Equipment: Part 1

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JULY 2008

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WIRE JOURNAL

I N T E R N A T I O N A L w w w. w i r e n e t . o r g

Equipment: Part 1 Ferrous view:

P. 28

U.S. wire rod prices: what’s going on and what’s to come?

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WIRE JOURNAL

®

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

Volume 41 | Number 7 | July 2008

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

CONTENTS

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F EATURE

Calendar . . . . . . . . . . . . . . . . 8 Industry News . . . . . . . . . . . 12 Ferrous View: U.S. wire rod . . 28 Asian Focus . . . . . . . . . . . . . 30 People . . . . . . . . . . . . . . . . 32

Equipment: Part 1 . . . . . . . . . . .46

Fastener Update . . . . . . . . . 36

If you could not attend wire Düsseldorf, this feature is for you. It presents a wide range of equipment, much of it presented at the German trade show, the world’s largest event for the wire and cable industry. More equipment will be presented in the September issue.

WAI News . . . . . . . . . . . . . . 38

T ECHNICAL P APERS

Chapter Corner . . . . . . . . . . 42

The effect of thermal expansion of dies on dimensional accuracyin drawn bar and wire Ryosuke Komami, Motoo Asakawa, Satoshi Kajino and Hiroaki Kubota . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Fiber Watch . . . . . . . . . . . . . 34

Technical Papers . . . . . . . 68-86 Products/Media . . . . . . . . . . 87

Advanced semi-automatic straightening technology Marcus Paech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Classified . . . . . . . . . . . . . . 93

Thermodynamic wire transformation process in the manufacture of steel tire cord Thomas W. Tyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

Career Opportunities . . . . . . 93 Advertisers’ Index . . . . . . . . 96

Cover: Suppliers in this feature, most of whom displayed at wire Dusseldorf, include U.K.’s Pave Automation, Germany’s WiTechs, and Germany’s Jouhsen-Bungdens GmbH. See p. 46.

JULY 2008 | 3

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INSIDE THIS ISSUE CONTENTS

W IRE

ROD PRICES : WHAT ’ S GOING

ON AND WHAT ’ S TO COME ?

. . 28

The below chart will not surprise anyone who has to buy steel wire rod. SteelOrbis analyst Murat Askin gives his company’s outlook at what has led to the current conditions and what’s likely to come.

4 | WIRE JOURNAL INTERNATIONAL

K EYNOTE

SPEECH

. . . . . . . .6

At Wire Expo 2008, General Cable Corporation’s Mark Thackeray explains how his company was able to make fundamental changes in its operations.

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EDITORIAL WIRE JOURNAL

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EDITORIAL

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

Two Wire Expo highlights The August WJI issue will have a complete wrapup on Wire Expo 2008, but it’s appropriate to say a few words here about one event – the Awards Breakfast on Monday, June 9 – which proved to be quite memorable on two different levels.

The first element was the keynote address by General Cable Corporation’s Mark Thackeray on the wire and cable industry, which was impressive in its scope and its message. Thackeray, the company’s senior vice president, North America operations, explained how the company was able to implement fundamental changes in its operations.

It was not a short-term evolution and it was not an easy one, but as he explained the different stages involved and what the company discovered, the reasoning behind the actions – counterintuitive at some points – made sense. The WJI plans to have more about this in a future issue, but here we will note one of the key findings cited by Thackeray: “inventory hides weaknesses.”

The other element had to do with the Donnellan Memorial Award.

This year, there were two winners: Continuus Properzi’s Giulio Properzi and, posthumously, the late Barry Loudon, the first executive director of the Australasian Wire Industry Association, who died August 12, 2006, at the far too early age of 53. Those who knew Barry understood just how special a person he was, hardworking and dedicated yet always personable. Loudon’s three daughters came to Wire Expo to receive the award on his behalf. There, the eldest daughter, Catherine, delivered an acceptance speech before several hundred attendees that was as moving as it was eloquent. She and her sisters received a standing ovation after she finished and if there was a common thought shared by the audience, it had to be that anyone would have been proud to have raised such daughters. Perhaps that’s the most lasting of legacies one could ask for.

Mark Marselli Wire Journal editor

From l-r, Loudon sisters Catherine, 23; Kirrilee, 18; and Alexandra, 20.

6 | WIRE JOURNAL INTERNATIONAL

Publisher | Steven J. Fetteroll Editor-in-Chief | Mark Marselli Senior Graphic Designer | Bill Branch Director of Sales | Robert Xeller Advertising Sales | Anna Bzowski Director of Marketing Services | Janice E. Swindells Proofreader | Livia Jacobs Circulation Manager | Jan Valois Publications Advisory Board Antonio Ayala | J.J. Lowe, Mexico Ferruccio Bellina | TKT Group/President ACIMAF, Italy Anand Bhagwat | Wire and Cable Services, India Malcom Michael | Australasian Wire Association, Australia Don Schollin | Q-S Technologies, USA Ken Scott | UK Ralph Skalleberg | Skaltek USA Dave Stackpole | Nutmeg Wire, USA Giulio Properzi | Continuus Properzi, Italy Robert Wild | Niehoff Endex North America, USA WAI Executive Committee Liaison Dane Armendariz | Henkel Corporation Technical Advisors John Drummond | Scotia Group Nate Rosebrooks | Fluid Coating Technology R. M. Shemenski | RMS Consulting, Inc.

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 mmarselli@wirenet.org. Address all correspondence concerning advertising production, editorial and circulation to the above address. WJI is printed in USA. Subscription rates: $95 per year, USA; $105 per year, Canada and Mexico; other countries, $125 per year (includes air mail). Single copies: $6 in the U.S.; all other countries $7. 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. © 2008 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: 313761-4700.

POSTMASTER: Send address changes to Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA.

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CALENDAR

CALENDAR September 18-20, 2008: Cable & Wire 2008 Istanbul, Turkey. To be held at the CNR Expo Center, this event will present cable accessories, wiring harnesses, machines and electro-insulating materials, equipment and production machinesContact: Mediaforce Fuarcilik Ltd. Sti., tel. 90-212-465-65-45; info@mediaforceonline. com; www.mediaforceonline.com.

September 23-26, 2008: wire China Shanghai, China. wire China will be held at the Shanghai New International Exhibition Center. Contact: Messe DĂźsseldorf North America, tel. 001-312-781-5180; fax 001-312-781-5188; info@mdna.com; ww.mdna.com.

October 15-17, 2008: Spring World 2008 Rosemont, Illinois, USA. To be held at the Donald E. Stephens Convention Center, this event is sponsored by the Chicago Association of Spring Manufacturers (CASMI). Contact: Tom Renk, tel. 847-433-1335; info @casmi.org; www.casmi.org.

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October 20-22, 2008: ITC Mexico Monterrey, Mexico. To be held at the Crown Plaza Monterrey, this WAI ITC includes a technical conference, tabletop exhibits, a plant tour and networking opportunities.

November 3-5, 2008: Electrical Manufacturing Expo Orlando, Florida, USA. This event, to be held at the Gaylord Palms Convention Center, is organized by the Electrical Manufacturing & Coil Winding Association.

Contact: Chuck Thurman, tel. 619-435-3629; cthurman@emcwa.org, www.electricalmanufacturing.org.

November 9-12, 2008: 57th IWCS™ Conference and Symposium Providence, Rhode Island, USA. The IWCS returns to the Rhode Island Convention Center. Contact: Internet www.iwcs.org; phudak@iwcs.org; tel. 001-732-389-0990.

November 20-22, 2008: Wire & Cable India 2008 Mumbai, India. Contact: Cheryl Fernandes, Business Fairs, Confederation of Indian Industry, tel. 91-2224931790, ext. 470; fax 91-22-24939463; www. ciionline.org.

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www.niehoff.de

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MASCHINENFABRIK NIEHOFF GmbH & Co. KG, Germany, Phone +49-9122-977-0, Fax +49-9122-977-155, E-Mail: info@niehoff.de, Internet: www.niehoff.de · NIEHOFF ENDEX NORTH AMERICA INC., USA, Phone 856-467-4884, Fax 856-467-0584, E-Mail: sales@niehoffendex.com MASCHINENFABRIK NIEHOFF GmbH & Co. KG, Germany, Phone +49-8342-7008-0, Fax +49-8342-7008-40, E-Mail: info@niehoff.de · MASCHINENFABRIK NIEHOFF s.r.o., Nymburk, Phone +42-325 519 751, Fax +42-325 519 755, E-Mail: info@niehoff.cz NIEHOFF-HERBORN MÁQUINAS Ltda., Brasil, Phone 11-41 98 43 22, Fax 11-41 98 42 34, E-Mail: diret@niehoff.com.br · NIPPON NIEHOFF Co., Ltd., Japan, Phone 3-3257-0911, Fax 3-3257-0910, E-Mail: s.kanazawa@nippon-niehoff.co.jp · MASCHINENFABRIK NIEHOFF GmbH & Co. KG, Singapore Representative Office, Phone 63369936, Fax 63364070, E-Mail: niehoff@pacific.net.sg · MASCHINENFABRIK NIEHOFF GmbH & Co. KG, Germany, Shanghai Representative Office, P.R. China, Phone 21-63906191, Fax 21-63906192, E-Mail: nscc@public1.sta.net.cn NIEHOFF of INDIA Private Limited, India, Phone +91 8455 224-391, -392, -393 , Fax +91 8455 224-394, E-Mail: info@niehoff.in NIEHOFF of Russia, Phone 7-495-230-5537, Fax 7-495-230-5539, E-Mail: info@niehoff.de · MASCHINENFABRIK NIEHOFF GmbH & Co. KG Dubai Branch, Dubai/United Arab Emirates, Phone +971-4 2045 153, Fax: +971-4 2045 154, E-Mail: m.dalal@niehoff.de

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April 25-30, 2009: Interwire 2009 Cleveland, Ohio, USA. To be held at the International Exposition Center (I-X Center), Interwire incorporates: Interwire Trade Exposition, the technical program and the WAI’s 79th Annual Convention. It addresses ferrous and nonferrous manufacturing, and electrical/data/voice segments as well as wire forming and related wire and wire products. Contact: WAI, tel. 001-203-453-2777; fax 001203-453-8384; www.wirenet.org. ■

CALENDAR

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WIRE ASSOCIATION INTERNATIONAL EVENTS For more information, contact the WAI, USA. Tel. 001-203453-2777; fax 001-203-453-8384; Internet www.wirenet.org.

