do is evaluate the market example, in 2009 the electric meter industry became conto see if there is another standard that can be adjusted. cerned when regulators threatened to stop the installation Going back to the smart meter example, the IEEE pubof all smart meters until NIST had a chance to complete lishes a number of modified versions of the ANSI/NEMA their standards evaluation role mandated by the Energy C12 standards. Independence and Security Act of 2007. The thinking by It’s not uncommon for an SDO like NEMA to get a the regulators was that the utility company investment request from another entity looking to create a derivative would be wasted if the underlying standards base changed. work from one of our standards. We do it too. The ANSI/ In essence, the common industry need was that smart NEMA standard for testing and certification is a derivative meters were not uniformly upgradeable. In response, work of the SGIP’s Interoperability Process Reference NEMA convened a working group to draft a smart meter Manual. The most common technique is to incorporate the upgradeability standard that included a combination of source standard by reference. 50 | WIRE JOURNAL INTERNATIONAL

Interoperability Panel (SGIP) attempted to broker a peace, but despite the efforts of many, the other organization chose to remain a closed group. As a result, the standard has been marginalized by the industry and has virtually no adoption.

WJI: Who pays for the process? Molitor: The vast majority of the work is paid for by the participants. In NEMA’s case, they pay dues to the association which covers the time and expenses of our program managers. The members pay their own labor and for their own travel and expenses in the event of a face to face meeting. Conference call expenses, where much of the work takes place, are part of the overhead in the NEMA dues. In certain instances we’ve received government contracts to develop standards. NEMA’s NTCIP standards for intelligent transportation systems, and the DICOS standard for airport security screening are the result of funding from the Dept. of Transportation and the Dept. of Homeland Security respectively. A certain amount of work is also self-funded through standard sales. No one pays a penny of dues to support our work on the ANSI Z535 standards for safety and emergency signage. Those expenses are 100% covered by the value of the standard sales.

WJI: How many stages are there to the creation of a standard? Molitor: In my mind, there are really only five: the solicitation period where the working group is assembled; the working period where the content is developed; the notice period where the draft standard is posted for public comment; the resolution period where those comments are resolved; and the balloting process, which may result in additional comments. Once the ballot is closed and all of the comments are resolved, the Codes & Standards committee conducts their review to ensure the appropriate process was followed and approves the standard for publication.

WJI: Must all parties that would be have an interest in the process be included? Molitor: For NEMA, the ANSI essential requirements mandate that we have diversity among the stakeholders; other non-accredited bodies do not. We were involved in a dispute with another SDO a couple of years ago over one of their standards for the smart grid. The Smart Grid

WJI: What kind of notice must be given to the industry? Molitor: An ANSI-accredited body has rigid requirements for notification – it’s included in the Essential Requirements. All comments received during the notification period must be resolved before the standard can be approved and published with either the NEMA or ANSI labels.

WJI: How often are stages delayed by requests for further information? Are periods of input from the industry required? Molitor: Delays are highly variable from one standard to another. Going back to the smart meter example, we completed the upgrade standard in about 90 days. The networking standard for smart meters (ANSI/NEMA C12.22) took the better part of a decade to complete. Interestingly enough, the NEMA smart meter upgrade standard has been submitted to ANSI to become part of the C12 family of standards. Further revisions are expected and the process is likely to take a couple of years.

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WJI: Who oversees the process? Molitor: For NEMA, the process is overseen by our Codes and Standards Committee. This is a collection of about 30 senior technologists from NEMA member companies. They are responsible for ensuring that a working group meets all of the hurdles required to maintain our ANSI accreditation. The day to day work is supervised by the NEMA program managers, our professional-layer staff of technical writers who specialize in standard writing. The C&S committee acts as judge and jury over that work. No document may bear the NEMA logo until C&S has signed off that the working group met the process requirements.

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WJI: What happens when interested parties have different ideas about how a standard should be written? Molitor: The job of the NEMA staff is to find the middle ground. In some cases the opinions are too entrenched and there can be no resolution. Because we operate under the consensus model, if no resolution can be achieved we simply have to declare that concept outside the scope of the standard. I was involved in the development of the DICOS standard for airport screening devices and I can honestly say that over three years, between the hundreds, if not thousand-or-more sections in that standard there were less than a handful of areas where we couldn’t find common ground. The compelling market need usually supersedes the individual differences of the stakeholders.

WJI: How long can a simple standard take to create? How long can a process take if there are objections? Molitor: As I mentioned earlier, the NEMA smart meter upgrade standard took 90 days whereas the ANSI C12.22 networking standard took something like 7 years to develop. WJI: How often does a standard, finally completed, reflect considerable ‘evolution” from what was originally envisioned? Molitor: In the end, the standard will fulfill the performance requirement as described in the proposal, but there can be considerable evolution of the actual standard content along the way. WJI: In terms of updates, are they considered a natural function as the industry responds to a new standard and questions/concerns arise? Molitor: NEMA has a specified maximum recertification period of five years. However, this may be shortened if the industry needs to respond to a significant change in the market. For example, anything life-safety oriented will prompt an immediate change to a standard. Other questions/concerns/modification/additions/deletions are accumulated and dealt with on a periodic basis not to exceed five years. Some standards may go through a revision cycle on an annual basis for a couple of years and then not change for the next decade outside of being recertified by NEMA when the five-year timer expires. The revision cycle is highly variable. WJI: Is the update process far simpler? Molitor: Yes, for the most part. However, some updates can become contentious because they may expose a stakeholder’s intellectual property. This is not uncommon for standards and products that have been in the market for a period of time. We have immediate flags in the NEMA process when IP comes into play. 52 | WIRE JOURNAL INTERNATIONAL

WJI: What happens when multiple standard organizations are involved in a process? Who has the final “say”? Molitor: We have a number of joint development agreements with other SDOs, but usually one of us is declared the lead on a joint standard process. This determines who has the chairmanship of the working group. Even if NEMA is not the lead SDO, the standard must clear our codes and standards committee before NEMA will sign off on the standard. And likewise if we are the lead, we don’t publish until all partner SDOs are satisfied. This adds a little bit of time to the balloting and comment resolution phases, but we’ve all been at this so long that we’re very comfortable working together. NEMA publishes joint standards with IEEE, ASHRAE and ASHTO, among others. WJI: How involved is NEMA when it comes to efforts to harmonize global standards for like products with other SMOs? Could and should this aspect work better? Overall, are manufacturers and end users well served by the collective existing guidelines? Molitor: NEMA is very involved in international harmonization. We are one of the founders of the Council for Harmonization of Electrotechnical Standards of the Nations in the Americas (CANENA, www.canena.org), a joint committee with our counterparts in Canada and Mexico who have undertaken the task of harmonizing national standards between our three countries. NEMA also holds several international secretariats for the International Electrotechnical Commission (IEC), the International Standardization Organization (ISO), and participates in dozens of U.S. Technical Advisory Groups (TAGs) for international standards bodies. The challenge with international harmonization is that it is a very slow and deliberate process. Part of this is the logistics of coordinating meetings with participants that reside on multiple continents, but the other part is that you are dealing with each country’s national committee which is the designated representative for the entire electroindustry for that country. Once a technical proposal is submitted, there is a lot of communication and coordination that has to take place within each participating country in order to achieve a national position on that proposal. This is a time-consuming process, but it is worth it in order to achieve a globally-acceptable position on a technical issue. In the end, international harmonization is very beneficial for manufacturers. First, it creates market access. Once a country adopts a globally-harmonized standard for their electric grid, manufacturers have a precise formula to build products that comply with that standard and provide those products to that country. Second, it reduces manufacturing burden. Harmonized standards allow a single manufacturing process to create products that can be installed in a variety of markets, as opposed to tailoring a basic product to multiple national standards. This a powerful tool for leveraging economies of scale, keeping costs down and maintaining competitiveness for NEMA member companies.

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Train tracks were a key driver to formation of ASTM ASTM International, an international standards organization that develops and publishes voluntary consensus technical standards, is well known to the wire and cable industry, but the story of how it came to be may not. ASTM’s legacy can be traced back to a single railroad company, and ultimately to a single person who worked there, a man who believed that material consistency was essential. The below piece, largely based on ASTM’s account of its history, and Wikipedia, provides context for how the organization came to be founded in 1895. For the full history, and more about the organization, go to www.astm.org. which disclosed enormous variaSteel and copper were used for tion in steel properties and quality, many years without any standards, raised a firestorm among steel but as technology made huge advancmasters, who disputed its findings. es the need for material standards The application of Dudley’s new become more apparent. The initial formula, they charged, produced drive for standards came from the unnecessary expenses that increased steel sector, led in the U.S. by the production costs. Steel producers, railroad industry. One of the largest determined to keep full control over operations was the Pennsylvania output and quality control, viewed Railroad (PRR), which was founded standard specifications issued by in 1846. To call it “big” would be a their customers as unacceptable major understatement: over the years, meddling. Dudley later reported it acquired, merged with or owned that steel companies often told the part of at least 800 other rail lines and railroads that “if they did not take companies. At its peak, PRR was the the rails (they) offered, they would largest publicly traded corporation in not get any.” the world, with a budget larger than Meanwhile, the railroad industry that of the U.S. government and a continued to grow, with traffic volworkforce of about 250,000 people. ume rising more than 300% during As railroads began using longer, the late 19th century. Dudley sought heavier trains powered by more to initiate a constructive dialogue powerful locomotives, the need grew between suppliers and their cusfor steel that was both stronger and An early Pennsylvania Railroad locomotive. tomers. Based on the antagonistic more consistent. There were quality relationship he saw in the 1880s problems with products such as steel between the PRR and its suppliers, he proposed a system of rails, with suppliers furnishing inferior materials. Some technical committees. They would provide representatives of manufacturers began issuing detailed descriptions (specs) the main parties with a forum to discuss every aspect of specfor the materials they needed. That did not go over well ifications and testing procedures for a given material. The with suppliers, some of whom feared that strict quality controls would lead to rejected products. Material specifications goal was to reach a consensus that was acceptable to both producers and to customers, i.e., the railroad. Although many were controversial as orders often were highly customized, initial meetings ended in failure due to the inflexibility of the applicable only to a specific customer. Industrywide stanparties involved, Dudley’s system held considerable promise dard specifications did not exist, which was a problem for large buyers. Without standard specifications, and with each and later formed the basis for ASTM’s committee structure. Dudley’s call for consensus building contributed to the 1895 mill following its own material testing procedures, buyers formation of the International Association for Testing Materials of industrial products were unable to ensure uniformity, and (IATM), which organized working committees to discuss frequently experienced uneven quality of steel rails. testing methods for iron, steel, and other materials. The IATM At Pennsylvania Railroad, Charles Dudley, who earned a encouraged members to form national chapters, and on June Yale PhD in 1874, organized a new chemistry department 16, 1898, 70 IATM members met in Philadelphia to form the for the company. He investigated the technical properties of American Section of the International Association for Testing oil, paint, steel and other materials the PRR bought in large Materials (ASTM). They grappled with two questions that quantities, and from those efforts he issued standard materiwere widely discussed throughout the engineering community al specifications for the company’s suppliers. at the turn of the century. First, how could standards for mateDudley soon realized that he had taken on a formidable rials contribute to industrial progress? And second, how could task. In 1878, he published his first major report, “The producers and users of industrial materials reach a consensus Chemical Composition and Physical Properties of Steel on standards? ASTM International’s early history was in large Rails,” in which he analyzed the durability of different part a quest to find answers to these pivotal questions. types of steel rails. He concluded that mild steel produced a During its early years, ASTM refined its consenlonger-lasting rail than hard steel, and Dudley recommendsus-building process. The key was balanced representaed an improved formula for mild steel for rails. His report, 54 | WIRE JOURNAL INTERNATIONAL

A standard okay that could sink you The International Organization for Standardization (ISO) is well known to the industry, but one would not want to depend on a tossed lifeline from some questionable registrars who are all-too-ready to certify to ISO standards. Per a June 30 report, Oxebridge Quality Resources (OQR), www.oxebridge.com, asked registrars approved by the American National Accreditation Board as well as some questionable registrar companies to certifiy LifeSink, “a manufacturer of cement life jackets,” to ISO 9001. The nonexistent company offered TRUSINK, a “negative buoyancy wearable flotation device for industrial deep sea mining and recreational diving.” The sent documentation stated that TRUSINK “had an inner lining made of cement and lead shot.” Other products in the works included “Death Bell” and “RapiSink.” Further, the company wanted a virtual audit of its office. While none of the American National Accreditation Board-accredited bodies would touch the proposal, each and every “certificate mill” were ready to start the ISO 9001 certification process, OQR reported. “These mills pose a direct and credible risk to public safety and human health,” OQR said. “They will offer to certify anyone willing to pay, even if they cannot actually verify the existence of an organization, and even if that product will kill people.”