August 7, 2008: Sixth Annual Ohio Valley Golf Tournament Solon, Ohio, USA. .The Ohio Valley Chapter returns to the Grantwood Golf Course.

September 11, 2008: New England Chapter's 14th Annual Golf Tournament Paxton, Massachusetts, USA. The chapter will return to the Kettle Brook Golf Club.

September 25, 2008: Mid-South Chapter's 7th Seventh Annual Golf Tournament Florence, Alabama, USA. The chapter will go to a new course, part of the Robert Trent Jones Trail.

October 15, 2008: Western Chapter's 8th Annual Wild West Shootout Industry Hills, California, USA. The chapter will return to the Industry Hills Golf Club.

October 20-22, 2008: ITC Mexico Monterrey, Mexico. To be held at the Crown Plaza Monterrey, this WAI ITC includes a technical conference, tabletop exhibits, a plant tour and networking opportunities.

October 30, 2008: Southeast Chapter's 7th Annual Golf Tournament Conover, North Carolina, USA. The chapter will return to the Rock Barn Golf and Spa. April 25-30, 2009: Interwire 2009 Cleveland, Ohio, USA. To be held at the International Exposition Center (I-X Center), Interwire incorporates: Interwire Trade Exposition, the technical program and the WAI’s 79th Annual Convention. It addresses ferrous and nonferrous manufacturing, and electrical/data/voice segments as well as wire forming and related wire and wire products. Contact: WAI, tel. 001-203-453-2777; fax 001203-453-8384; www.wirenet.org.

10 | WIRE JOURNAL INTERNATIONAL

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INDUSTRY NEWS

INDUSTRY NEWS South Korea’s LS Cable to acquire Superior Essex for $900 million LS Cable Ltd. and Superior Essex Inc. announced that an agreement has been reached whereby the South Korean cabler company will buy Superior Essex for US$900 million, a combination that will result in the creation of the world’s third largest wire and cable manufacturing company.

The combined companies, which had 2007 revenues of approximately US$12.8 billion, will have a “strong product portfolio and capabilities in power cable, magnet wire, communications cable and copper rod,” the release said. It noted that LS Cable has a strong presence in power cable and communications cable, while Superior Essex is the world’s largest producer of magnet wire and a leader in the North American communications cable market. LS Cable has an extensive footprint in Asia and the Middle East, which will be complemented by the operations of Superior Essex in North America, Europe and China, it said.

Per the release, “LS Cable currently expects that there will be no changes in the operations or workforce of Superior Essex as a result of the transaction and intends to run the company with its existing management and employees. Superior Essex will continue to execute its previously announced global magnet wire factory restructuring activities.”

“Bringing our companies together accelerates both companies’ strategic plans and will position us to leverage our operations to drive value and to capture synergies between the two businesses,” LS Cable Chairman John Koo said in a press release. “Together, we will have worldwide reach through our diverse network of manufacturing and distribution facilities. Given the highly complementary geographic locations of our two companies, this combination greatly expands our global presence.”

“With LS Cable, our employees will be part of an industry leader who is equally committed to operational excellence and to maintaining the quality and service heritage of Superior Essex,” Superior Essex CEO Stephen Carter said in the release, noting that LS Cable has a strong R&D program and will provide an increased global presence. “By combining their manufacturing capabilities and product portfolio with our own, we can better meet the needs of our customers and extend our reach into new and growing end-markets.”

According to the release, LS Cable, which has 6,100 employees and more than 25 manufacturing sites located in 12 countries, with operations on three continents, provides a wide range of energy and telecom cable solutions as well as electronic components and industrial machin-

ery for the energy infrastructure, construction, automotive, railway, telecommunication and electronic industries.

At its website, Superior Essex notes that it operates 26 manufacturing facilities in the United States, Mexico, France, Germany, the United Kingdom, Portugal and China, with more than 4,400 employees.

Once the deal closes, Superior Essex will continue to operate under its current name as a wholly-owned subsidiary of LS Cable, the release said. Superior Essex will maintain its headquarters in Atlanta and its manufacturing and distribution facilities in the U.S., Canada, China, France, Germany, Italy, Mexico, Portugal and the U.K.

International Wire Group to acquire the U.S. business of Global Wire U.S.-based International Wire Group, Inc. (IWG), announced that it has entered into an agreement to pay $28.6 million to acquire the U.S. assets and operations of Global Wire, Inc., as well as certain equipment owned by an affiliated company.

A purchase agreement calls for IWG to acquire Global Wire’s plants located in Littleton, New Hampshire and Jewett City, Connecticut. The Littleton, New Hampshire plant will be purchased outright, and the Jewett City, Connecticut plant will be leased, with an option to purchase at a later date, it said, adding that some equipment being purchased will be moved from Israel to the U.S. plants.

The to-be-acquired operations serve the aerospace, electronics and data communications and industrial markets, the release said. Global Wire’s net sales and operating income for the year ended December 31, 2007, were $93.4 million and $0.7 million (after $3.4 million of depreciation, stock option expense and non-recurring costs), respectively.

IWG expects to realize significant synergies by adding the Jewett City operations to the bare wire segment and by adding the Littleton plant to the High Performance Conductors segment, which will enhance the segment’s capacity to supply high temperature silver and nickel plated products, the release said.

The release said that IWG will also enter into a lease/purchase agreement for the Jewett City property and assume certain liabilities. As part of the deal, IWG will acquire approximately $15.1 million of net working capital and $13.4 million of property, plant and equipment and have an option to purchase the Jewett City property at a later date for $0.8 million, it said. The working capital adjustment is expected to result in an additional payment of approximately $3 million, it said.

“The acquisition of Global Wire will expand and com-

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

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plement our existing operations in the U.S., especially in high temperature products for the aerospace market,” said IWG CEO Rodney D. Kent. IWG has 16 facilities located in the U.S., Belgium, France and Italy.

INDUSTRY NEWS

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CommScope to expand reel recycling U.S.-based CommScope, Inc., reports that it is expanding its cable reel recycling program to include customers of Andrew Wireless Solutions, a division it acquired last December that provides communications systems and products.

The goal of the Andrew Reel Recycling Program is to reduce the waste of reels on which Andrew’s HELIAX® cables are shipped, a press release said. It noted that CommScope, which launched its own ReelSmart®recycling program in 1988 for its broadband and wireless cable reels, today recycles more than 66,000 reels per year, saving approximately 20,000 trees annually. It added that the North Carolina-based company has twice won the Governor’s Award of Excellence in the large business waste reduction category.

The Andrew program will be launched in the U.S. and Western Europe this year. It currently is available in Spain, with the U.S. rollout set for July, to be followed by additional European nations later in the year, the release said. The company, it added, hopes to recycle more than 15,000 reels in the continental U.S. alone during the first year of the Reel Recycling Program.

The new program is expected to be far more active than what Andrew had in place, said Stan Catey, group vice president and general manager, Cable Extending the life of reels is the goal Products, of Commscope’s recycling programs, Andrew. Andrew which now include its Andrew Wireless customers even- Solutions operations. tually will be charged for reels used for shipping HELIAX cables with the charges either partially or completely reimbursed to customers that properly follow the recycling program. “After we begin charging customers for reel cores, reels returned in excellent condition will be eligible for reimbursement above the initial charge,” the release said. It noted that absent of recycling programs, cable installers usually break down the wooden reels and either burn or dispose of them in land-

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INDUSTRY NEWS

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fills. Andrew expects to establish five recycling centers across the U.S. to which cable reels can be returned, it said.

General Cable Corporation continues its steady path of global acquisitions U.S.-based General Cable Corporation announced that it has entered a joint venture for majority ownership of E.P.E/EN.I.CA.BISKRA/SPA (Enica Biskra), an Algerian state-owned manufacturer of low- and medium-voltage power and construction cable.

Enica Biskra was described in a press release as a leading provider of utility cables to the principal Algerian state-owned power utility and gas producer. In 2007, the business generated about US$108 million in revenues. It is located in the province of Biskra, some 260 miles southeast of Algiers, where it has an 86-acre site with approximately one million sq ft of manufacturing, warehousing and office space, it said. “(General Cable) plans to aggressively invest in this business, primarily for the fast growing Middle East and North African regions, which combined have in excess of four billon euros of addressable wire and cable demand,” the press release said. It noted that plans call for more than US$30 million in investments to be made over the next few years to upgrade and expand the product capabilities for medium voltage utility cables as well as cables for industrial applications for both the domestic market and export into neighboring North African and European markets. There will also a focus on training employees in the areas of LEAN and manufacturing efficiency, it said.

“We are very pleased to be a partner of the Algerian government in the privatization of the wire and cable industry which will enhance economic growth and development,” said Domingo Goenaga, Executive Vice President and CEO of General Cable Europe.

“The acquisition of Enica Biskra represents the latest step in positioning General Cable as a global leader in cabling systems for energy infrastructure, which began with the 1999 acquisition of BICC,” said Gregory B. Kenny, president and CEO of General Cable. “General Cable expects to have as much as (US$310 million) of annual revenue in the Middle East and North African region after giving effect to this investment project. This acquisition establishes an important position in these markets and a platform to further invest and grow in the region.”

General Cable has grown substantially from acquisitions, most notably its 2007 purchase of Phelps Dodge International Corporation from Freeport-McMoran Copper & Gold Inc.

Anhui in the city of Tongling, is the Tongling Jingda Rea Special Enameled Wire Company, a press release said. It will have an estimated annual capacity of 36,000 metric tons of high-temperature class magnet wire for the refrigeration compressor and industrial motor markets. The other joint venture is the Tongling Jinggong Rea Special Wire Company, which will have an estimated annual capacity of 36,000 metric tons of lower-temperature class materials for the oil-filled transformer, appliance, and automotive markets, it said.

“With our partner Tongling Jingda, we are reaching our objective of providing world-class products within the most comprehensive servicing network in China to our strategic customers,” said Jingda Rea Vice Chairman Dwight Mattmuller.

The release said that Tongling Jingda and Rea are the largest magnet wire producers in China, with six manufacturing operations. Tongling Jingda is the 4th largest magnet wire producer in the world while Rea is the largest magnet wire producer in North America and second largest in the world, it said.

Rea Magnet Wire established joint venture magnet wire factories in China with Tongling Jingda in 2002 and 2004.

Ansteel and Bekaert enter partnership China’s Anshan Iron and Steel Group Corporation (Ansteel) and Bekaert have agreed to a 50-50 partnership between the two steel manufacturers that will see them “explore strategic cooperation projects” to meet the growing demand for advanced wire products on the Chinese market.

Ansteel and Bekaert will invest approximately US$235 million to build a new steel cord plant in the Shuangqiao District within the Chongqing Municipality, a press release said. The investment will take place in phases, starting with first-phase production in 2009 that will cost about US$62 million, it said. Both companies were scheduled to sign the investment agreement with the Shuangqiao District Government in Chongqing on June 8, 2008.

Rea Magnet Wire enters 2 JVs in China U.S.-based Rea Magnet Wire Inc. has further expanded its working relationship with Tongling Jingda, establishing two more joint ventures with the Chinese company.

One of the two joint ventures, in the Chinese province of

14 | WIRE JOURNAL INTERNATIONAL

Ansteel and Bekaert plan to build a new steel cord plant in the Shuangqiao District.

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INDUSTRY NEWS

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Ansteel manufactures wire rod, hot-rolled and coldrolled sheet, galvanized steel sheet, color coating plates, silicon steel and seamless steel pipes, with 2007 production of more than 16 million tons of steel, the release said. Combining Ansteel, which has “growth ambitions and a strong understanding of the needs of the Chinese market, and Bekaert, which has recognized technology and solid activity platforms in China, collectively should create a new and successful pillar, supporting the further development and leadership position of both companies,” it said.

“We have had an outstanding relationship with Bekaert for many years. Now, we want to expand that relationship into a strong partnership with a world leader in advanced wire products,” said Zhang Xiaogang, Chairman and CEO of Anshan Iron and Steel Group Corporation (Ansteel).

“In Ansteel, we have an excellent partner which has always been a reliable supplier of wire rod to Bekaert and which, in its achievements, goals and spirit of enterprise, perfectly complements Bekaert’s strategy of sustainable profitable growth and its better together philosophy,” said Bekaert CEO Bert De Graeve. “Mr. Zhang and myself share the willingness to build a solid strategic partnership.”

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Prysmian buys German cabler Prysmian reported that it has acquired Germany’s Facab-Lynen Gmbh & Co. KG., which it described as one of the main German players in higher added-value markets of industrial cables for the renewable energy, transport and mining sectors.

A press release said that Facab-Lynen has one manufacturing plant with some 270 employees that generated US$96 million in 2007. The purchase price, it said, was about US$45 million. “The strategic plan to reinforce Prysmian’s presence in the German market envisages bringing Facab-Lynen’s profitability to the same levels of the (Prysmian) Group, through increases in production capacity and the integration of facilities.”

Prysmian currently has two production plants in Germany that generated some US$695 million revenues in 2007, the release said. It noted that the company’s client base includes major utilities, multinational industrial groups and worldwide operating wholesalers.

“According to its growing strategy in higher value-added markets and products, through the acquisition of FacabLynen Prysmian further reinforces its position in the industrial cables market, particularly in the growing renewable energy sector,” it said.

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U.S. ITC: 6 wire rod duty orders to continue, Canadian one to end In a case that has been closely followed by the ferrous industry, the U.S. International Trade Commission (ITC) has decided not to revoke existing countervailing duty orders on carbon and certain alloy steel wire rod from Brazil and the existing antidumping duty orders on imports of that product from Brazil, Indonesia, Mexico, Moldova, Trinidad and Tobago, and Ukraine.

The ITC found that revoking the duty orders could lead to continuation or recurrence of material injury within a reasonably foreseeable time. At the same time, it found that that revoking the existing antidumping duty order on imports of that product from Canada would not.

As a result of the Commission’s affirmative determinations, the existing orders on imports of carbon and certain alloy steel wire rod from Brazil, Indonesia, Mexico, Moldova, Trinidad and Tobago, and Ukraine will remain in place. As a result of the Commission’s negative determination, the existing order on imports of that product from Canada will be revoked.

The action comes under a five-year (sunset) review process required by the Uruguay Round Agreements Act. The five-year (sunset) reviews concerning carbon and certain alloy steel wire rod from Brazil, Canada, Indonesia,

Mexico, Moldova, Trinidad and Tobago, and Ukraine were instituted on September 4, 2007.

Lincoln Electric Holdings plans to build consumables plant in China U.S.-based Lincoln Electric Holdings, Inc., plans to build a state-of-the-art welding consumables facility in Nanjing, China, that will be part of the company’s Asia Pacific subsidiary, Nanjing Lincoln Electric Co., Ltd. (NLE).

The plant, a press release said, will be located in the Jiangning Science Park, in the Jiangning District of Nanjing. It said that NLE will expand its product range and business scope at the new site to meet “the growing needs of its customer base in China for higher productivity and more advanced welding processes and applications.” The company currently has stick electrode manufacturing in Nanjing, and those operations will be moved and upgraded at the new site, it said.

Plans call for construction of some 324,000 sq ft of building space that will house the latest manufacturing processes as well as welding demonstration and training facilities aligned with Lincoln Electric’s total solutions approach to the welding industry, the release said. The plant is scheduled for completion by next July.

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Lincoln Electric noted in the release that it acquired the Nanjing welding business last July from Kuang Tai Metal Industrial Co., Ltd. Previously, Lincoln was a minority owner of Nanjing indirectly through its investment in Kuang Tai, it said.

Based in Cleveland, Ohio, Lincoln has 38 manufacturing locations, including operations, manufacturing alliances and joint ventures in 20 countries and a world-

wide network of distributors and sales offices covering more than 160 countries. The company focuses on the design, development and manufacture of arc welding products, robotic arc-welding systems, plasma and oxyfuel cutting equipment and has a global position in the brazing and soldering alloys market.

El Sewedy Cables to build plant in Egypt El Sewedy Cables Company plans to build a modern facility for producing power and dry type transformers in Tenth of Ramadan City, Egypt, a US$50 million plant that it said will be the first of its kind in the Middle East and North Africa (MENA) region.

Through its subsidiaries, El Sewedy Cables, an Egyptian company founded in 1938, manufactures wires and cables in addition to electrical products.

A report from FG-Hermes said that the company will produce transformers under license from Chinese transformer manufacturer TBEA. The plant, it said, will span 260,000 sq m and employ abut 800 workers. The company will have an initial annual production capacity of 600 dry type transformers, each powered by 22 kilovolts, and 105 power transformers ranging from 66 to 220 kilovolts, it said. Dry type transformer production is scheduled for April 2008, while the production of power transformers was scheduled for the first fiscal quarter of 2009, it said.

The dry type transformers are mainly used to service chemical plants, oil and gas refineries, utilities and power plants, hospitals, hotels, schools, airport terminals, water treatment plants and paper and steel mills while the power transformers, which use oilimmersed technology, are used mainly in utilities, power plants and subway and rapid transmission projects, the report said. “By offering both types of transformers, El Sewedy will be able to expand its share of the electrical products market and to diversify its customer base in the Egyptian, Middle East and African markets,� it said.

El Sewedy Cables also reported that it has obtained approval to establish a copper smelter and refinery under the name of Red Sea Copper in a free zone

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in Ain Sokhna. El Sewedy Cables will own 74 percent of the smelter and Swiss-based Glencore International AG the remaining 26 percent. El Sewedy Cables has purchased 1.7 million square meters of land near Ain Sokhna port for the project, which is expected to cost about US$850 million and to have a production capacity of 300,000 tons of copper cathodes, it said. The copper will be sold through long-term off-take agreements between Red Sea Copper, El Sewedy Cables and Glencore.

Glencore is also expected to provide one million tons of copper concentrates to Red Sea Copper under a long-term supply agreement.

machines for the global wire processing market, specializing in machines for the automatic assembly of loose parts to wires, especially automatic and semi automatic installation of weather seals.

PAWO also owns PAWO Inc., which is located in El Paso, Texas, in the same building as Schleuniger’s El Paso office, the release said. Both offices are responsible for sales and service to Mexico as well as Central America. “Together, the combined location will offer a much larger sales and service network while providing the most innovative wire processing expertise and products in the market.”

Schleuniger Group acquires PAWO AG

Leoni lands contract from Airbus

The Schleuniger Group, based in Thun, Switzerland, a supplier of wire processing machines, announced that it has acquired PAWO Systems AG, Unterägeri, Switzerland, for an undisclosed price.

A press release said that PAWO, which has about 100 employees, was seeking an early succession for the current ownership. “For Schleuniger, it is a strategic development which will further enhance their position in the market,” it said.

PAWO designs and produces precision, niche-oriented

The Leoni Group announced that it has won a five-year contract from airplane manufacturer Airbus to equip approximately 500 aircraft of the French company’s planes families with cable harnesses. The contract is expected to generate sales of some US$77 million.

A press release said that the components, for parts such as the vertical tail and the landing gear, will be used for Airbus models from the A318 to the A340. With its first volume order from EADS subsidiary Airbus, Leoni has now succeeded in entering the aerospace market. “Being

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commissioned by Airbus is a key milestone in implementing our strategy of profitable growth in promising markets,” said Leoni AG President and CEO Klaus Probst.

The objective of the company’s aerospace business unit is to offer a complete design-to-build package from a single source (Design to Build): from wiring systems development as well as production of wires, cables and whole cable harnesses through to on-site customer support, the release said. “Leoni will in so doing benefit from its many years of experience in developing and manufacturing wiring systems for the automotive industry as well as cable harnesses for medical equipment and industrial applications.”