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tion of producers and users of materials in technical committees. To allay old fears that producers would dominate the standard-setting process, ASTM’s rules stipulated that supplier representatives on a given committee could not outnumber the representatives of buyers, and that supplier representatives could not serve as Charles Dudley committee chairmen. Moreover, the “Procedures Governing the Adoption of Standard Specifications” adopted in 1908, required that once technical committee members had drafted a specification, a two-thirds majority was necessary to refer it to ASTM’s annual meeting for consideration. At the annual meeting, a simple majority of members could amend the specification, which was finally presented to the meeting for a ballot vote. Negative votes carried considerable weight and were referred to the committee, whose members discussed them and tried to resolve differences. Negative votes that remained unreconciled could be overruled by the committee for good cause. This basic structure of checks and balances, designed to ensure fairness in the standards-setting process, proved highly effective and remains essentially in place to this day. At last count, ASTM International has more than 12,000 standards that are used worldwide.

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Copper standards for electrical conductors

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The below article, by industry veteran Horace Pops, Horace Pops Consulting, looks at standards from a different perspective. Standards spell out the specifications, but here he focuses on how the process relates to those guidelines. for example, applications requiring large wire sizes where Electrical conductors are engineering materials that have the requirements are less severe than those needed for been processed into wire using mostly copper redraw rod. magnet wire. This has been possible because both materials Final properties and processing behavior are directly related contain more than 99.90% copper and have similar electo chemistry and can be adequately explained using basic trical conductivities, namely, their international annealed metallurgical principles. Most of the necessary testing procecopper standard (IACS) values are greater than 100%. dures and product specifications are based upon the ASTM Almost all of the aforeStandard B 49, which pertains mentioned final wire propto copper rod. This document erties are linked to residual has not only served the global impurities, and have been wire and cable industry quite defined in several differwell for many decades, it is ent ASTM specifications constantly being updated and including B 49. If ETP improved to satisfy the ever copper rod having the desigincreasing demands by the nation C11040 is produced industry for better wire quality from copper cathodes, the and more diverse applications. impurity limits are identical It bridges the gap between to those listed in the ASTM incoming chemistry needs and specification B 115 for final wire properties. Horace Pops speaking during the Fundamentals of electrolytic cathode copper. Inasmuch as high electrical Manufacturing panel discussion at Interwire 2013. From a commercial perspecand thermal conductivities tive, no distinction is made in this standard for the method are two of the most important requirements for conducof manufacture, because it is not relevant if the cathodes tors, copper is the preferred choice and predominant are produced by electrolytic refining or electrowinning. commercial material in the electrical wire industry. More Only chemistry is important in standards, which is a varithan half of all domestically produced copper is in the able that also applies for both ETP and FRHC rods. form of wire or cable for such diverse markets as magnet Recent additions to B 49 contain several new improvewire, telecommunications, building wire, power cable ments over earlier versions. For example, two different and automotive applications. To obtain the required final methods (hardness and torsion) are currently described properties and to enhance performance in service, unalfor performing annealability tests on rod. Both tests help loyed copper rather than its alloys is mostly employed. to predict the ease with which hard drawn wire will softThis requires a few key specifications and test methods en during subsequent annealing. However, the European that fall under the purview of standards. Standard EN 1977 for copper and copper alloy wire rods, The term “copper” often is used generically, but in realwhich was last revised in 2013 and was approved by CEN ity, close to four dozen different wrought alloys contain national standards bodies of 33 different countries, includes a minimum copper content of 99.3%, and have been desa rapid elongation annealability test method for ETP copper ignated as “coppers” by the Unified Numbering System rod. This particular standard covers nine different grades of (UNS). The majority of electrical conductors are made copper including ETP, OF and FRHC, and nine silver-bearfrom electrolytically refined tough pitch copper (ETP), ing copper grades. Only the ASTM B 49 standard places an which is 99.90% copper alloyed with oxygen in the range upper limit of 750 Angstroms (7.5x10-8 m) for the uniform between 0.01% (100 ppm) and 0.065% (650 ppm). For surface oxide thickness. The standard E 1606 was develhigh quality applications such as magnet wire and ultraoped by the ASTM committee on nondestructive testing to fine wire, the oxygen limits are usually much tighter and measure surface related defects using eddy-currents, and normally between 125 and 400 ppm. Whenever copper is currently being revised to help calibrate new test coils. wires are exposed to hydrogen gas for extended times at Since specification B3 on soft or annealed copper wire lists elevated temperature, the use of oxygen-bearing coppers the required minimum tensile elongations, this mechanical can cause hydrogen embrittlement problems. Under these property is very useful for electrical applications. circumstances, oxygen contents are restricted to less than The above text provides a sense of how copper products 10 ppm, and the resulting grades are oxygen-free (OF) or continue to change, and it is obvious that as the industry oxygen-free electronic (OFE). For a few limited products evolves, so must the standards that govern them. That such as power transformers that must be rigid to prevent process is not always simple or readily agreed upon, but movement under surge loads, heavy-gauge silver-bearit is utterly essential that the products offered for end uses ing copper (OFS) finds limited use. For the past several meet their intended usage, which ultimately is the indusdecades, fire-refined, high conductivity alloys (FRHC) try’s collective goal. have been used internationally as a replacement for ETP, as 56 | WIRE JOURNAL INTERNATIONAL

Frank Peri, the executive director of the Communications Cable and Connectivity Association (CCCA), has more than 25 years of structured cabling experience. He believes that while the standards creation process can be slow moving at times, it gets good results. He has served on standards committees for both the NFPA (National Fire Protection Association) and TIA (Telecommunications Industries Association). Below, he shares his thoughts on their effectiveness. The structured cabling industry is codes and standards driven. Without them, it would be a freefor-all from a quality, performance and safety point of view. Codes and standards are closely related, but codes dealing with safety are required, i.e mandated by state or city statutes, while standards dealing with performance are voluntary. The standards creation proFrank Peri cess is designed to gather the best information from people who are experts in the field. For the NFPA, a Technical Committee often has 20 to 30 people and typically includes not just cable industry representatives and manufacturers, but a fire marshal, a UL staffer, an electrical inspector, and a union representative. NFPA codes are generally reviewed and revised on a three-five year cycle which includes public input for committee consideration and action. For TIA cabling standards, committee members pro-

vide “contributions,” which are the result of testing and research on areas such as systems measurement procedures or minimum performance limits for worse case conditions. A physical layer standard like cabling also has to be harmonized with other higher level standards, which for TIA would mean assuring that the cabling system specified is compatible with transmission protocols such as Ethernet, which falls under the purview of the IEEE (Institute of Electrical Electronic Engineers). A lot of discussion takes place in the TIA standards committee meetings, but not the back-and-forth type of completely unstructured exchanges that you might expect. The meetings are largely conducted under Robert’s Rules of Order, which does not allow for such interaction. Eventually, a consensus is reached and the standard development process can move forward. A popular notion among codes and standards committees is that a consensus is reached when everyone is equally disappointed, a credo that contains more than a little truth. Yet the sometimes-arduous path to a group consensus may unearth potential problems, which actually results in a better

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Perspective: standards creation process is transparent and fair

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work product. The process is both very transparent and very fair, and there are checks and balances. Nobody can bulldoze things through the process. A given committee process can take well over a year, often more, to achieve a point where a draft standard is ready for ratification. The standard then goes to ballot, and members can vote to accept or reject by stating what they do not agree with. TIA standards for electrical transmission outside the U.S. typically take into account country or international standards-making bodies as Ethernet or Internet protocols are universal. NFPA fire codes, however, often cannot because of philisophical differences with Europe. Standards set industry ratified requirements, but they tend to lag technology innovations, as long as three to five years. Basically, commercial factors can first drive new technologies and determine what technologies become generally accepted. In a real sense, standards often reflect and “codify” technologies already adopted and forged in the real world of competition and capitalism. Standards work has gone on for many years, and seldom draws a lot of attention because the committees strive for agreement and consensus, not controversy. Yet whether a standard is quietly passed or passed after much internal debate, the result is a well-defined set of requirements for manufacturers to meet to assure end users that cable and connectivity products will perform as expected. That, in turn, helps everyone. It’s one of the big reasons I volunteered, and I consider it time well spent. n

ISO 31000, a 2009 guideline that some companies want to pass on ISO 31000:2009, Risk management – Principles and guidelines, provides principles, framework and a process for managing risk. At first glance, the above wording seems to make sense: having a basis for addressing risk sounds practical. Per ISO, “Using ISO 31000 can help organizations increase the likelihood of achieving objectives, improve the identification of opportunities and threats and effectively allocate and use resources for risk treatment. ... (The) guideline cannot be used for certification purposes, but it does provide guidance for internal or external audit programmes.” The concept, however, has not been warmly embraced. Observed one person, “Risk taking is essential to an entity’s survival. How can you put this in a standard? ... Corporate managers need to be less risk-averse. But new rules and regulations are making them more reluctant to take risks. Meaningful and practical ways to calculate probability and severity of risk...have yet to be developed.” Another person opined that the standard goes beyond the ISO mandate. “ISO has created a new method of management that has never been vetted in any industry, much less one which reflects an accepted ‘best practice.’ They are now inventing new methods, rather than publishing known, validated methods.”

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MORDICA LECTURE Part 1: Trends in drawing technology for bars and wires This article, in two parts, reviews drawing processes used for drawing bar and wire and introduces a very flexible nonslip continuous method of wet drawing. By Motoo Asakawa The processing and production of bars and wires are extremely important, especially for the manufacture of automobile parts, industrial equipment and electronic and electrical devices. Bars and wires are commonly used as safety components in engines, drives, suspensions and life-saving features. Therefore, they must be manufactured with superior dimensional accuracy and mechanical and metallurgical properties. In this study, the author’s research group primarily focuses on processes related to drawing bars and wires. First, the fundamental drawing elements are discussed, such as the axial residual stress of drawing, the effect of the additional shear strain layer, the delamination of high-carbon steel wire and diameter thickening during drawing. Second, the applied drawing technologies are discussed, such as inline phosphate reaction soap treatment technology, ultrasmooth, extruded aluminum alloy bars using single-pass protrusion die drawing and magnetic scales made by drawing with transformation induced plasticity effect. Finally, a novel nonslip continuous wet drawing method is introduced for fine wires in which any pass schedule and back-tension conditions can freely be set.