Ashland Distribution China to represent Teknor Apex in China U.S.-based Teknor Apex Company announced that Ashland Distribution China will represent its vinyl compounds in China. The news was jointly released during Chinaplas 2008, whose exhibitors included Teknor Apex’s subsidiaries, Singapore Polymer Corporation (SPC) and Teknor Apex (Suzhou) Advanced Polymer Compounds Co. A major focus for Ashland will be the medical device

24 | WIRE JOURNAL INTERNATIONAL

market, for which Teknor Apex offers an extensive range of flexible vinyl compounds, Teknor Apex Company Executive Vice President Bertram Lederer said in a press release. SPC and Teknor Apex Suzhou both have the capability to manufacture compounds that are identical to those developed by the parent company in the U.S. and are already compliant with regulations widely required in major medical markets, the release said.

Ashland Distribution supplies thermoplastic resins and compounds in key manufacturing areas throughout China, the release said. It is a division of Ashland Inc., a diversified global chemical company.

Repco Industries to represent Sikora Sikora International announced that Nick Liotus/Repco Industries, LLC, has joined Sikora’s organization of manufacturers’ representatives.

Liotus had been involved in the wire and cable business for many years before opening his own business in 2003, a press release said. Repco Industries, located in Madison, Wisconsin, will be responsible for Sikora’s midwest customers. The contact number for Repco Industries is tel. 608-845-3950.

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Rea Magnet celebrates 75 year mark Rea Magnet Wire Company this year celebrates being in business for 75 years. Founded by Victor Rea, the U.S.based company began in Fort Wayne, New Jersey, and has grown into an international operation with 13 manufacturing facilities in the United States, Mexico and China.

“I think Victor would be pleased with how we have perpetuated his dream,” Rea Magnet Chairman James M. Vann. “Victor established a unique family culture within the business focused on taking care of his customers and his employees. We believe this is at the core of our success, and we continue to work diligently to cultivate his vision.”

Rea Magnet Wire was purchased from the Rea family in 1960 by Alcoa. In 1986, James M. Vann, William T. Gorman, Ronald B. Foster and William J. Wyatt bought the company from Alcoa with the assistance of Richard Doermer, who at the time was president of Summit Bank of Fort Wayne. Since 1986, Rea Magnet Wire has grown to be the largest provider of magnet wire products in North

America and China.

“We have never aspired to be the biggest, but we certainly want to lead our industry in the quality of our products, the safety of our employees, and in service to our customers,” said CEO Chuck Fisher. “As everyone knows, success still boils down to having the right people; and I am privileged to be working with such a dedicated group of folks that have such a passion for what they are doing.”

A privately held company, Rea Magnet has annual sales in excess of one billion dollars and employs over 1100 people worldwide.

Autac reports OEM contracts U.S.-based Autac Inc. announced that it has expanded its business and services, entering into long term contracts with several OEMs supplying cords for scissor lifts, forklifts and emergency equipment.

A press release said that the company has also expanded into the service industry by doing value-added work. The company can coil cords from manufactured wire supplied by customers as well as make custom cables to customer specifications. It notes that its new line of TPR cords, available in stock lengths of 1, 2, 3 and 4 ft, can extend on a 1:5 ratio if needed.

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Davis-Standard LLC to host extrusion workshop in October

of various polymers and the mechanics of essential downstream processes, a press release said. Topics include extruder components, temperature control, maintenance Davis-Standard, LLC, will host a workshop on “The and screw design.

Basics of Plastics Extrusion” on October 15 and 16, 2008 In addition to instruction, course participants will tour at its headquarters in Pawcatuck, Connecticut. USA. Davis-Standard’s laboratory and manufacturing facilities The two-day class will cover the fundamentals of plasand will have access to polymer process engineers and tics extrusion, as well as the composition and properties technical specialists, the release said. The fee is $750 with a 10 percent discount for groups of three or more. Course books and materials are included, and class size is limited.

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U.S.-based Belden Inc., announced that it has agreed to acquire Trapeze Networks, a provider of wireless local area networking (WLAN) equipment and management software, for $133 million. The deal, a press release said, furthers Belden’s position “as a complete signal transmission solutions provider by adding a recognized leader in the wireless LAN market.”

“The acquisition will make Belden the world’s largest unified wired and wireless solutions provider and will provide expanded market access for Trapeze Networks’ Smart Mobile solutions,” Belden CEO and President John Stroup said.

Friedrich Kocks GmbH opens office in China Germany’s Friedrich Kocks GmbH & Co. KG reports that it has established a representative office in Beijing.

“The demand for KOCKS products and its success in this booming market is persistent,” the company said in a press release. “The continuously growing circle of customers on the Chinese market with regard to all areas of the Kock’s product range require close proximity with the customers as well as shorter reaction times to all customer requirements. This does not only apply to acquisition but also to service and consulting.” ■

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FERROUS VIEW

FERROUS VIEW U.S. wire rod prices: what’s going on and what’s to come?

By Murat Askin

couple of explanations. First, unlike rebar, rod production in the U.S. is only a fraction of the total consumption.

Actually, in 2004, rod imports captured more than 50 percent of the market. North American rod mills have struggled to make money for years, so many of them eventually resorted to cutting production. However, 2007 saw the lowest import figures in more than a decade, and this trend has continued into 2008.

With imports reduced to less than their normal volumes, the demand for American rod has turned around, and producers have started seeing decent interest from their customers. At the same time, they are very reluctant to crank up production to its maximum capacity, as this would require adding additional shifts and labor. And honestly, why would they mess with a good thing? Right now they are making more money with less production, and it

It all started with a soft steel market in the fourth quarter of 2007. Wire rod and wire prices were both weak, and consumption and demand were both far less than desired by producers. Then, due to the rising scrap price trend, came a few price increases for rod and wire, which started a chain reaction that has blasted rod prices up to the sky. What’s more, it appears that there is still some fuel left in the tank for more of the same.

During the takeoff, many rod buyers were stunned by how quickly the rules of the market changed, reacting in the following five stages: Ridicule: “What’s the price? Who do you think I am? Rockefeller?”

Anger: “These suppliers must be crazy! Sales are weak and there is no way I can accept these new numbers.”

Denial: “When the dust settles, the prices will go down. I better wait.”

Anxiety: “Imports are gone, prices are up and I’m almost out of steel!”

Acceptance: “OK, it is what it is. I’ll buy what I need to cover myself.”

OK, not everyone reacted in that exact order, but surely, many rod buyers have experienced at least some of these feelings. Almost all of them will tell you that they have never experienced anything like this before, not even in the phenomenal year of 2004.

What makes this steel market unique is that this strong and relentless rally of This chart reflects the meteoric rise of wire rod prices over the last year. prices is taking place in such a weak Chart courtesy of SteelOrbis. Figures based on its historical data. sales environment. And no, these market conditions are not unique to wire rod; the same sharp increases were also observed for other seems that this situation will not change in the near long and flat rolled products. All steel product prices future. across the board have made huge gains since the beginWhile imports had a U.S. market share of about 43 perning of the year. Let’s take a look at wire rod, rebar and cent in 2006, the market share dropped rapidly to 26 perhot rolled coil for comparison. cent. Why did imports go down so dramatically? First of On Jan. 1, 2008, wire rod (low carbon) was $683 a metall, the weak dollar has made imports more expensive ric ton. By June 1, 2008, it was $1,113, a 63% increase. than the domestic prices. This has been routinely the case For rebar, on Jan. 1, 2008, the price was $715, and by this year. Every single ton of imported rod has been sold June 1, 2008 it was up to $1,036, a 45% increase. For at a higher price than the domestic material at the time of HRC, on Jan. 1, 2008, the price was $617, and by June 1, purchase. There is also talk that the American producers 2008, it was up to $1,240, a 101% increase. purposely kept their prices lower than the foreign prices By comparison, rod prices have risen less than hotin order to keep out the imports. That makes for interestrolled coil prices this year, but more than rebar prices — ing conspiracy talk, but the real reason, however, is that so don’t feel that the wire rod has being singled out. And other major markets are hotter than the U.S. market. In as for why rod prices went up more than rebar, there are a 28 | WIRE JOURNAL INTERNATIONAL

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particular, the Middle East, CIS and Eastern Europe are experiencing a construction boom that has attracted most of the available export tons from around the world to those regions. Thus, the U.S. market has become less and less relevant to international exporters.

From a price perspective, wire rod prices (low carbon, metric ton) have climbed from $683 on Jan. 1, 2008, Murat Askin to $1,183 on June 1, 2008, a 63 percent increase. From a supply perspective, wire rod imports have dropped from to 42.44% in 2006 to less than 26% in 2007.

As of mid-June, U.S. wire rod prices reached $1,200 a metric ton, continuing the string of monthly leaps that have taken place every month so far this year. This level is now close to international market levels, or only slightly below them. While the slightly lower U.S. prices will keep the imports out, the U.S. prices will continue to rise until the end of the year, adjusting along with the international trend. And, worldwide, the price momentum is

clearly still headed upwards.

How about beyond 2008? The relentless price rally of U.S. wire rod prices and steel prices in general is, without question, a global phenomenon that is fueled by the improving economies and consumption of China, India, CIS and Eastern Europe. In addition, the weak U.S. dollar is helping to keep out imports, and the production in North America is not expected to increase in a significant way in the next few years. Therefore, even though the American wire drawers are seeing less-than-stellar sales and more competition for their end products from overseas, they will have to endure a tight rod market and high rod prices for at least a few more years to come.

Editor’s note: the next SteelOrbis column will focus on the European and Asian wire rod markets.

SteelOrbis provides steel news, sector analysis, trade statistics on steel and prices and more as well as a secure e-trade platform for steel buyers/sellers. Murat Askin is SteelOrbis’s general manager in the Americas region. Prior to working for SteelOrbis, he had a lengthy commercial career in the North American wire rod market. Askin can be contacted at tel. 713-589-6049, maskin@steelorbis.com, www.steelorbis.com. ■

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ASIAN FOCUS

ASIAN FOCUS A need for raw materials leads to jockeying for position in Asia

By Anand Bhagwat Industries around the world are facing ever-increasing commodity and other raw material prices. The metals industry, particularly iron and steel, is not immune to this either. A lot of this shift towards high-cost era is largely blamed for increasing growth in the developing countries like China and India. Raw materials, such as iron ore, coking coal, crude oil, are seeing explosive price increases. With the unprecedented growth in these countries, it’s not only shifting the demand side, but also putting stress on the raw materials necessary to produce these commodities - case in point: iron ore.

Access to the ore is becoming one of the top priorities for steel companies globally. The China Iron and Steel Association (CISA) recently advised Chinese steel companies to secure long-term contracts for iron ore supply. It also recommended ownership stakes in overseas mines for “strategic” reasons. Such jockeying for key raw materials for steel is prompting use of “nationalistic” arguments by steel companies with captive mines from iron ore-rich countries. China imposed a 25% export duty on metallurgical coke, another key ingredient in steel making.

India has about 18 billion MT of iron ore reserves. In 200607, it mined 160 million MT, while exporting 95 million MT. Steel consumption in India is projected to rise from current 48 million MT to 300 million MT by 2025. It is growing at an annual rate of 12%, while production is increasing at only 8%. At this rate of consumption, as the arguments goes, India will be out of iron ore in 40-50 years.

India steel companies have been lobbying the government to levy an export tax similar to China’s coke tax on iron ore to conserve country’s natural resource, which the government is considering. Some even recommend a complete ban. In February, The Associated Chambers of Commerce and Industry of India urged the Indian government to impose a 35% ad-valorem duty on FOB price for export of iron ore.

Ram Vilas Paswan, India’s Union Minister of Steel, said that India must discourage iron ore export if it is to develop its steel industry. Addressing attendees at a recent conference, he said, “The government should a take long-term view on iron ore requirement of the steel industry and only excess production, if any at all, should be allowed for export.”

Some critics argue that such tax is not only “protectionist,” but also gives undue advantage to the domestic steel makers over price controls. There appears validity in arguments from both sides. However, if recent contracts signed by the Japanese steel companies with Vale for iron ore are any indication, price increases will far outpace any export tax.

Whatever the government policies, one thing is certain for

Unloading of iron ore, an increasingly precious commodity for companies with plans to be long-term steel suppliers to the global market. wire producers: high raw material prices will keep steel and steel wire rod prices high in the near future.

One good example of why this is important can be seen in ArcelorMittal’s plans to spend upwards of $20 billion to set up two new integrated steel plants in India. In a wire story, ArcelorMittal spokesman Julien Onillon told CNN that “India is a very exciting growth story for us.” The country’s per capita consumption of steel is only 40 kg, compared with a figure of 500 kg for Europe and 270 kg for China, he said.

The company has identified India as a key growth market to help it reach 150 million metric tons of production by 2012, but it also noted that there is “a range of variables, including availability of power and iron ore, that would have an impact on the plant’s production start.”

To adjust for key steel inputs such as iron ore and coking coal, ArcelorMittal is moving to secure the supply and price of these commodities, Onillon said. As part of its plan to achieve 75 to 85 percent self-sufficiency in iron ore by 201415, the company has signed a 10-year agreement with Brazil’s Vale, and is looking to increase supplies from Ukraine, Liberia and Senegal, he said in the CNN report. It also announced it would pay about $606 million for a 14.9 percent stake in Australia’s Macarthur Coal, which is a major supplier of pulverized coal for use in steel making.

Being the world’s largest steel company gives ArcelorMittal an advantage in its efforts to control its supply chain, but directly and indirectly, the cost and availability of iron ore is likely to be very challenging for many other companies.

Anand Bhagwat is managing director of WAI Wire and Cable Services Pvt. Ltd., the Association’s India subsidiary.

Have news that belongs here? If so, e-mail it to editorial@wirenet.org.

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ASIAN NEWS BRIEFS Iljin Electric wins largest-e ever power cable deal South Korea’s Iljin Electric, a manufacturer of electric cables, reports that it has won a combined deal for extra-high voltage power cable projects in Singapore and Taiwan.

“We’ve won a US$44 million won deal in Singapore and also agreed to a deal worth some US$6.86 million won with a state-backed Taiwanese electric agency to export cables,” a company spokesperson said in the report published on the cabledirectory.com. It added that the deal with Singapore represents the biggest one the maker has made since it started exporting.

“We will operate an additional line, which is now being constructed, from August this year to meet the growing demand for extra high voltage power cables, capitalizing on the Southeast Asia region,” the spokesman said in the article.

Last October, it noted, Iljin agreed with a local wire maker in Vietnam to create a 51:49 joint venture. Since then, it added, the South Korean manufacturer has engaged in detailed internal talks to set up another overseas affiliate in one of the countries in the region.

“Considering the pace of improving living standards and calls for more socio-infrastructure, the demand for electricity

there will soar in the coming years,” CEO Choi Jin-yong said in the report, which stated that the Southeast Asian nation’s electricity market is forecast to grow by 10 percent, annually, according to industry estimates.

Taiwan’s Yieh Hsing expands wire rod output Citing strong demand and stable nickel prices, Yieh Hsing Enterprise Company has expanded its carbon wire rod and stainless wire rod output. According to a report in steelguru.com, a company spokesman said that the company has doubled its monthly output of 5,000 metric tons a month.

It expanded its carbon wire rod production based on increased demand from the slide fastener manufacturing industry in Taiwan, the report said, adding that it also increased its stainless wire rod output by 1,000 metric tons due to increased exports.

India’s Cords Cable reports Middle East order India’s Cords Cable Industries Limited (CCIL) reports that it has landed an export order worth around US$12 million for supply of IT power cables for a major project in the Middle East, reports topnews.in. The order is to be completed in the next six to seven months’ time. ■

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PEOPLE

PEOPLE Allied Wire and Cable reported two personnel announcements.

Debby Lupo has been promoted to a sales position at the company’s Wisconsin office. She has been with AWC since July 2006 but has extensive experience as she has been in the wire and cable industry since 1991, with prior employers Debby Lupo including Industrial Electric Wire & Cable in New Berlin, Wisconsin, and World Class Wire & Cable in Waukesha, Wisconsin. Also joining the company’s sales force, at its New England Division, is Traci Saunders, who is an inside sales representative. She has previous experience in the wire and cable industry, having worked as a purchaser, and has 15 years of experiTraci Saunders ence in customer support. Before coming to Allied Wire, Saunders worked at Azores Corp in Wilmington, Massachusetts. Based in Collegeville, Pennsylvania, USA, Allied Wire & Cable is now one of the largest independent value-added manufacturers and distributors of wire and cable products in the U.S. JoeTools has named two new employees. Niki Bensley is a customer service representative. She has more than 16 years in customer service, including more than 10 years with Canterbury Engineering.

Andrew Depue is inventory control manager. He held a management position in Niki Bensley commercial property development while also serving in the US Marine Corp Reserves. He holds a degree in economics from the University of Georgia. Based in Carrollton, Georgia, USA, JoeTools is a full service extrusion product manufacAndrew Depue turer.

Fushi Copperweld, Inc., has named Dwight Berry to the newly created position of Vice President of Commercial Development, based in Fayetteville, Tennessee, USA. His responsibilities will include oversight of the company’s sales and R&D functions. He has

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15 years of direct CATV/wire and cable experience and over 20 years experience in manufacturing management.

Most recently, he in general manager and operations manager positions where he had responsibility for sales and customer service as well as for manufacturing operations.

He holds a B.S. degree from Mississippi College in Clinton, Mississippi and studied financial training at the Wharton Financial School at the University of Pennsylvania. The company also noted that former COO Chris Finley will serve as a consultant for the next year.

He had recently stepped down from his position largely due to his extensive travel schedule between the company’s facilities in China, Europe and the U.S. Based in Dalian, China, Fushi Copperweld, Inc., through its wholly owned subsidiaries—Fushi International (Dalian) Bimetallic Cable Co, Ltd., and Copperweld Bimetallics, LLC — manufactures bimetallic composite wire products, principally copper-clad aluminum wires and copperclad steel CCS. Belden Inc. has named Rizaldy C. Manlapig as its account manager for the Philippines, responsible for Belden Industrial Cabling Solutions. He has been in industrial sales for many years, including JJLapp Cable Philippines, a German based company that specializes in Rizaldy C. industrial control cables and accesManlapig sories. Based in St. Louis, Missouri, USA, Belden Inc. provides signal transmission solutions for the global industrial automation, data centers, broadcast studios, and aerospace markets.

Tappan Wire and Cable has named Dale Diedrichs as Distributor/OEM Sales Director of the Carolinas. He has more than 25 years of sales experience and most recently worked for Belden Cable as a field sales representative, responsible for electronic, OEM and distribution sales for North Carolina. Based in Blauvelt, New York, USA, with stocking locations in New York, Georgia, Texas and California, Tappan Wire & Cable, Inc., manufactures lowand medium-voltage cables that are sold through distribution throughout North America, South America and Europe.

Mohawk announced the appointment of Lee Snedaker for the company’s South Texas territory. He has more than three years of broad industry experience from Lockheed-Martin, TCI Cablevision, Datacom Design Group, the 2002 Olympics Organizing Committee in Salt Lake City and most recently ACS Dataline. Mohawk,

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a division of Belden that is headquartered in Leominster, Massachusetts, USA, and has been providing fiber and copper cable innovations for over 50 years.

T & T Marketing, Inc. has recently added two new Account Managers for its Wire & Cable Distribution business. John Accorsi will be responsible for T&T clients in the New England states and is also Product Manager for Nylon products. Amy Theobald will be responsible for T&T clients in the Mid-Atlantic states, as well as Product Manager for T&T’s dispersions and concentrates product line. Based in Allamucchy, New Jersey, USA, T&T Marketing, Inc., represents suppliers of colorants, compounds, elastomers and insulation.