Introduction The author has been fortunate to research bar and wire processing for 40 years. After the study of these elements transferred from the industrial field to universities, new research was conducted in aspects such as sheet forming, functional material, processing and evaluation of aerospace engineering. However, this field of research continues to focus on rolling, drawing and straightening in bar and wire processing. A meeting for the drawing technology of bars and wires, established in 1976, is one of branches of the Japan Society for Technology of Plasticity (JSTP). The research conference is held twice a year, and each time, over one hundred researchers and engineers participate and discuss rolling, drawing, straightening, processing equipment, lubrication, and other topics. See Fig. 1. These materials and parts are commonly used for automobiles, railways, airplanes, electricity and various industrial equipment. These industries demand high-quality dimensional accuracy and superior mechanical and metallurgical properties. 60 | WIRE JOURNAL INTERNATIONAL

Fig. 1. Researchers and engineers participate at a 2013 meeting about Japanese drawing technology. Here, the author introduces an outline of various drawing technologies and products. The large-size drawing products of bars and wires are used as follows: “drowned” shafts for automobile parts (3–50 mm in diameter), as shown in Fig. 2(a); drowned blight shafts for office automation apparatus (4–15 mm), as shown Fig. 2(b); high-strength prestressed concrete wires (3–9 mm) and bars (10 mm or more) for civil engineering construction, as shown Fig. 2(c); high-strength wire for constructing bridges (5–9 mm). Recently, 1770 MPa high-strength drowned 0.80% carbon eutectoid steel (5 mm) was used for the longest span bridge in Japan, as shown Fig. 2(d). In addition, 0.97% hypereutectoid carbon steel (5 mm) with strength of 1960 MPa was developed and will be used for even longer span bridges. To increase engine power and reduce fuel consumption, the weight of automotive valve springs is reduced by drawing, oil quenching, and oil tempering (2–6 mm). High-fatigue, high-strength, super-clean valve spring wire rods without surface defects are needed to greatly reduce valve spring weight, as shown Fig. 2(e). Regarding fine and thin drowned wire products, many lives have been saved from cholesterol deposits after 0.35 mm stainless steel guide wires began to be used for narrowing coronary arteries. See Fig. 2(f). When a surgeon rotates these wires by 90 degrees, the torque transmission

filamentation of several microns is manufactured from stacking drawing. Here, the author focuses on drawing technology, such as size accuracy and surface roughness, primarily based on the authorâ&#x20AC;&#x2122;s fundamental research and applications of such technology. The author hopes to contribute to the development of the technology of this field in the present and in the future.

Fundamental research of drawing: residual stress of drawing A great many studies have been performed in the drawing field, including pass schedules, strain aging, and central bursts. Drawing conditions, such as the geometry of the die shape, friction coefficient, reduction, and drawing speed, significantly influence the quality of the end products produced by drawn bars and wires. Customers demand high-quality production, but residual stresses represent large problems. Axial residual stresses, in particular, cause changes in dimensions and straightness during cutting and grinding or heat treatment. Axial tensile residual stresses are easily generated on the surfaces of bars under drawing. This decreases the fatigue strength of the end products; therefore, it is necessary to reduce axial tensile residual stresses in the drawing process. Much research has been carried out in this

Fig. 2. Drawing products of bars and wires in various sizes. AUGUST 2014 | 61

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characteristic and the restoration point at which the blood vessel rotates at the same time are operated by 90 degrees. High-carbon wire of 0.2 mm is often used for steel cords; already, 4â&#x20AC;&#x201C;4.5 GPa of strength has been achieved, and the highest strength is reached in practical metals. See Fig. 2(g). A 0.2 mm high-carbon saw wire is used for cutting tools to slice silicon wafers and sapphires for solar batteries and LEDs. Recently, as shown in Fig. 2(b), diamond abrasive grain has been electrodeposited on the surface wires and converted to a fixed abrasive grain wire that cuts sharply, thus rapidly improving the productivity of slicing. See Fig. 2(h). Tungsten wires under 100 m in diameter are used as probe pins for electrical property measurement treatment devices of IC package substrates. See Fig. 2(i). These straight, fine wires have been used with the high-density integration of approximately 3000 filaments for an area of 1 cm2. Fig. 2(j) shows 20 m stainless fine wire used for mesh. These filaments are used for printing meshes, and demand has now expanded for their use in the filters of chemical equipment. Fig. 2(k) shows high-level fishing lines, 16 m, with high strength of 5.4 GPa. Large amounts of NbTi are used for superconductive wires. Niobium tins (Nb3Sn) demonstrate the electromagnetic performance of a critical magnetic field. See Fig. 2(l). The

TECHNICAL PAPERS

Fig. 5. Experimental results of the residual stress distribution for the A-type die, changing bearing length, L, by the Heyn-Bauer method. Fig. 3 Results of δ measured by the slitting method. field, but residual stresses have not yet been sufficiently studied. A comparison of residual stresses using two die types was investigated by the elastoplastic finite-element method (FEM) MSC.Marc. In addition, the results of the numerical analyses were experimentally evaluated. Angle-type (A type) means that the geometry of the die approaches a constant semiangle, α. Circle-type (C type) means that the geometry of the die approach has a constant circle or radius, R. A-type and C-type dies are shown schematically at the top of Fig. 31–3. First, α of the A-type die and R of the C-type die were varied. Second, the influence of the bearing length, L, on residual stress was examined. Finally, the effect of the reduction in area, Re, on residual stress was investigated by varying the diameter of the bar before

Fig. 4. Distribution of axial residual stresses in A-type and C-type dies. 62 | WIRE JOURNAL INTERNATIONAL

drawing. The 0.45% plain carbon steel bars, d0 = 11 mm, were drawn through a tungsten carbide die. The bearing diameter, d1, was 10 mm, so Re was 17.4%. The longitudinal slitting method was used as a qualitative evaluation of residual stress after drawing, as shown at the bottom of Fig. 3. By slitting the bars into two equal parts, the residual stress was relieved and the two parts were bent inside out. The axial residual stresses were qualitatively evaluated by measuring the gap, δ, of the slit. The δ of the slit increased as α increased in the A-type die, and also increased as R increased in the C-type die. The Heyn-Bauer method was applied as a quantitative method for measuring the residual stresses. See Fig. 4. First, the longitudinal length of drawn bars was measured after cutting the surface layer. Next, the axial residual stresses were evaluated by using both this strain and the equation of the equilibrium of the stress of bar sections. The distribution of axial residual stresses was quantitatively measured by studying this work. In this study, theoretical analyses were based on the utilization of MSC.Marc. It was assumed that the piece under examination exhibited elastoplastic behavior and that the die was rigid. The von Mises condition was used as a yield condition. The elastoplastic material law by Prandtl-Reuss, based on an updated Lagrange method, was used for the analysis to correspond to large deformation and strain, considering the coefficient μ = 0.05, according to Coulomb’s friction law. This law shows the distribution of axial residual stresses in the depth of the bar. In the A-type die, the maximum tensile residual stress was generated on the surface of the bar. In the C-type die, the maximum tensile residual stress was also generated around the surface, but began to decrease under the surface of the bar. When R ≥ 50 mm, compressive residual stress was generated on the surface. These results clearly suggest that adjusting R can control the residual stress on the surface and decrease the axial residual stresses. The result of this calculated solution qualitatively corresponds to that of the experiments. Drawing dies can be supplied with a definite L. The optimum bearing length will improve straightness, dimensional accuracy, quality of surface smoothness, and tool life. Fig.

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Even in low carbon steel, the tensile strength performs to over 3 GPa in 0.1 mm diameter. The author has focused on the factor of the additional shear strain layer generated beneath the surface layer. The fine wire drawing process contributes to these superior mechanical and metallurgical properties. To determine the cause of this combination of superior strength and ductility, several factors are considered, such as the size effect between the crystal grain and the thin diameter of wire, or heating and cooling from the surface to the center of the wire. To measure Fig. 6. Depths of additional shear strain layers of different diameters (single the depth, λ, of the additional shear strain layer, the hardness distribution in pass drawing with 16% reduction after annealing). large and fine wire was measured after drawing of 0.1% low carbon steel, which was annealed before drawing at 1073 K, as shown in Fig. 6. The specimen was drawn with 16–18% reduction, α was 7 degrees, and the depth of each wire was a constant 0.03 mm–0.05 mm, regardless of the wire diameter, d. Fig. 7 shows the results of tensile tests for 0.3-mm-diameter annealed wire and for 0.275-mm-diameter drawn wire thinned by electropolishing, with 16% reduction of the surface layer. The tensile strength of the annealed wire was constant in wire of all diameFig. 7. Effects of surface layer on tensile strength. ters after electropolishing. However, for drawn wire, the tensile strength decreased 5 shows the experimental results of the axial residual stress as the surface layer was thinned. From these results, it is distribution for the A-type die, for which the value of the clear that the tensile strength of the surface layer affects the bearing length was changed. Except for the case in which increase of tensile strength in drawn fine wire. L = 0 mm, the axial residual stress on the surface decreased The tensile strength decreased gradually as the surface and the maximum residual stress was generated under the layer was thinned. The tensile strength of the surface layer surface of the bar. As the bearing length increased, axial was 1.4 times the strength of drawn wire and twice the residual stress decreased. The relationship between Re and strength of annealed wire. the axial residual stress on the surface was also investigatAs shown in Fig. 8, the crystal orientation of the surface ed. The surface residual stress decreased in both ranges of layer differed from that of the center in drawn wire. There Re ≥ 15 and Re ≤ 3.0%. In particular, it is well known that was only one crystal orientation in the center layer, but two compressive residual stress is generated on the surface in the crystal orientations in the surface layer. Some crystal orienrange of Re ≤ 0.5%. tations of the surface layer rotated because of the additional If R and L nearly equal zero, the maximum axial tensile shear deformation. This is one way additional shear deforresidual stress is generated on the surface of the bar, but when mation affects fiber texture. In this study, the depth of this R and L grow, the residual stress decreases on the surface comadditional shear strain layer was measured at approximately pared to the interior. Consequently, α, R and L are key factors 0.04 mm and constant for different diameters. For a 0.1 mm to control the axial residual stress of drawing. wire, this layer represented more than 80% of the cross-sectional area, as shown in the extreme cases of λ and d in Fig. 9. Hence, the additional shear strain layer is one of Additional shear strain layer in drawing the reasons fine wires have improved strength and ductilFine wires on the order of 0.1 mm have become popity. The additional shear strain layer increased the tensile ular for mechanical and electrical applications, such as strength while maintaining ductility as the diameter of the microsprings, micropins, printer mesh and cutting wire wire shrank by increasing the area ratio of the additional for electrical discharge machining (EDM), silicon and shear strain layer. This explains how superior strength can quartzes. In general, fine wires produced by the drawing be obtained by using small diameter wires 4–9. process are acceptably strong while maintaining ductility.

TECHNICAL PAPERS Fig. 8. Crystal orientations in center and surface layers. Fig. 11. Work-hardening characteristics because the regulation of the pearlite lamellar represents a complicated metal flow. For this research, eutectoid steel (C = 0.82%) wires with two types of diameters were prepared. Delamination occurs in a large wire (9.0 mm) but does not occur when there is the same total reduction in a wire with a small diameter, 1.03 mm. Delamination tends to occur more frequently in a large wire than in a small wire. The process of generating delamination was seen in a large wire, 9.00 mm, that was drawn down to 3.15 mm, Fig. 9. Schematic illustration of constant depth of additional shear strain layer 位 in bulk db and fine df wire.

Delamination of high carbon steel wire Recently, the mechanical properties of high-carbon steel wire have been improved by the progress of drawing and material technology. However, Fig. 10 shows that sometimes there can be cracking, called delamination, in which the twist torque decreases as the strength of the wire is increased, so it is impossible to draw the wire to the drawing limit. Through conventional research, it has become possible to control delamination to some extent by heat treatments and ingredient adjustment. There are four stages to increase the strength of high-carbon steel. See Fig. 11. The first stage is the hardening of ferrite. The second stage is the regulation of the pearlite lamellar. In the third stage, the pearlite lamellar is work-hardened; finally, the drawability limit is reached. The author focuses on the third stage,

Fig. 10. Delamination of high carbon steel wire. 64 | WIRE JOURNAL INTERNATIONAL

Fig. 12. Surface observation of parallel cracks just after occurrence of delamination (top), enlargement of surface crack, and necking generated inside cracks (bottom) in 3.15 mm wire.