Amphenol Corporation announced that, effective January 1, 2009, R. Adam Norwitt, currently the company’s President and COO, will become its CEO and a member of the Board of Directors. Martin H. Loeffler, who currently serves as chairman and CEO, will be appointed to the newly created position of Executive Chairman, with specific emphasis on the company’s

strategic direction and the continued development of the its leadership team. He had served as CEO for the last 12 years. Norwitt has held a variety of management, business development and operating positions in Amphenol operations in Asia and the United States since joining Amphenol in 1998. Prior to his appointment as president and COO on January 1, 2007, he served as a senior vice president and as group general manager of the company’s Worldwide RF and Microwave Products Operations. He is a graduate of Georgetown University and has a law degree from the University of Michigan and an MBA from INSEAD. Based in Wallingford, Connecticut, USA, Amphenol Corporation manufactures and markets electrical, electronic and fiber optic connectors, interconnect systems and coaxial and specialty cable.

Robert K. Simpson will become president of The Association for Manufacturing Technology (AMT) on October 7, 2008. He has joined the association and will work in transition with President John B. Byrd III, who will retire after five years at AMT. ■

OBITUARIES Larry G. Bill, 72, founder and president of Pelican Wire Company, died April 25, 2008, following a lengthy illness. He started Pelican Wire Company in 1967 in Hebron, Illinois.

A U.S. Army veteran, Larry Bill served at White Sands Missile base in New Mexico, and after his discharge in 1964, he enrolled at Southern Methodist University in Dallas, Texas, where he graduated with a degree in mechanical engineering. He worked for Chance Voght Aircraft Company while he was attending school, until he was called home to help care for his ailing father.

In 1965, he worked for Claude S. Gordon Company in Richmond, Illinois as the applications engineering manager. He founded Pelican Wire Company in 1967 while still at Gordon, which he worked for through 1976. At that time, he relocated his business to Naples, Florida, where he and his wife, Theresa, operated the company.

Larry G. Bill Its primary business was the insulating of bare copper alloys with nylon and glass; later, the company expanded into thermocouple and heater elements and under-floor heating cable. Larry Bill was very active in the daily operations of the company until his death. A longtime WAI member, he attended many of its conventions and was very interested in finding new ideas and equipment. Larry Bill was passionate about his family and his employees. In his spare time, he enjoyed fishing and automobile racing.

The company has grown to manufacture products that are shipped worldwide, and currently employs 40 people on two production shifts. The company is currently being overseen by his son, Theodore, and a management team.

Larry Bill is survived by his wife, Theresa, his son, Theodore, his sister, Deborah Miller, and his brother, Kermit Bill.

Benjamin C. Schilberg, South Windsor, Connecticut, died Sunday, May 25, 2008 at Manchester Memorial Hospital, Manchester, Connecticut. After attending the University of Connecticut, he served in the U.S. Army during World War II and after he returned, he joined his father as a scrap rags paper and metal dealer. He was instrumental in growing a peddler trade into Schilberg Integrated Metals, Corp., a metal merchant business. He served as president for 30 years until his retirement in 2002. He was a member of The Copper Club, American Copper Council, Institute of Scrap Recycling Industries and the Wire and Cable Manufacturers Alliance, from which he was awarded the Distinguished Career Award. He leaves his wife, Joyce (Feinberg) Schilberg; sons, Bernard C. Schilberg and Nathan B. Schilberg; a brother, Sidney Schilberg; and five grandchildren.

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FIBER WATCH

FIBER Offer them broadband access, and the broadband-hungry are willing to row Fiber To The Home may be the ultimate broadband delivery system, but getting there, especially for rural regions, can be a long journey. A recent report from BBC news cited some the pluses and minuses for U.K. users, predicting a likely future with more fiber access.

Not surprisingly, broadband users who live in London enjoy average speeds of 4.5 megabits per second (Mbps) nearly double those who live in Northern Ireland, where it was 2.3 Mbps, while the rates for Wales was 2.6 Mbps and Scotland was 2.9 Mbps, the BBC report said. The reasons for that, it said, are related to length of telephone lines and access to cable. It noted that speed tests were analyzed by thinkbroadband.com over a two-month period in 6,000 locations and found the average speed to be 3.2 Mbps.

Ofcom, a “telecoms watchdog,” reported that the geographical digital divide had been closed after its research found that homes in rural areas were more likely to have broadband than those in towns. However, Andrew Ferguson, editor of thinkbroadband.com, said those figures A customer willing to row across a were misleading Scottish loch for on-line access may because the slower be an indicator of the degree that speeds limited consumers want broadband. usage.

There is demand for access, but it is far from easy for some locations, although there have been some surprising results. The BBC article cited the residents of Arnisdale, a remote village on the west coast of Scotland, who cannot get broadband at all by conventional means. The village is nine miles from the nearest BT exchange at Glenelg, too far for a broadband connection to work. However, the village can get a wireless broadband connection from a series of masts which beam a signal from the Isle of Skye via a project backed by the University of the Highlands and

34 | WIRE JOURNAL INTERNATIONAL

Islands and by the University of Edinburgh.

Edinburgh University Professor Peter Buneman, who is the project leader as well as an Arnisdale resident, had tried to get BT to bring broadband to the village, before realizing that the community would have to find its own solution, which ultimately led to wireless. “I'm now getting better than 10Mbps, faster than you would get in a city,” he said.

Many places in Scotland that depend on copper wire from a BT exchange cannot get fast broadband, Buneman said in the BBC report. “To get ‘city’ speeds of 8Mbps you need to be less than two miles from an exchange, and remember that 8Mbps is pretty low by international standards.” Brendan Dick, BT’s Director for Scotland, said Arnisdale residents were to be applauded for their initiative, the report said. From 2002, the U.K. has gone from less than 150,000 broadband connections in 2002 to about 13 million now, he said.

The government is considering plans for next-generation broadband and there appears to be a consensus that “the copper wire that connects most homes to a telephone exchange will eventually have to be replaced by fiberoptic cable, if the UK is to match its international rivals in building an ultra-fast network,” the report said. The challenge, as ever, is the cost, but if a single anecdote can be viewed as an indication of demand, it may be one man in North West Scotland cited in the BBC report who is willing to row across a loch to go online wirelessly.

Fiber flying high in wire harness role Gulfstream reports that it has achieved success in using a GV testbed fitted with a fiber-optic “fly by light” (FBL) control system for its recently introduced G650Gulfstream, its fastest, longest-range large-cabin jet.

The FBL technology was described as a “generation beyond the fly-by-wire system,” according to a report in Aviation International News OnLine. It noted that the Gulfstream had a 75-minute flight using the FBL system, a fiber-optic harness transferred pilot control input from a flight control computer to spoilers on the wing. One advantage of using the FBL technology is that it provides significant weight savings over fly-by-wire systems by streamlining a “bulky wire bundle into just four fiberoptic cables,” the report said. The FBL system also improves safety by transmitting a redundant signal, an inherent feature of the fiber-optic system that would require a second wire bundle for a FBW system to match, it said.

The FBL testbed may be commercially available in less than 10 years, the article said. ■

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FASTENER UPDATE

FASTENER UPDATE Honeywell sells unit to BE Aerospace U.S.-based Honeywell International, Inc., reported that it will sell an aerospace distribution unit to B/E Aerospace for $1.05 billion in cash and stock. The Honeywell unit, which distributes aerospace fasteners and hardware, generated 2007 revenue of $524 million.

Honeywell Aerospace President and CEO Rob Gillette said that the consumables unit, formerly known as the Hardware Products Group, no longer fits with Honeywell’s strategic focus on more advanced technologies. “Conversely, the acquisition of Consumable Solutions sets up B/E Aerospace as a dominant presence in the fastener distribution market,” he said in a report in aviationweek.com.

B/E Chairman and CEO Amin Khoury said Honeywell will end up with a 6.1% stake in B/E Aerospace, the aviationweek.com report said. B/E also will get a 20-year contract to supply Honeywell production facilities with consumables and standard fasteners, it said. Combining HCS and B/E Aerospace “will create a leading global distributor and value added supply chain manager of aerospace hardware and other consumable products from locations in all key geographic markets,” he said in the report. “The combined company will serve as a distributor for every major aerospace fastener manufacturer ...”

Khoury expects significant synergies, at least $10 million in 2009 and $30 million in 2010, by consolidating sales offices/facilities, the report said.

Under the agreement, B/E Aerospace will enter a 30year contract to become Honeywell’s exclusive licensee in this area, and a 20-year contract to supply Honeywell production facilities. B/E Aerospace expects to spend about $200 million over three years to convert the Honeywell unit to its own business model.

U.S. DOC ‘nails’ Chinese companies, okays producers from the UAE The U.S. Department of Commerce has ruled against all but one of the Chinese companies that were part of an antidumping duty (AD) investigation of imports of certain steel nails while ruling for exporters from the UAE. The investigations covered certain steel nails, having a shaft length of up to 12 inches, and produced from various grades of steel and have a variety of finishes, heads, shanks, points, and sizes.

The DOC found that Chinese exporters have sold steel nails in the U.S. at 0 to 118.04 percent less than normal value. China’s two mandatory respondents, Paslode Fasteners (Shanghai) Co., Ltd., and Xingya Group, received final rates of 0 percent and 21.24 percent, respectively. In addition, 64 respondents qualified for a

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separate rate of 21.24 percent. All other Chinese exporters received the China-wide rate of 118.04 percent.

The DOC sided with Dubai Wire FZE/Global Fasteners Ltd., and other UAE exporters.

The U.S. International Trade Commission (ITC) is scheduled to issue its final injury determination in the China investigation on or before July 21.

The petitioners for these investigations are: Mid Continent Nail Corporation; Davis Wire Corporation; Gerdau Ameristeel Corporation/Atlas Steel & Wire Division; Maze Nails/Division of W.H. Maze Company; Treasure Coast Fasteners, Inc., and a workers union

Fastener hides surfaces for clean look U.S.-based Trek Company, a major supplier of composite decking, railing and fencing, has introduced new technology, the Trex Hideaway™ Hidden Fastener System (HFS), that it said eliminates the need for all deck surface fastening and provides a cleaner look, free of visible screws and nails.