TECHNICAL PAPERS Fig. 13 Perlite lamellas are bent and cracks are generated. a total reduction of 88%. Fig. 12 shows the surface layer of the wire, which was twisted until immediately after the occurrence of delamination. There are several cracks in the surface layer, and each crack is not a simple, straight line. This shows that each crack has a step. Necking is generated inside the step, and the twist torque decreases with time. That is, delamination starts before twist torque decreases. Pearlite grains of 3.15-mm wire were observed after delamination occurred. As Fig. 13 shows, many lamellas were bent near the starting point of delamination, where voids were generated and cracks occurred as a result of the voids. As shown by measuring austenite grains by the hardening-tempering method, the austenite grains are larger in a large wire than in a small one, so the pearlite gains are larger in a large wire than in a small one. Therefore, the pearlite grains in a small wire more easily rotate into the drawing direction than in a large one. As mentioned earlier, the effect of the additional shear strain layer was that the tensile strength increased while maintaining ductility; this happened as the wire diameter decreased by increasing the area ratio of the additional shear strain layer. Voids and cracks in a large wire promote the generation and proliferation of delamination10.

Fig. 14. Relationship between drawing time and die temperature.

Dimensional accuracy of drawing products In precision forging products, the drawn bar demands superior dimensional accuracy. However, during the actual drawing process, the diameter of the drawn bar has been known to increase, resulting in dimensional errors in the precision forging products. For example, when the diameter of drawn bars is 12 mm or less, the dimensional tolerance ranges from 0 to 0.02 mm. This tolerance range represents approximately 0 to 0.17% of the diameter; in the future, drawn bars will demand higher dimensional accuracy. In addition, it is necessary to frequently check the diameter of the drawn bar, which decreases productivity. The author has conducted fundamental studies of the diameter of drawn bars. Three main factors are involved in the variation of diameter. The first is the shape of the die, the second is back-tension, and the third is thermal expansion of the diameter of the die. Here, the focus is on the thermal expansion. A coil-to-coil drawing machine (v = 110 m/min) was used to investigate the effect of

Fig. 15. Elastoplastic two-dimensional drawing FEM analysis. thermal expansion of the die on the diameter of the drawn bar. The drawn bar was composed of low-alloyed steel with chromium molybdenum (AISI 4135), and calcium carbonate was used as a lubricant. The die temperature distribution during the actual drawing process was measured. As shown at the top of Fig. 14, the temperature measuring points were hole A to hole D and the surface. The horizontal axis indicates time and the vertical axis indicates die temperature. The temperature increased rapidly for the first 2.5 min, drawing approximately 90 kg. During this time, the diameter of the drawn bar increased. After 10 min, the steady-state temperature of hole A was 160째C and the temperature of the die surface was 110째C. AUGUST 2014 | 65

TECHNICAL PAPERS Fig. 16. Numerical simulations of thickening ratio while changing various parameters.

The difference between the initial diameter and the steadystate diameter is an important factor in the actual drawing process. The diameter thickening ratio increased for the first 200 kg; the thickening ratio of the steady-state diameter was 0.1%. The bottom of Fig. 14 enlarges this area of decreased temperature. The horizontal axis indicates time, the left vertical axis indicates the temperature of hole A, and the right vertical axis indicates the diameter thickening ratio. As the drawing machine stopped, the diameter thickening ratio decreased. For 10 min, the temperature of hole A decreased by 90°C (from 170 to 80°C), and the diameter thickening ratio decreased by 0.12%. In summary, the diameter thickening ratio was greatly affected by the thermal expansion of the die’s diameter. This diameter change may have been generated even if the temperature was maintained constant. To solve this problem, the basic and theoretical mechanisms that influence diameter change were investigated by using nonlinear elastoplastic two-dimensional FEM analysis of MSC. Marc, as shown in Fig. 15. The die case (alloyed steel) and the chip (tungsten carbide) assumed an elastic body. The 0.2% low carbon steel assumed an elastoplastic body. The thickening ratio of the diameter, η = ((d1 − d)/d) × 10, and the diameter of the die hole was d = 12 mm. The standard model included: α = 7°; R = 6 mm; L = 6 mm; Re = 10%; back-tension, seb = 80 N/mm2; coefficient of friction, µ = 0.05; material value, F = 1100 N/mm2; material value, n = 0.2. These parameters were changed from the standard values and each effect on the diameter was evaluated. The die in a standard model and the analytical results of the bar shape are shown in Fig. 16. According to the FEM simulation, the diameter thickening ratio, η, changes as follows: the elasticity deformation of the die +η 1(a → b), the undershoot −η 2 (b → c), diameter expansion +η 3 (c → d), and elasticity recovery +η 4 (d → e). The most effective factor is the undershoot phenomenon by seb. This phenomenon was experimentally confirmed under severe back-tension and high approach angle, as shown in Fig. 1712–13.

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Fig. 17. Phenomenon of undershoot confirmed by experiment (material: AISI 1010; reduction: 10%; approach semiangle: 13°).

Professor Motoo Asakawa accepts the 2014 Mordica Memorial Award. Professor Motoo Asakawa, the winner of the Mordica Memorial Award, was employed by Sumitomo Metals in Japan from 1968 to 1995, where he earned 19 patents. He holds a doctoral degree in bar and rod rolling from Japan’s Waseda University, and in 1996 he joined the school’s faculty at the Mechanical Engineering Department of the School of Science and Engineering. He has been a prolific author, presenting more than 27 technical papers on wiredrawing, straightening, rolling and material processing, including 16 papers for WAI since 2001. The professor has won numerous awards, including the Okochi Memorial Prize, the Society for Technology of Plasticity Prize, and the Iron & Steel Institute Prize in Japan as well as WAI’s Allan B. Dove Memorial Award for the best ferrous technical paper in 2003. This Mordica Lecture was presented at WAI’s 84th Annual Convention, Indianapolis, Indiana, USA. May 2013. Editor’s note: The second half of this presentation will be in the September issue. It will further the discussion and include details about a new promising wet, nonslip, continuous drawing machine.

Analysis of wire-clamped joints by FEM Numerical analysis (FEM) was used to estimate the efficiency of a given shape of clamp joints, and a modelling methodology of clamped joints is proposed that allows for new clamped joint designs as well as for improvement of existing ones. By Janusz Juraszek

Clamped joints, which can be classified as the permanent ones, are often used for connecting and fixing of steel wire ropes, electric cables or hydraulic conduits. For example, such joints are used in power engineering for fixing and connecting of different items, e.g., conductors, cables, elements of overhead transmission lines, etc. In aviation they are used as an alternative way for making of a control cable tip. Other examples can be found in cranes (lifting rope tip) and in hydraulic piping (joining of conduits). Another type of permanent joints connecting steel wire ropes consists in filling the joint with a low melting alloy, which is a very laborious, expensive and toxic (lead and zinc vapors) process. Moreover, it cannot be used in all the aforementioned cases. It should be mentioned that the temporary joints reveal also some substantial disadvantages, such as complex designs, large dimensions and mass, which substantially rises the costs of making such joints. The method of clamping is relatively inexpensive, requires little work, and its broad applicability also covers outdoor uses. The main advantage of clamped joints consists in their small size. A typical example is a hexagonal clamped joint. The main idea of fastening consists here in changing the initial circular shape of a sleeve into a hexagon inscribed in that circle. See Fig. 1. The process of clamping is performed using two clamping jaws. The surface of jaw contact determines the joint parting plane, which is also its plane of symmetry. In power engineering applications (see Fig. 2), the Al-Fe (aluminum and steel) conductor tip, after being inserted into a sleeve, is clamped due to transversal

Fig. 1. Rope clamped into a hexagon.

plastic deformation of the sleeve. The joint operation is two-fold: besides doing mechanical work, such as load carrying, it works also as a conductor so that the electric circle is not broken. The material of the clamping sleeve should have good conducting properties. The sleeve is often made of aluminum A0. There are also other forms of the clamping jaws available, including octagon, dodecagon, ellipsis, modified ellipsis, circle (one parting plane), modified circle, axi-symmetric forms, etc. Some papers devoted to that problem can be found in the literature as well. Some of the more interesting ones are presented below. The distribution of pressure in the course of the clamping process is not a uniform one. The proposed axi-symmetric clamping4,5,8,11,12 noticeably eliminated the nonuniformity revealed by the pressure distribution. That approach, however, requires application of a special hydraulic power press with a complex design and the clamping process should be carried out at a laboratory or the adequate factory department. Other research is going into inventing a new method for mounting wires for temperature measurement in an oily seed silo, using a self-clamping cone. The wires used to break off along the radius of the inner hole-tocone segment. The axi-symmetric way of clamping allowed for elimination of the wire breaking, which made both the design and mounting much simpler. Based on the prior examples, one can conclude that the clamped joints exert a decisive influence upon the safety level and reliability of the design they are applied to (fixing of lifting ropes in cranes, overhead transmission

Fig. 2. Sample joints used in power engineering systems.

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line supports, electric cables, etc.). A proper qualitative strength analysis may result in improving the safety and allowing for a proper choice of joint parameters. Each clamped joint has two elements: rope, cable or hydraulic conduit; and a clamping sleeve. For the first element, the steel wire ropes, electric cables and hydraulic hoses should meet the requirements specified in the relevant standards for properties3,9. Molnar presented the problem of 3D modeling of ropes9,10,13. The second element is a clamping sleeve made of plastic material that deforms in a plastic way when subject to the external pressure. After unloading, the residual stresses remain on the sleeve-rope contact surface. When modeling the phenomena appearing in a clamped joint, the values of material parameters introduced into the model after exceeding the yield point value are of crucial importance. The values of parameters available from literature differ substantially from those measured for a given material at its working point or within the expected loading range. To make the calculations more accurate, a Digital Database of Material Parameters has been proposed. Most interesting research on the contact problems between a wire rope and foundation was presented at the 8TH International Congress for Transport by Rope OITAF held in San Francisco in 19992. The authors carried out numerical analysis and experimental investigations into the contact between a rope and a rubber-aluminum wheel. Numerical simulations were performed using the AbaQus code, with the phenomenon of wheel heating introduced into the model that, however, presented only a simplified external contour instead of the real wires. J. Kliber10 carried out numerical analyses of large plastic deformations with the phenomenon of linear strain hardening included. M. Kleiber and R. Buczkowski1examined the models with the friction introduced into elasticplastic problems. A model of contact should be specified before analyzing the process of clamping of the wire rope. J. Altenbach presented an incremental method for contact description in 2-D models, while Hrycaj, S. Cercotto and J. Oudin showed an elastic plastic model with the Coulomb friction introduced. Among the papers devoted to clamped joints, one should mention the analysis of clamping into hexagon6, research into multi-clip joints8, equivalent transversal stiffness of a steel wire rope and steel-aluminum cables5,7. The problems of large deformations in plastic forming were analyzed by B.J. Mac Donald14, and M.S.J. Hashmi using the ANSYS code. J. Landre presented the discussion of FEM mesh changes during upset forging with the Cockroft-Latam criterion taken into consideration. C.G. Provatidis showed an interpolation of the Coon type applied to an axi-symmetrical problem, which allowed for making the calculation time much shorter for non-linear problems of large deformations. Most often, the joint designs result from the experience gained by different manufacturers12. A survey of the available designs reveals the lack of a consistent 68 | WIRE JOURNAL INTERNATIONAL

main idea laying behind the joint design. Moreover, one should mention the lack of data on strength calculation, designing and a proper choice of rope fastening (connections between the elements that reveal substantially different stiffnesses). The investigations are conducted by the centers associated with the manufacturing companies and, consequently the market competition prevents the publication of results.

Theoretical background The changes in material parameters in the course of the deformation process were taken into account. The Amont-Coulob fricton model was introduced into the sleeve-rope contact area. The clamping process was assumed as a quasi-static one. Taking the FEM approach assists the analysis of plastic deformation problems. The equation of equilibrium for a medium can be derived from the virtual work principle1 and in the case of general Lagrange formulation one can derive: Eq. (1) where: Sij = component of the second Piola-Kirchoff stress tensor; and Îľij = component of the Green-Lagrange strain tensor. The work done by the external forces R can be represented in terms of the surface and volume works, respectively Eq. (2)

The above equation was derived on the assumption that the body configuration changes from one loading step to another. In Eq. (2), the symbols A and V stand for the surface and volume, respectively, of the body, while p and f represent components of the vectors of surface and volume forces, respectively, acting upon a unit surface and unit volume of the body corresponding to the initial configuration. represents the displacement variation while stand for the strain variations. Eq. (3)

The above equation, after applying the FEM approach, can be rewritten in the following discrete matrix form: Kâ&#x20AC;˘U=Râ&#x2C6;&#x2019;F Eq. (4) One can arrive at Eq (4) after substituting the following matrix forms for the integrands

Eq. (5)

Analysis of clamped wire

symmetry of the system, one can take into consideration only ¼ of the clamped joint model (see Fig. 3b). To arrive at the results for the whole joint, those obtained for one quarter were mapped with respect to the corresponding axes, that allowed for shortening of the calculation time by 83% and the resulting file size reduction by 68%. In the first part of calculations (the analysis of clamping) the jaw comes closer to the element to be clamped at a very low speed, i.e. the process can be considered as a quasi-static one. In practice, the jaws are pressed against each other until they come into contact. On the presented scheme, this part of the process is denoted as “translation.” At this stage, the initial circular shape of the clamping sleeve changes into the shape determined by the clamping jaws. The boundary conditions, based on the assumption of symmetry, with respect to the ‘x’ and ‘y’ axes, are marked as well. The next stage of the process consists in unloading the joint by taking the jaws away up to their initial position. The process is performed according to the unloading curve and requires a high number of unloading steps. After completing the unloading process, some stresses, known as residual stresses, still remain in the material. These very stresses, as confirmed by the author’s investigation results, determine the joint carrying capacity. The carrying capacity here means the maximum force act-

As noted above, the choice of clamped joint type is usually made based on the manufacturers’ experience. The main issue to be considered is the analysis of the clamping and unloading processes, respectively, for allowing proper assessment of the states of displacements and deformations, together with the stress state, depending on the type of clamping jaws employed. A one-plane-hinged jaw of a hexagonal shape, inscribed in a circle, is used most commonly. Such a jaw is simple in use, and the clamping process can be performed with a small flash of the clamped material. On the opposite end of the application list is the axi-symmetrical jaw, which is hardly ever used. For the axi-symmetrical clamping process to be employed, four parting planes should have been introduced turned about 45 degrees relative to each other, which highly complicates the clamping process. The hydraulic systems used prevented simultaneous translaFig. 3a tion of the jaws. Therefore, a mechanical system driving translations of all jaws in a controlled way, combined with a hydraulic driving of motion, was introduced that allows a proper axisymmetrical clamping process to be performed. This approach reveals very high complexity in view of the process technology. It should be noted that in addition to the two aforementioned “extreme” types of jaws, there are several other shapes available: octagonal; octagonal-twisted; dodecagonal; dodecagonal-twisted; elliptic; modified elliptic; circular (one parting plane); modified circular; and a special shape. In the last case, roughly speaking, the clamping jaws have a polygon shape inscribed in a circle or ellipsis. Fig. 3a. Symmetry The main advantage of this type of jaw in shaping its introduced into the contours is how it ensures additional displacement or model and the boundary proper metal forming of the sleeve internal surface. conditions. All the aforementioned types of clamping jaws were analyzed. The presented jaws comprise all those used in practice as well as several new ones proposed, some possibilities of jaw modifications are also Fig. 4. shown. The clamped element was the rope T1X7 very difficult to be dealt with in such joints. A parametric model was produced allowing for introduction of the rope wire diameter with the corresponding external diameter. Each of the presented jaws has at least two parting planes (see Fig. 3a) that have, simultaneously, two axes of symmetry. Basing on the Fig. 4. Octagonal jaw.

Fig. 3b

Fig. 3b. Symmetry introduced into the model and boundary conditions introduced into the model and the boundary conditions. Fig. 5.

Fig. 5. Octagonal-twisted jaw. AUGUST 2014 | 69

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The following denotation was used in Eqs (4) and (5):

TECHNICAL PAPERS

that ensures larger magnitudes of residual stresses after unloading. The effect is most profitable for the dodecagonal-twisted jaw. Sample simulation results of the clamping processes, respectively, for a circular jaw are shown in Fig. 6. During the clamping process the material effort of the clamping sleeve reaches the magnitude of 300 MPa, while within the sleeve-rope wires contact zone it attains 500 MPa. In view of the joint carrying capacity the distributions of stresses and deformations over the rope-sleeve contact zone play the most important role. To allow for carrying out the analysis within this area, the mesh nodes were suitably selected. The results are presented in the form of circle diagrams. The figure presents nodal displacements in the courses of both clamping and unloading for a dodecagonal jaw. The lateral Fig. 6. Equivalent stresses: the process of clamping. planes of jaws together with their parting planes are clearly visible. The clamping efficiency revealed by the joints ing upon the joint clamped with the use of octagonal and dodecagonal that does not cause jaws, respectively, were compared in terms of analysis the rope or cable of the reduced residual stress (unloading) that deterto slip out of the mines the joint carrying capacity (see red lines in Fig. clamping sleeve. 7). The efficiency was determined by the area below The magnitudes the diagram or a mean value of the reduced residual and distributions stress. For the dodecagonal joint, the mean value was of residual stresses, 157 MPa, while in the case of elliptic one, 57 Mpa; Fig. 7. Nodal displacements within besides offering the therefore. the difference between stress magnitudes the rope-sleeve contact zone during possibility of monreaches 100 MPa. See Fig. 8. The dodecagonal jaw the processes of clamping (black) itoring the deforallows for increasing magnitudes of the residual stressand unloading (red), respectively. mation process, es within the contact almost three times. also provide very The comparison between the dodecagonal jaw important information about the process efficiency. Figs. twisted through 12.5 degrees about the axis and the 4 and-5 show samples of octagonal and dodecagoelliptic jaw was made. See Fig. 9. The efficiency of nal jaws. The jaw is twisted about the rope wires to joint forming means here the magnitude of reduced achieve the most suitable jawsleeve-rope configuration residual stress. From the figure it can be clearly seen that higher values appeared for dodecagonal-twisted, elliptic and circular joints, respectively. It is obvious that most uniform stress distributions can be observed in axi-symmetrical joints. Due to technological aspects of the clamping process, a hexagonal joint is most commonly employed, the efficiency of which is comparable with that revealed by the octagonal joint. The results obtained were verified experimentally using the diffraction-based sin2(gamma) method for stress state measurements at chosen points of the joint. The diffraction instrument D-8 Advance, made by Broker, was used for measuring the stress tensor components within the contact zone. For example, the radial stress component of 228 MPa Fig. 8. Reduced residual stress in the dodecagonal clamped joint was measured for the axi-symmetrical (clamping process â&#x20AC;&#x201C; red, unloading â&#x20AC;&#x201C;black).

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Fig. 9. Reduced residual stress in the dodecagonal clamped joint and elliptic - unloading. joint, which agreed perfectly with the simulation results. This new magnetic memory method, invented by Prof. Dubov, was verified as well. The main advantage of equivalent stress verification by this method is that it offers the possibility of taking measurements both during the clamping process and in unloading. The method is based on the fact that the diffraction of magnetic field depends on the stress distribution in the sleeve. The resulting cross-sectional distributions of the magnetic field agreed with the stress distributions.

Conclusions • The analysis allows for comparison between the clamped joints made using clamping jaws of different shapes. • Most uniform reduced residual stress (according to the Huber-Mises - Huncky hypothesis) distribution is achieved in the case of axi-symmetrical joint, the shape of which is closest to a dodecagon. In this respect the octagonal jaw yields most disadvantageous results, which however can be improved by means of turning the jaw about the rope axis through 12 degrees. • Higher stresses appear in the course of clamping, after the jaw release the internal (residual) stresses take much lower values. • The special-shape jaw brings about a relatively uniform stress distribution along the internal sleeve edge. The main advantage it reveals consists in the largest sleeve-rope contact zone as compared to the other ones, which influences strongly the maximum force carried by the joint. However, it also reveals some disadvantages, namely, a very large deformation of the external surface and a very complex shape difficult to follow in the course of manufacturing process. • The presented modelling methodology of the clamped joints allows for new designs, as well as for improving the available ones.

1. R. Buczkowski and, M. Kleiber, Finite Element Analysis of Elastic-Plastic Plane contact Problem with nonlinear Interface Compliance Mechanika Teoretyczna i Stosowana, Journal of Theoretical and Applied Mechanics, 4, 30, 1992. 2. A. Dorfmann, O. Pabst and R. Beh, “Combined Numerical and Experimental Analysis of the Mechanical and Thermal Stress Distribution in Rubber-Aluminium Roll,” 8th International Congress for Transport by Rope OITAF, San Francisco, 1999. 3. P. Hrycaj, S. Cescotto and J. Oudin, Elasto-Plastic Finite Element Analysis of Unilateral Contact with Generalized Columb Friction Engineering Computations, Vol. 8, pp. 291303, 1999. 4. J. Juraszek, Method of analysis of wire clasp joint, The International Journal of Transport & Logistics, No. 6, 2004. 5. J. Juraszek, Analysis of the Hexagonal Clasp-Joint - plastizitat, GAMM, 1994, s5.7 str78, TU Braunschweig. 6. J. Juraszek, Modeling of Steel Ropes and Steel-Aluminium Wires with Substitute crosswise stiffness. International Congress on Industrial and Applied Mathematics, ICIAM 95, Hamburg 1995. 7. J. Juraszek, Elasto-plastic Analysis of the Wire, GAMM 2007, Computatinal Mechacis str 48 TU Regensburg. 8. J. Juraszek, Elasto-Plastic Analysis of the Clasping Process. Gesellschaft fur Angewandte Mathematik und Mechanik, GAMM, 2011. 9.J. Juraszek, Analysis of steel wire clamp by FEM, International Wire Conference, Sept. 19-22, 2012. 10. J. Kliber, Theoretical and Technological Aspects of Rails Rolling, 9th International Met. Conference, Metal 2000, May 16-18, 2000, Ostrava. 11. J. Maligda, E. Stanova and M. Danci, Geometrical dresing of steel cable using optima strands of circular cross section, Transactions of the Universities of Kosice, No. 2, 2000. 12. Molnar V., 2012, Computer Utilization for Desing of the Rope Constructions and Their Strain Modeling, The International Journal of Transport & Logistics, No 6, 2012. 13. Landre J., Pertence A., Cetlin P.R., Rodrigues J.M.C and Martins P.A.F., On the utilisation of ductile fracture criteria in cold forging, Finite Elements in Analysis and Desing, Vol. 39, No . 3, January 2003. 14. Mac Donald B.J., and Hashmi M.S.J., Shape design sensitivity analysis and optimization of general plane arch structures. Finite Element in Analysis and Desing, Vol. 39, No. 2, Dec, 2002.