A press release said that Trex Company is partnering with Tiger Claw, which it described as a pioneer in the deck fastener industry, to manufacture two styles of hid-

The Trex Hideaway™ Hidden Fastener System (HFS) eliminates the need for deck surface fastening. den clips that are designed to be used exclusively with the new grooved boards. The Connector Clip, available in 50and 500-sq-ft coverage options, is for use between deck boards and automatically ensures proper gapping, it said, adding that the Start/Stop Clip, which allows for onesided connections, is the first of its kind on the market.

Trex Company said that the fastener technology has been used in the company’s Brasilla line of exotic hardwood that comes in burnished amber, cayenne and espresso. The colors, it said, are deep and warm color and offer minimal fading over time.

Contact: Trek Company, www.trex.com. ■

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WAI NEWS

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NEWS

Monterrey should be an apt host for WAI’s ITC this November in Mexico The August WJI will have a full preview of the WAI’s International Technical Conference, to be held in Mexico on October 20-22, but below is some background on Monterrey, the host city.

Monterrey is a major industrial center among cities in Mexico, ranked second in 2005 for doing business and ranked third best by América Economía magazine.

According to Wikipedia, the municipality of Monterrey has a population of more than 1.1 million, with 3.6 million for the metropolitan area, which includes the adjacent cities (municipalities) of: Apodaca, Escobedo, García, Guadalupe, Juárez and Salinas.

The profile notes that because of its strong steel industry, Monterrey is often called “the Pittsburgh of Mexico.” The city has prominent positions in sectors such as steel, cement, glass, auto parts and beer and in 1999 Fortune magazine recognized Monterrey as the best city in Latin America in which to do business. The magazine attributed its economic wealth in part to its proximity with the United States-

38 | WIRE JOURNAL INTERNATIONAL

Mexican border and mentions Monterrey as a significant city with economic links to the United States.

The city accounts for about 95% of the State of Nuevo Leon’s GDP, and 30% of Mexico’s manufactured exports, Wikipedia notes.

This cathedral is one of the The metals sector, dom- sites of interests attendees can inated by iron and steel, see in Monterrey, the host to accounted for 6 percent WAI’s ITC this October. of manufacturing GNP in 1994. The steel industry is centered in Monterrey, where the country’s first steel mills opened in 1903. Steel processing plants in Monterrey, privatized in 1986, accounted for about half of Mexico’s total steel output in the early 1990s.

Monterrey was ranked 94th worldwide and fifth in Latin America in terms of quality of life according to Mercer

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it’s really all about: who you know what you know where you go being in the right place at the right time leading the way finding a mentor professional growth personal development a global economy saving money sharing ideas putting words into action the destination the journey education experience working hard playing smart finding an edge staying sharp

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If you answered “true” to any of these statements WAI membership is for you. Learn what thousands of wire industry professionals from 70 countries already know about WAI. During our last 77 years of program development, we’ve learned that all of the above are true. So, we think you’ll find that our benefits are as individual as your goals.

If you’re already a member, why not be true to a colleague? See www.wirenet.org for details or pass along the application form on the reverse side.

At WAI, it’s really all about you!

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REFERRED BY

A. Which ONE of the following best describes your company’s type of business?

WIRE MANUFACTURING FASTENERS, WIRE FORMING, FABRICATING 10 ❏ Aluminum & Aluminum Alloys (Rod/Bar, Bare Wire, Both ) 61 ❏ Fastener Manufacture 20 ❏ Copper & Copper Alloys (Rod/Bar, Bare Wire, Both) 62 ❏ Four-Slide Forming 30 ❏ Steel & Steel Alloys (Rod/Bar, Bare Wire, Both) 64 ❏ Hot and/or Cold Forming and Heading 40 ❏ Other Metal (Rod/Bar, Bare Wire, Both) 66 ❏ Spring Manufacture 50 ❏ Electrical Wire & Cable (Insulated Wire) 68 ❏ Wire Cloth Mesh Screening 69 ❏ Other Forming and Fabricating (Please specify) 53 ❏ Communications Wire & Cable (Insulated Wire) 55 ❏ Fiber Optics SUPPLIER TO THE WIRE INDUSTRY 72 ❏ Machinery 74 ❏ Process 76 ❏ Accessories B. Which ONE of the following best describes your primary job function?

10 ❏ General & Administrative Management 30 ❏ Technical, Research & Development, Quality Control 20 ❏ Engineering, Operations, Production 40 ❏ Purchasing

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WIRE END-USER 11 ❏ Appliance 12 ❏ Communications (Voice/Data) 13 ❏ Computer 14 ❏ Construction/Building 15 ❏ Electrical (Equipment/Components/Power) 16 ❏ Transportation/Vehicular 17 ❏ Wire Formed Durable Goods OTHER 80 ❏ Service Centers, Distributors & Warehouses 90 ❏ Consultants 92 ❏ Government, Library and allied 50 ❏ Sales & Marketing 90 ❏ Other (please specify)_________________________

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Reference Guide

NOTE: All checks must be in U.S. Dollars drawn on a U.S. bank. Credit card payments are preferred for members from outside the U.S. and Canada. If a check or credit card is not used, a wire transfer may be sent in U.S. dollars.

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Your membership dues may be deductible as an ordinary and necessary business expense, not as a charitable contribution.

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Dues are non-refundable and are billed annually based upon the member’s anniversary date. Annual dues are set by the WAI Board of Directors, and are subject to change.

July 08

International Technical

Conference Proceedings

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Human Resource Consulting (2006) and was ranked number two in 2005 and number four in 2006, according to America Economia.

For more details on the conference, go to wire.net.org and click on the “Monterrey” icon.

Wanted: industry photo for 2009 Reference Guide cover The WAI is seeking a photo to grace the cover of the Association’s annual Reference Guide in 2009. This industry call is open to all companies/individuals, with the image to be chosen by WAI’s marketing team.

“We’ve featured a variety of product shots and abstract wire and cable industry photographs on the covers of the Reference Guide issues for the past 18 years,” said Janice Swindells, WAI’s Director of Marketing Services and Reference Guide editor. “With so many professionally staged product photo shoots going on in the advertising business, we thought it would be interesting to put out a call for photos with the intent of identifying an image for use as the 2009 cover shot,” she said.

Guidelines: images must be high-res digital photos able to be used as a full bleed at 300 dpi at a size of 9.5 in. wide x 11.125 in. high. Company name and logo must not be visible and images must be accompanied by a photo release letter/written permission to publish the image. Images that have an artistic flair, dramatic angle, or show blue, green, and analogous hues in either the lighting or product have a better chance of acceptance.

E-mail submissions to jswindells@wirenet.org

by July 25, 2008. Send a low-res file (1 MB or smaller) and include name, company name and image description with “RG Cover” in the subject line. If selected, high-resolution files must be available by August 1, 2008.

Technical questions?

Images like this one have been Contact WAI Graphic used on the cover of WJI’s Artist Adrienne Simpson Reference Guide each year. at 203-453-2777, ext.

134, or asimpson@ wirenet.org. Photos not selected may be used for WAI promotional literature as long as they are accompanied by a photo release.

The Wire Journal International Reference Guide is published annually for wire professionals. It serves as a key industry tool and includes thousands of company profiles and data organized by type of business and geographic location. The Reference Guide is sent free to all WAI members and is sold for $125. ■

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JULY 2008 | 41

WAI NEWS

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CHAPTER CORNER

CHAPTER CORNER Three WAI chapters report winners of scholarship programs for 2008 In conjunction with The Wire Foundation, three Wire Association International chapters announce the names of six students to receive $1,000 each in scholarship monies to help defray the costs of their college educations. The New England, Midwest and Southeast chapters have gone through an extensive selection process, with the student nominations approved by the board of the Foundation.

New England WAI New England Chapter President Paul McDermott announces the Chapter’s third annual scholarship recipients, Kyle Forrest and Jillian Leclerc.

Forrest is the son of Whitney Blake Company product engineer Steven P. Forrest. He is graduating from Fall Mountain Regional High School in Langdon, New Hampshire, and will pursue a business degree at Lehigh University.

Leclerc is the daughter of Donna Leclerc, materials manager at Harbour Industries, Inc. She is graduating from Bellows Free Academy Union High School in Saint

42 | WIRE JOURNAL INTERNATIONAL

Kyle Forrest

Jillian Leclerc

Albans, Vermont, and will attend Saint Michael’s College to study theatre and English.

“Seven students applied for this year’s scholarships, all of whom were worthy candidates,” said chapter President Paul McDermott of Q-S Technologies. “It is impressive to see how well-rounded these kids are today, and even more so when you note that both of the recipients are ranked at the top of their class as well as being very active in school and community activities.”

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Midwest The WAI Midwest Chapter established its scholarship program this year in order to assist the children of chapter members defray the costs of their freshman year in college. Chapter President John Kukalis of Henkel Corp.

Hannah Downey

Lauren Quick

announced the inaugural recipients of the $1,000 awards as Hannah Downey and Lauren Quick.

Downey is the daughter of Fort Wayne Wire Die Sales Manager John Downey. She is graduating from Huntington North High School in Huntington, Indiana

and will pursue a double major of biology and Spanish at either Butler University, Emory University or Indiana University.

Quick is the daughter of James Quick, quality/technical manager at Charter Steel. The soon-to-be graduate of Cedarburg High School in Cedarburg, Wisconsin, will pursue a pre-medicine course of study at either the University of Minnesota-Twin Cities or the University of Wisconsin-Milwaukee.

“The Scholarship Committee did a great job, led by chair Jim Tomei of A-1 Wire Tech, Inc.,” said Kukalis.

“They had six outstanding candidates and really had a tough time selecting these final two.”

Southeast The WAI Southeast Chapter introduced its scholarship program this year with a slight twist by allowing students currently enrolled in college to also apply for the awards.