Janusz Juraszek

Janusz Juraszek is a professor at the University of BielskoBiała in Poland. Since 2009, he has headed the school’s Technology Transfer Center. He specializes in practical analysis by the finite element method and experimental verification. This paper was presented at WAI’s 83rd Annual Convention, Atlanta, Georgia, USA, May 2013.

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References

TECHNICAL PAPERS

ILVE

TECHNICAL PAPERS

Processing technology of high dimensional accuracy shaped wire drawing for spring wire Research showed that shaped wires used for springs can be fabricated from circular wires by two-pass drawing that meets FEA predictions as well as the required cross-sectional shape. By Kazunari Yoshida, Kenta Suga, Keita Nakazima, Kotaro Watanabe and Koji Umezu

Springs used in automobiles and machine tools need to be lightweight, high-strength and able to serve a long lifetime1. Springs with a rectangular cross-section are preferable to those with a circular cross-section because they take up less space and have the capability of storing a greater amount of energy2. Springs with a rectangular cross section are manufactured as follows. Shaped wires are prepared by drawing using shaped dies, coiled into springs by winding, then subjected to treatments to improve the quality of the materials, such as annealing and shot-peening. The number of drawing passes carried out to obtain shaped wires used for springs should be decreased to as few as possible to reduce production costs. It is also necessary in drawing to produce shaped wires with high dimensional accuracy and no defects3. In this study, the authors examined two processes: two-pass drawing of circular wire using shaped dies to prepare shaped wires used for springs; and the winding of shaped wires to form springs. First, finite element analysis (FEA) of the drawing process was carried out to determine suitable drawing conditions. Subsequently, drawing was experimentally performed to examine the conditions resulting in successful or unsuccessful drawing and the shape and dimensional accuracy of the obtained shaped wires. Moreover, the winding process was also analyzed by FEA to predict the cross-sectional shape of springs obtained by winding and compare the analytical results with experimental results. The mechanical properties of the springs were also investigated to determine the optimal processing conditions to obtain high-performance springs.

Experimental and FEA methods SAE9254 spring steel was used for the specimens in this study. MSC.Marc, a software package for nonlinear elastoplastic FEA, was used for analysis. A

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Table 1. Material property for FEA. 1/2 analytical model was used to shorten the analysis time. The cross-sectional shapes of dies used for the first (intermediate) and second (finishing) drawing passes are shown in Fig. 1. The die half-angle (Îą) was 6o, 8o, 10o or 12o. The reduction per pass (R/P) was 15%, 20%, 25% or 30%. Tables 1 and 2 summarize the mechanical properties of the specimen and the analytical conditions, respectively.

Experimental results and discussion: effect of R/P on dimensional accuracy In drawing using shaped dies, shape defects in drawn wires result in a fatal failure. Here, the drawing of mother wires with different diameters using the intermediate die with Îą = 10o was simulated by FEA (R/P = 15%, 20%, 25% or 30%). Fig. 2 shows the cross-sectional shapes and the distribution of the total equivalent plastic strain of the wires drawn using the shaped die obtained by FEA. The filling ratio in the figure is calculated by dividing the cross-sectional area of the drawn wire by that of the die hole. When R/P = 15% and 20%, the die hole was not completely filled by the drawn wire. This

TECHNICAL PAPERS Fig. 1. Cross sectional die shapes for shaped drawing and FEA model.

Fig. 2. Effect of one-pass reduction on profiles and equivalent strain distributions of drawn shaped wire by FEM. means that there are defects in the drawn wire, and the surface of the wire section not in contact with the die may be rough owing to plastic deformation. The results indicate that, in drawing using shaped dies, the greater the value of R/P, the higher the dimensional accuracy; however, wires may break during drawing when R/P is excessively large. Therefore, the optimal R/P was found to be about 25% when using the intermediate die.

Effects of die half-angle on dimensional accuracy and drawing stress The FEA of drawing using the intermediate die was performed by fixing R/P at 25% and setting Îą to 6o, 8o, 10o or 12o. The dimensional accuracy of the drawn wires was investigated. See Fig. 3. For smaller Îą of 6o and 8o, the wire easily ran in the drawing direction, resulting in the increased occurrence of defects. The

Fig. 3. Effect of die half-angle on profiles and equivalent strain distributions of drawn shaped wire by FEA.

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was experimentally performed using the intermediate and finishing dies. As noted earlier, the intermediate die with α = 10o was used and R/P was set to 25%. In this experiment, the wires were examined to see whether they could be successfully used for springs under these drawing conditions. The value of α for the finishing die was 14o. Fig. 6 shows the experimental and FEA results. The cross-sectional shapes of the drawn wires were in good agreement between the two results.

Winding conditions for springs Fig. 4. Drawing stress with various die half-angles. results of calculating the drawing stress from the FEA results (Fig. 4) indicate that the drawing stress increases with increasing α. During drawing using a die with α = 12o, the drawing stress was high and was close to the tensile strength of the material, indicating a very high likelihood of breakage. From the above results, the optimal α was found to be approximately 10o.

Drawing experiment For this research, 9 mm steel wire were prepared as mother wires and annealed under the conditions shown in Fig. 5. The annealing temperature was 760oC. Two-pass drawing

The shaped wire obtained by drawing using the shaped die under the above-mentioned conditions was coiled into a spring by winding, which was simulated by FEA (see Fig. 7). The pitch angle β was 6o and the inner diameter of a turn was 15 mm (see Table 3). For reference, wires with circular and square cross sections of the same area as that of the shaped wire were similarly subjected to winding. Fig. 8 shows the cross-sectional shape, the distribution of total equivalent plastic strain, and the distribution of hydrostatic stress for these wires after winding. Upon winding, the outer side of the spring was subjected to tension, resulting in the reduced diameter of the wire and the increased strain on the outer side. The shaped (almost trapezoidal) wire examined in this study deformed into a rectangular wire upon winding. Springs with a rectangular cross section have high strength and a large allowable displacement. The square wire was coiled into a spring with the outer side thinner than the inner side by winding. The circular wire was coiled into a spring with an elliptical cross section. The shaped wire was also experimentally coiled into a spring by winding, confirming the reliability of the FEA results. Fig. 9 shows the cross-sectional shapes of the springs obtained in the experiment and by FEA. These results were in good agreement. The mechanical and fatigue characteristics of the experimentally obtained springs were found to be good.

Fig. 5. Heat treatment condition for annealing.

Fig. 7. FEA model for winding of shaped drawn wire.

Fig. 6. Cross sectional shapes of drawn shaped wires by FEA and experiment. 74 | WIRE JOURNAL INTERNATIONAL

Table 2. Material property for FEA.

TECHNICAL PAPERS Fig. 8. Cross-sectional shape, distributions of equivalent strain, and distributions of hydrostatic stress for these wires after winding.

Fig. 9. Cross-sectional shapes of the springs obtained in the experiment and by FEA.

Conclusions Shaped wires were examined to see if they can be successfully fabricated by two-pass drawing using shaped dies and the optimal drawing conditions. The winding of the shaped wire to form a spring was simulated by FEA to predict the cross-sectional shape of the spring. The findings are summarized as follows.

Suga

Yoshida

• Shaped wires used for springs can be fabricated from circular wires by two-pass drawing; • The dimensional accuracy of drawn shaped wires and their drawability can be predicted by FEA; • The optimal drawing conditions for shaped wires used for springs are R/P ≈ 25% and α = 10o;; and • The cross-sectional shape of springs obtained by winding can be predicted by FEA.

References 1. N. Kamiya and E. Kita, J. of JSME (A), Vol. 56, no. 529, 1990, pp. 2026-2031. 2. Japan Society of Spring Engineers, Design, manufacture, and reliability of springs, 2001, pp. 6-8, Nikkan Kogyo Shimbun, Ltd. [in Japanese]. 3. K. Yoshida and M. Maejima, Proc. of 12th JSME conference, no. 04-15, 2004, pp. 433-434.

Nakazima

Watanabe

Umezu

Kazunari Yoshida is a professor at Tokai University, Japan. He has served as a member of the steering committee for Japanese Wire Drawing. He holds a Ph.D. degree in engineering. He authored a prize-winning paper for the Japan Society for Technology of Plasticity and won medal awards from WAI for the best paper and won Mordica award in 2011. Kenta Suga and Keita Nakazima are graduate students at Tokai. Kotaro Watanabe and Koji Umezu work at Tama Spring Co., Ltd., Japan. This paper, which was presented at WAI’s 83rd Annual Convention, Atlanta, Georgia, USA, May 2013, won the Association’s Silver Certificate Award in the ferrous sector.

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PRODUCTS for the shop floor

Cold-rolling system offers customers multiple choices for configurations Italy’s Eurolls SpA showed, among other pieces of equipment at wire Düsseldorf, a three-draft version of its new cold-rolling line, NLGH, which comes with the trend-setting Eurolls cassette CL25CB33. It reported the following. The line has extreme flexibility in design, allowing a manufacturer to choose the number of blocks (one-twothree) depending on the wire size range to be produced, with no fixed reduction imposed between each step. The standard wire production range is 3.40 mm to 12 mm in diameter at a maximum speed of 18 m/sec, but different configurations are possible in order to satisfy client’s specific needs, allowing one to be thinner or thicker. The horizontal configuration of the blocks allows easier accessibility to the unit both for setup and for operation, making for a clearer and cleaner working environment. A stress relieving unit can be added to the last draft, increasing in this way the elongation of the material. Further, a TeleAssistance System can be installed in the electrical cabinet, making it possible via an existing phone line connection, of a link, with webcam and microphone, between the line and Eurolls’s service department, for immediate understanding and intervention in case of need.

(pictured), which is designed to provide the optimum welding solution for industrial mesh and display products. Operating with one, two or four independent secondary welding circuits, the systems offer programmable air pressure, weld time and current, along with soft-approach weld cylinders, all of which result in flexibility, fast change-over and a high-quality final product. The models can process stainless steel wire, zinc coated wire, aluminum-zinc coated wire, black wire, cold drawn or cold-rolled wire or non-insulated wire.

Options include an automatic line wire magazine (double, triple or quadruple); preloading magazine for higher productivity; a crosswire magazine (double, triple or quadruple); a lower crosswire magazine; a crosswire stretching and trimming system; magazines for flat strip, tube and frame handling; slitting shears and cutting stations; bending utilities; stacking and handling systems; open interface for automation software; laser setup tools, self-adjustable grippers and other setup and changeover reduction utilities; and customized requirements. Contact: IDEAL-Werk, www.ideal-werk.com, and IDEAL Welding Systems, LP, www.idealweld.com. By the end of wire Düsseldorf, three lines were sold on the floor: the first a two-draft system to Central Africa, a first time sale for the Machinery Division; the second, to the Caribbean, can produce 3.4 mm ribbed wire at 18 m/ sec; and the third to North Africa, strengthening a deep bond with a very good client. Contact: Eurolls SpA, www.eurolls.com.

Welding system offers superior flexibility At wire Düsseldorf, Germany’s IDEAL-Werk and its U.S. business, IDEAL Welding Systems LP, showcased the company’s resistance welding machines. At the company’s website, it notes the following about the company’s quick setup mesh welding machine series

76 | WIRE JOURNAL INTERNATIONAL

Preassembled aerial cable line offered U.S.-based Kerite, founded in 1854 and a member of the Marmon Utility Group of companies, is offering a full line of preassembled aerial cable. A press release said that the aerial cables from Kerite, a manufacturer of insulated medium-voltage utility and industrial power cable, are ideal for areas subject to site limitations or where underground construction is not feasible. A typical usage could be for use between substation getaway riser cable and the circuit’s open-wire distribution portion, for express feeder circuits with site limitations, and for installation along space-constrained alleys and backyard boundaries and areas subject to tree-related storm damage, it said. The preassembled aerial cable is composed of three

Multi-axis lump detector provides continuous fault inspection of fiber At Wire Expo 2014, Germany’s Sikora AG, and its U.S. business, Sikora International Corp., introduced the FIBER LUMP 6003 MICRO, a multi-axis lump detector designed to detect faults on optical fiber surface continuously during the drawing process at a speed of up to 3,000 m/min.

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shielded conductor cables banded together, plus a messenger wire, the release said. The conductor, either aluminum or copper, is insulated with Kerite’s time-proven Permashield semiconducting layer and Kerite discharge resistant EPR system, which is used by Kerite on cable designs up to 138kV, it said. The cable’s insulation shield is a free-stripping design and the metallic shield consists of a five mil cupro-nickel or copper tape and/or copper concentric wires, the release said. The single conductor cable, it noted, may also have an overall jacket, and the entire twisted assembly is bound to a Copperweld messenger with a copper or optional stainless steel strap that can also be covered with a PVC or PE jacket. Contact: Kerite, www.kerite.com.

A press release said that the model provides quality assurance in drawing towers, a capability achieved by the use of six axes that eliminate shadow areas. Faults as small as 5 µm high and 50 µm long can be detected, and in combination with double sensor technology, punctual non-conformities can be detected, it said. The FIBER LUMP 6003 MICRO is designed for product diameters from 100 to 500 µm. The device can easily be integrated into new or existing drawing towers, and it can be connected to either the Sikora display and control system FIBER ECOCONTROL or to a line computer, it said, adding that it is suitable for coloring lines. “The response to our FIBER LASER 6003 for the measurement of the diameter, position, vibration frequency, tension and the spinning of fibers, confirmed our decision to bring this additional lump detection device to the market,” said Dr. Siegmar Lampe, head of R&D at Sikora.

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He said that many customer are interested in detecting very short fault lengths from 50 µm, especially as quality requirements are getting higher and higher. In response, Sikora’s FIBER LUMP 6003 MICRO not only meets those needs with its high accuracy, but “impresses by its 100% control of smallest faults from 5 x 50 µm.” Contact: Sikora AG, www.sikora.net, and Sikora International Corp, www.sikora-usa.com.

cations. The Cat. 6A Ethernet cables are engineered for the demands of modern airborne digital networks, able to support TIA-568 applications up to 10 gigabits while increasing signal density with reduced cable diameter. The cables are available in two standard sizes: 24 awg and 26 awg.

Line of low-smoke concentrates is alternative for multiple applications At Wire Expo, OTECH Corp. showcased its subsidiary’s line of FireTones concentrates, which it notes is a smart alternative for use in plenum, riser and tray cable manufacturing applications. It reported the following. The FireTones concentrates from Color Resource, LLC, which when combined with OTECH Corp.’s ground-breaking low-smoke compound technology, optimizes the reduction level of low smoke and fire resistance in any PVC wire application. “By creating concentrates with built-in low smoke and fire resistant capabilities, we ensure our customers easily stay ahead of changing standards and requirements. It’s a competitively priced alternative that could save customers a lot of money down the road,” said Greg Gitto, Color Resource National Accounts Manager & Marketing Director for Color Resource. Standard concentrates may detract from the efficacy of low smoke fire resistant compounds, especially in higher loadings. The creation of the high-performing FireTones concentrates mirrors these compound technologies, like FIREXIT compounds, by allowing for low smoke and fire resistant capabilities at every level. In testing, the new FireTones concentrates outperformed all other concentrates in their class. “The difference is significant enough to make you jump back when used in conjunction with FIREXIT compounds,” Gitto said. Contact: Color Resource, LLC, tel. 978-537-3700, info@color-resource.com, www.color-resource.com.

Ethernet cables offer high data rates U.S.-based W.L. Gore & Associates, Inc. (Gore) has introduced GORE® Ethernet Cables to meet the military and civil aerospace markets’ emerging need for higher data rate cables in a lightweight, flexible, and routable package. A press release said that the product, which uses the unique cable jacket material found in GORE 1394b FireWire Cables, provides the ideal combination of high speed and light weight necessary for a wide range of aerospace appli78 | WIRE JOURNAL INTERNATIONAL

The release said that the Ethernet cables “carry on the heritage and proven success of GORE Aerospace Cables, including the GORE 1394b FireWire Cables, which have long been the premier solution for 1394b FireWire data links on Lockheed Martin’s F-35 program.” Typical applications for GORE® Ethernet Cables include: avionics networks, digital video systems, cabin management systems, flight management systems, Ethernet backbone and in-flight entertainment systems, the release said. Contact: W.L. Gore & Associates, Inc., www.wlgore.com.

Velocimeters provide both precise speed and length measurement Switzerland’s Zumbach AG, whose U.S. business is Zumbach Electronics Ltd., reports that its LSV 1000/2000 velocimeters enable manufacturers to confidently monitor quality in steel, cable, wire and tubing production. A press release said that the line of compact velocimeters provides length and velocity data quickly and reliably for both process control and cut-to-length applications. Precise detection of very small movements, it said, is possible because the measuring accuracy is not dependent on the speed. It noted that precise knowledge of length and current speed, a key cost and process optimization factor for producing cables, helps control wear and slip push material costs and reduces rejects. The LSV 1000/2000 velocimeters exceed the performance of conventional contact-based measuring methods, at the same time offering maximum robustness with minimized maintenance requirements and costs, the release said. The all-in-one system can be easily integrated into production processes, and the visible lasers simplify alignment in the measuring field. The low-weight units (4.3 kg) and supplied mobility kit allow rapid mobile deployment as well as the connection to a laptop, it said.

Ultrasonic equipment excels at single-pulse welding of tinned wires U.S.-based Sonobond reports that the companyâ&#x20AC;&#x2122;s SpliceRiteTM Wire Splicer cost-effectively produces splices in wire bundles up to 60 square mm in size.

A press release said that with just one pulse, the wire splicer can process tinned or oxidized wire bundles up to 35 sq mm. The unit, it said, can accommodate lightly tinned or oxidized wires up to 60 sq mm without pre-cleaning. It noted that the SpliceRite is the ultrasonic splicer with upper and lower welding heads, which allows it to weld stranded copper wire bundles of up to 100 sq mm in a single pulse. That, it said, is makes it ideal for assembling heavy-duty cables used for trucks, cars, trains, industrial machinery and similar applications. Both the SpliceRiteâ&#x201E;˘ and the Dual Head SpliceRite feature easily and economically replaceable tool steel taper lock tips that can last up to 100,000 welds, and require no recalibration, along with a microprocessor that stores and recalls up to 250 jobs, the release said. Contact: Sonobond, www.sonobondultrasonics.com.

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The LSV models can supply reliable results for length and speed even in adverse conditions and are certified for protection classes IP 66 and IP 67 (per EN 60529). The rapid, state-of-the-art signal processor is equipped with a powerful command system for efficient system communication via serial or Ethernet interface. In light of its performance and the remarkably low operating and maintenance costs, the ROI is extremely attractive, it said. Contact: Zumbach AG, www.zumbach.ch, and Zumbach Electronics Ltd., www.zumbach.com.

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Rigid strander line meets new specs and provides higher tolerances At wire Düsseldorf, India’s Associated Engineers & Industrials (AEI) Ltd., a supplier of rotating equipment, showcased its latest line of rigid stranding systems.

A press release said that AEI’s newest rigid stranders address the need of power cable manufacturers to supply products that meet higher tolerances and new specifications for overhead conductor. The stranders, it said, deliver accurate back tension, smooth strand deviation and precise lay control. Equipped with the heavy duty compacting head (die/ roll/prespiral-Millken), the features result in superior quality compacted conductor for low, medium and extra-high voltage power cables, it said. Enhanced cage speeds and use of fully automatic bobbin batch loading systems (floor- or sidetrolley type) ensure higher production efficiency and uptime, features essentially required for overhead conductor manufacture, it noted, adding that AEI has also developed heads to make the latest generation HTLS/TW overhead conductor. Contact: Associated Engineers & Industrials Ltd., sales@aeimachines.com, www.aeimachines.com.

Enhanced controller provides more accuracy to cable jacketing extrusion At wire Düsseldorf, U.S.-based Maguire Products, Inc., showcased the company’s enhanced LineMaster™ XC-2X system, which is designed to increase accuracy in cable jacketing extrusion. A press release reported the following about the LineMaster system. The loss-in-weight hopper is mounted on the throat of the extruder and suspended on a pair of load cells that continually monitor material weight in the hopper. Each second, the LineMaster controller calculates the amount of material being metered into the extruder. A special drive control interfaces between the controller 80 | WIRE JOURNAL INTERNATIONAL

and the extruder drive, takeaway drive, or both. If line speed needs to be determined, Maguire supplies a digital encoder, mounted on the takeaway rollers downstream of the extruder, that monitors line speed so the weight per length of product can be calculated. The system has seen two enhancements, as follows. The first is TRIM mode, an enhancement to the company’s XC-2X system for maintaining target weight per length of jacketing layer. It increases the speed of response to sudden large changes in line speeds, such as when a cable reel or drum is changed when full, by instantly adjusting extruder speed. For an optical cable sheathing line, it can maintain the number of grams per meter of sheathing to a customer tolerance of +/- 0.2 mm, even during large decreases and increases of line speed. The second advance is the MGF™ gravimetric color feeder, which now can communicate directly with the LineMaster controller, increasing the accuracy of color dosage, a key factor in uniform physical, electrical properties, and appearance. Contact: Maguire Products, Inc., www.maguire,com.

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Redesigned website showcases industry association’s focus The Communications Cable and Connectivity Association (CCCA), a non-profit group of connectivity and cabling manufacturers, distributors and material suppliers, has launched a completely redesigned, user-friendly website. Per a press release, www.cccassoc.org, CCCA’s website, houses an extensive and constantly evolving library of information crucial to the structured cabling industry in four main areas: anti-counterfeit, code compliance/standards, environmental sustainability and a data center. The new site tells visitors what they need to know about CCCA’s mission, said Frank Peri, CCCA executive director. The site is more agile and easier to scan, read and navigate, he said, noting that visitors can find resources such as white papers, presentations, press releases, articles, and videos. A search of “anti-counterfeit,” for instance, will reveal a white paper on the liability of installing copper-clad aluminum as communications cable and a video explaining CCCA’s CableCheck™ app, which is used to spot and avoid suspect counterfeit cable. CCCA, which provides a resource for well-researched, fact-based information on the technologies and issues vital to the structured cabling industry, notes that it is also proactive at codes and standards bodies as well as working with other trade, industry and governmental organizations. Contact: Communications Cable and Connectivity Association, www.cccassoc.org. n

WIRE ASSOCIATION INTERNATIONAL MEMBERS seeking positions are entitled to free “Position Wanted” classified ads. Limit: one ad per issue, three ads per year. This benefit is not transferable to nonmembers or to companies.

BLIND BOX INFO: Responses to Blind Box ads should be addressed to: Wire Journal International, Box number (as it appears in print or on-line), P.O. Box 578, Guilford, CT 06437-0578 USA.

CLASSIFIED AD RATES: • $1.30 per word for WJI and on-line classifieds at wirenet.org (20-word minimum). • Blind box numbers, add $25. • Boldface headlines, add $6 per line (up to 18 characters per line). Specify category.

PAYMENT POLICY: All ads must be pre-paid. DEADLINES: Copy is due a full month in advance. Contact: classified@wirenet.org for more details.

CAREER OPPORTUNITIES

PERSONNEL SERVICES

DIES

SOUTHWEST ACCOUNT MANAGER. Wire & Cable Distributor is seeking Account/Product Manager for TX, LA, AL, MS, OK, TN, KS, and select accounts in GA. Experience: 5 years in sales and 5 years in W&C industry. Must have a record of proven sales results. Must reside in one of the states in the territory and be able to work independently. Technical and marketing experience a plus. Opportunities for advancement are available. Industry leading pay and benefits will be offered. Please send resume to jhoogendoorn@ttmarketinginc.com.

“LET OUR SUCCESS BE YOUR SUCCESS” Wire Resources is the foremost recruiting firm in the Wire & Cable Industry. Since 1967 we have partnered with industry Manufacturers to secure the services of executives, managers, and thousands of key individual contributors. Contact: Peter Carino, pcarino@ wireresources.com or online at www.linkedin.com/in/petercarino1/ Wire Resources Inc., PO Box 593, Riverside, CT 06878, tel. 203-6223000. www.wireresources.com.

APOLLO DIA-CARB COMPANY Sells Natural/PCD diamond dies. Fair prices/excellent lead times. Contact Paulette, Owner/Sales Tel. # 1 (508) 226-0946 or e-mail: apollodie@comcast.net.

PLANT/MANUFACTURING MANAGER. MA-based privately held custom cable manufacturer seeks manufacturing manager due to pending retirement of current one. Extensive background and experience in Wire & Cable industry is required. We are a smoke & drug free EOE offering excellent pay, benefits and room for personal and professional growth for the right candidate. Send Resume to: generalwire@aol.com. LUCRATIVE OPPORTUNITY FOR REPS AND AGENTS in WIRE & CABLE. Earn up to 10% commission for relationships you already have! llied Wire & Cable, a leading global specialty manufacturer and value-added distributor of electrical wire and cable, is looking for independent reps to support our dynamic and growing sales team. With this opportunity, you can work for us part-time. Want to learn more? Contact us confidentially by email: agent@awcwire.com or by fax: 484302-4275.

MACHINERY WWW.URBANOASSOCIATES. COM. For New (Hakusan Heat Pressure Welders, Ferrous & NonFerrous; Marldon Rolling Ring

FOR SALE 1 - HACOBA Model DF24 24-Carrier Braider 2 - WARDWELL 24-Carrier Braiders 1 - NEB 72-C #2 Braider, Long Legs, Motor 1 - TRENZ 64-C Horizontal Braider 1 - NEB 24-C CB-1 Cable Braider 7 - KINREI 560mm D.T. Twisters 1 - MGS 50” Caterpuller Capstan 1 - REEL-O-MATIC 24” Caterpuller Capstan 2 - FARRIS 22”, 30” Caterpuller Capstans 1 - ALLARD 36” Closer 2 - NEB 12-Wire 8” Vertical Planetary Cablers 1 - ALLARD 30” S.T. Closer 1 - DAVIS STANDARD 4.5” 24:1 Extruder Line, 2009 1 - DAVIS STANDARD 3.5” Rubber Extruder 1 - DAVIS STANDARD 2.5” Hi-Temp Extruder 1 - DAVIS STANDARD 2.5” 24:1 Extruder Line, 2009 1 - DAVIS STANDARD 1” 24:1 Extruder 1 - AFA 84” Portal Payoff 1 - LESMO 1800mm Gantry Payoff, Model SPF1800 1 - SKALTEK 1600mm Payoff, Model A16-4K 1 - DYNAMEX Tape Payoff, Model TPB30-2-D Commission

B r o k e r s

1 - MALI 1+3 Bow Strander Line, 2009 1 - ROSENDAHL 630mm P/A Dual Reel Take-up 1 - SPHEREX 18” Dual Reel Take-up, refurbed 1 - CLIPPER Model SP16 Dual Spooler 1 - AL-BE Model MS12 Respooler, 18” Reels 1 - BARTELL 120” Shaftless Take-up 1 - BARTELL 108” Gantry Take-up 1 - TULSA 36” Rewind Line 1 - METEOR Model ME301 3-Head Winder 1 - TEC Model DTC630 D.T. Twister 1 - ENTWISTLE 4WDT24 4-W 24” D.T. Twisters 2 - NEWMCO 16” D.T. Quadders 1 - METRONIC AlphaJet C Inkjet Printer, 2005 1 - HALL Tape Accumulator 1 - WARBRICK “Chalkmaster” Talc Applicator 1 - EUBANKS Model 4000-04 C/S Machine 1 - SCHLEUNIGER Model UC3750 Cutter 1 - SCHLEUNIGER Model ES3200 EcoCut 1 - SCHLEUNIGER Model ES9320 EcoStrip 1 - SCHLEUNIGER Model HS4500 Hot Stamper 1 - SCHLEUNIGER Model CT32, CT42 Crimpers 1 - IDEAL Model STP Stripper, Part #45-930

Commission Brokers Inc., Cranston, RI 02920 • 401-943-3777 www.CommissionBrokers.com • marty137@aol.com

AUGUST 2014 | 81

CLASSIFIEDS

Traverses) & Used Wire & Cable Equipment (buttwelders, coldwelders, ers and pointers). Tel: 727-8634700 or by e-mail, please send to urbassoc@verizon.net.

MEDIA SIX SIGMA AND OTHER IMPROVEMENT TOOLS FOR THE PRACTICAL APPLICATION OF THE PROCESS CAPABILITY STUDY. Creating a universal language for problem solving, this 135page indexed booth (published in 2011) was written by industry expert Douglas B. Relyea, founder of Quality Principle Associates, a New Englandbased consulting firm specializing in the education and application of data analysis techniques to industrial problem solving. The book includes: the benefits of statistical process control over statistical product control; real-world industrial examples and case studies showing how to use the

82 | WIRE JOURNAL INTERNATIONAL

techniques; ways for management to determine if the investment in process capability studies is providing an appropriate return; methods to correct lack of stability and capability once either condition has been identified, such as the ANOVA technique and the simple three-factor designed experiment; and a flow chart that enables machine operators to execute a process capability study without interfering with productivity. The list price is $45, $40 for WAI members, plus shipping. To purchase, go to wirenet. org and click on The WAI Store. THE SMALL SHOP. This book, 327 pages, by Gary Conner, the author of Lean Manufacturing for the Small Shop, describes Six Sigma and how it is used by smaller companies. Published by the Society of Manufacturing Engineers, it shows the relationship between continuous improvement, lean, and quality, and focuses on implementation for operators, managers, and owners. It includes

a supplementary CD-ROM. Price, $95, $75 for WAI members, plus shipping. To purchase, go to wirenet.org and click on The WAI Store. THE ROEBLING LEGACY. This 288-page indexed book by Clifford W. Zink presents a different perspective of the Roebling legacy. “But it’s all wire,” proclaimed a 1950s Roebling brochure about its product line, which included wire rope, copper magnet and electrical wire, screens and hardware cloth, aircord and aircraft strand, flat and braided wire, PC wire and strand, galvanized bridge wire, among others. To maximize quality, the Roeblings started drawing their own wire in the 1850s, rolling bars into rods in the 1870s, and making their own steel in the 1900s. Wire is the binding thread through 125 years of Roebling and American industrial history. The price is $75, $50 for WAI members, plus shipping. To purchase, go to wirenet.org and click on The WAI Store. 

ADVERTISER............................. PAGE

ACIMAF.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Micro Products Co . . . . . . . . . . . . . . . . . . . . . . . 27

AlphaGary Corp. . . . . . . . . . . . . . . . . . . . . Cover 2

Paramount Die Co. . . . . . . . . . . . . . . . . . . . . . . . . 4

Anbao Wire & Mesh Co Ltd. . . . . . . . . . . . . . . . 37

PKG Equipment Inc. . . . . . . . . . . . . . . . . . . . . . . 57

Beta LaserMike . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Pressure Welding Machines Ltd. . . . . . . . . . . . 37

Carris Reels Inc. . . . . . . . . . . . . . . . . . . . . Cover 4

Proton Products Ltd. . . . . . . . . . . . . . . . . . . 21, 79

Cemanco LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Queins Machines GmbH. . . . . . . . . . . . . . . . . . . 23

Commission Brokers Inc . . . . . . . . . . . . . . . . . . 81

Rainbow Rubber & Plastics Inc. . . . . . . . . . . . . . 2

George Evans Corp. . . . . . . . . . . . . . . . . . . . . . . 32

REELEX Packaging Solutions Inc. . . . . . . . . . . 19

Howar/Unitek. . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Sandvik Hard Materials. . . . . . . . . . . . . . . . . . . . 33

Huestis Industrial . . . . . . . . . . . . . . . . . . . . . 58, 77

Sanxin Wire Die Inc. . . . . . . . . . . . . . . . . . . . . . . 13

Inosym Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8, 51

SIKORA AG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

IWG High Performance Conductors Inc. . . . . . 25

Sjogren Industries Inc.. . . . . . . . . . . . . . . . . . . . 45

KEIR Manufacturing Inc. . . . . . . . . . . . . . . . . . . 18

Steel Cable Reels . . . . . . . . . . . . . . . . . . . . . . . . 38

Lamnea Bruk AB. . . . . . . . . . . . . . . . . . . . . . . . . 11

August Strecker GmbH & Co KG.. . . . . . . . . . . 17

Locton Limited. . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Teknor Apex Co. . . . . . . . . . . . . . . . . . . . . . . . . . 39

AUGUST 2014 | 83

ADVERTISERS’ INDEX

ADVERTISERS’ INDEX PEOPLE

ADVERTISER ............................ PAGE TMS Specialties Manufacturing Co Inc . . . . . . 83 Paul Troester Maschinenfabrik . . . . . . . . . . . . 53 Unitek/Howar Equipment . . . . . . . . . . . . . . . . . 29

ADVERTISER ............................ PAGE

October 2014 WJI

• Manufacturing trends • IWCS preview

Vandor Corporation . . . . . . . . . . . . . . . . . . . . . 15 WAFIOS Machinery Corp . . . . . . . . . . . . .Cover 3 Windak USA Inc . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Wire & Plastic Machinery Corp . . . . . . . . . . . . . 9 Woodburn Diamond Die Inc . . . . . . . . . . . . . . . 22 Wyrepak Industries . . . . . . . . . . . . . . . . . . . 24, 55 Zumbach Electronics Corp. . . . . . . . . . . . . . . . 47

WIRE ASSOCIATION INTERNATIONAL ADS WAI membership . . . . . . . . . . . . . . . . . . . . . . . . 26 Interwire 2015 . . . . . . . . . . . . . . . . . . . . . . . . 30-31 Interwire Call for Papers . . . . . . . . . . . . . . . . 35-36 Global Continuous Casting Forum . . . . . . . 43-44 WAI Industry Search . . . . . . . . . . . . . . . . . . . . . 82

WIRE JOURNAL I N T E R N A T I O N A L

SALES OFFICES NORTH AMERICA

EUROPE

Robert J. Xeller/Anna Bzowski Wire Journal International Tel: 203-453-2777 Fax: 203-453-8384 sales@wirenet.org

U.K., France, Spain, Holland, Belgium, Denmark & Scandinavia Jennie Franks David Franks & Co. Tel/fax: 44-1223-360472 franksco@btopenworld.com

ASIA/WAI India Office Wire & Cable Services Pvt. Ltd. (WCS) 501, Rainbow Plaza, S. No. 7 Pimple-Saudeagar Vil. Rahatani, Pune - 411017, India Huned Contractor mobile - +91 988 1084 202 hcontractor@wirenet.org

Germany, Austria, & Switzerland Dagmar Melcher Media Service International Tel: 49-8801-914682 Fax: 49-8801-914683 dmelcher@t-online.de

84 | WIRE JOURNAL INTERNATIONAL

Advertising Deadline: Sept. 1