As a result, Chapter President Steve Vannais of Davis-Standard Corp. is pleased to announce one

Adrian Duval

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JULY 2008 | 43

CHAPTER CORNER

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graduating high school senior and one college senior as its award recipients: Adrian Duval and Katie Mailloux, respectively.

Duval is the daughter of Venus Wire Industries Ltd. marketing director Paul Duval. She is graduating from Stafford High School in Stafford Springs, Connecticut, and will be attending Central Connecticut State University in the fall.

Mailloux is entering her final year in pursuit of her degree in social work at Georgia State University in Atlanta, Georgia. She is the daughter of Robert Mailloux, sales manager for J.J. Lowe Associates, Inc. Katie Mailloux “The chapter leadership wanted to open the opportunity up a bit more to our members by allowing for current college students to apply,” said Vannais. “While it didn’t have to be one of each, it was nice that it turned out that way for our first year.”

44 | WIRE JOURNAL INTERNATIONAL

“It’s great to see WAI’s chapters “It’s great to see returning value WAI’s chapters to their members through these returning value to scholarship protheir members through grams,” said Wire Foundation chair these scholarship John Drummond. programs,” “The Wire — John Drummond Foundation is Chairman, Wire Foundation pleased to make it easier for the chapters to add to their scholarship funds by providing the opportunity for tax deductible donations to be made through the Foundation.

For more information about WAI’s chapters and these three scholarship programs, contact WAI’s Chip Marsh at cmarsh@wirenet. org or by calling him at tel. 001-203453-1748. ■

IFE Ap CLEV RE ril EL TUR 2 7- AND NS The only show in the 30 IN TO • Americas exclusively focused I-X 200 Ce 9 on machinery and tooling for the nt er From Patagonia to Prudhoe Bay...

design and manufacture of fasteners and precision formed parts.

Following the successful 2007 event, IFE returns to Cleveland in 2009 and will again co-locate with INTERWIRE to present the widest array of resources...anywhere in the Americas...for manufacturing fasteners and precisioned formed parts. See the latest advances in:

• Machinery • Materials • Tooling • Components • Accessories • Supplies • Manufacturing Systems, Controls and Support Services

For suppliers to the international fastener industry, IFE is your most efficient and cost-effective opportunity to meet the active buying market in a key region of fastener manufacturing activity. Show attendees come from every industry group, including automotive, aviation/aerospace, appliance, building and construction, electronics, industrial and heavy equipment and many other core fastener segments. All are ready and eager to discuss their product specifications and application requirements.

You’ll meet the key personnel from design engineering, product development, production, manufacturing IT, QA/QC, facilities management, distribution and other authoritative decision makers—representing captive, OEM, and contract manufacturing operations. Whether actively involved in developing next-generation smart fasteners, or meeting the requirements of their customers’ application-specific designs, IFE attendees are prime customers and prospects for your products, equipment and systems.

Contact us now to discuss your participation and exhibit space requirements at IFE ‘09.

If you’re a manufacturer, there’s no better place than IFE ‘09 to see and explore the full range of information and product and equipment resources for bringing innovative fastening solutions and precision formed parts from concept to your customers. Plan now to attend.

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INTERNATIONAL FASTENER & PRECISION FORMED PARTS MANUFACTURING Exposition and Conference Ap ril 27-30, 2009 • I-X Center Cleveland, Ohio USA Co-located with

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FEATURE

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Equipment: Part 1

T

his feature present a wide range of capital equipment, much of it presented at the wire Düsseldorf show that was held earlier this year. Below are brief

write-ups provided by equipment suppliers. More equipment will be presented in the second equipment issue in September.

Aumann GmbH/Aumann North America During wire 2008, Aumann GmbH, based in Espelkamp, Germany, presented with great success its complete range of horizontal wire enameling machines for wire diameters of 0.015 to 1.000 mm. Aumann exhibited its sophisticated ultra fine wire enameling system DLH 2 in operation, covering the diameter range of 0.015 – 0.070 mm.

The new generation DLH 8 appealed very well to the customers. Several A horizontal wire enameling machine machines for the from Aumann GmbH. complete range of 0.16 – 1.00 mm with vxD-values of more than 200 were demonstrated to several customers in the company’s factory in Espelkamp. The complete Aumann systems consist of inline drawing unit, annealer, enamel applica-

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tor, baking oven with cooling system, inline control devices, double spooler for bi-conical coils and control with modern visualization. The machines offer high production speed, constant enameled wire quality, easy handling and a high economic lifetime creating a high production achievement and enameled wire quality per investment for lower costs per kg enameled wire.

Winding machines and automation systems, as well as complex production lines are also its core business.

Aumann can automate a customer’s production.

Aumann North America, Inc., tel. 260-478-1777, sales@aumannusa.com, www.aumannusa.com.

BWE Ltd. U.K.-based BWE Ltd. used the recent wire 2008 exhibition in Düsseldorf to launch its new ‘S’ range of Conform™ continuous extrusion machines with immediate success. Since the show, the company has received orders for three systems for rectangular copper wire.

BWE exhibited the Conform™ S315i model with induction heated tooling system, which was sold to SMETA Donetski, Ukraine. Initially, SMETA intends to extrude

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round aluminum tubes (refrigeration tubes) from 9.5 mm diameter aluminum rod.

Additional tooling has been ordered for other products.

The ‘S’ range of machines, to be BWE’s Xin Fang with the compa- manufactured and assembled in ny’s Conform™ S315i model.

China, will be available at much reduced prices. To maintain U.K. quality standards, assembly will be under supervision of BWE’s specialists and all machines will be subject to final inspection and CE certification in the U.K. Standard design features a planetary gearbox to ensure long bearing life. Some equipment, such as heat exchangers and hydraulic pumps, will be of European origin. Initially, BWE will begin to supply its popular 315 model for small copper and aluminum applications, with other models to follow. BWE’s new and unique developments, such as the very successful “Induction Heated Tooling System,” will be available as options. Ancillary items that complete the line can be supplied by the customer or purchased as an option from BWE. The S315 is the perfect machine for applications such as: copper and aluminum rectangular wire (magnet wire) and sections; solid aluminum conductor (SAC); aluminum round and multivoid tubes (refrigeration, heat exchanger, air-conditioner tube). Other applications and alloys may be possible upon request. Conform is a Registered Trade Mark of BWE Ltd. Kevin Bennett, tel. 44-1233-627736; kevinbennett@bwe.co.uk, www.bwe.co.uk.

Conductix Wampfler/Delachaux Group France’s Conductix Wampfler, part of the Delachaux Group and a leading manufacturer of fiber optic machinery, exhibited its new prooftester, type PT-2500 during wire Düsseldorf. The new model, which can reach a production speed up to 2500 m/min, has a stopping time, in case of fiber break, of five seconds on the takeup. It is equipped with an easy and fast Conductix Wampfler’s new threading system to prooftester, type PT-2500. reduce the labor costs, and the traversing quality is better than the previous models (no more OTDR step). It can accommodate spool diameters of 500/310, 500, 100 kg. For customers who cannot buy this

new model, Conductix can upgrade its former prooftester, model PT-1800, per customer requests, to make it capable of: production speeds of 2200 m/min (or 2500 m/min, depending on the spool size); using an increased spool size; increasing the quality of the traversing without any intervention of the operator after the starting adjustments; noise reduction; integrating (if requested) the new central part equipped with the easy and fast threading system; and contacting the prooftester to the data file (ORACLE).

Conductix Wampfler/Delachaux Group, tel. 33-4-79-4250-88, www.conductix.com.

Davis-Standard LLC U.S.-based Davis-Standard, LLC, offers a complete range of payoff and take-up systems designed to handle products as small as 40 awg soft copper and as large as jacketed cable to 6 inches in diameter. The payoff product offering includes flyer type, both single and dual, in sizes up to 50 in. with accompanying lift trucks and tension brake assemblies, single reel payoffs (both motorized and drag type), and single reel take-ups in various configurations, including roll-thru, retracting arm shaftless and shaft type, with ranges from 12-in. to 144-in. flange diameters with weight capacities to 60,000 lb. For precise control, a complete line of oscillating designs is available.

Dual-reel fully automatic take-ups range in size from 6 to 50-in. and include both shaft type for speeds to 5,000 fpm and shaftless designs running at speeds to 9,500 fpm. One A payoff/take-up model from example is the Davis-Standard, LLC. roll-thru payoff and take-up, Model AK and AKO, a versatile model configured for either payoff or take-up operation. The frame can be supplied in single, double or triple widths to accommodate front and rear positioning and X-Y “Park” positioning.

Models are available to accommodate reels with 30 to 144-in. flange diameters weighing up to 60,000 lb. For accurate winding, it has a digital traverse system to positively lay cable to the diameter set on the control panel.

Another example is the PORA/TURA payoff and take-up, a system that has a shaftless design equipped with either pneumatic reel lift or dual electric screw-jack actuators dependent on reel size and weight. They are designed for driven electrical engagement of reels. Larger units utilize independent arm movement for reel engagement. For accurate winding, the take-ups offer a digital traverse system to positively lay product to the diameter set on the operator control panel. Larry Fitzgerald, Davis-Standard, LLC, tel. 860-599-6121, lfitzgerald@davis-standard.com, www.davis-standard.com.

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FEATURE

DISA Industrie AG At wire Düsseldorf, Switzerland’s DISA Industrie AG displayed its new DISA RDS MINI for shot peening of valve and small pressure springs. The system continuously rotates single work pieces that travel on horizontal rollers through the machine, which strengthens valve springs and suspension springs by shot peening at a throughput rate of more than 5,000 springs an hour, depending on relevant DISA Industrie AG’s new DISA requirements. The RDS MINI system. springs are fed individually on a straight-line conveyor or other loading systems and then move through the blasting zone on continuously rotating horizontal rollers. Axial movements are effected by cams attached to chains. Inside the blasting zone the springs are properly guided by adjustable baffle plates that also serve to focus the shot stream on the work

48 | WIRE JOURNAL INTERNATIONAL

pieces for optimal exposure within the “hot spot” of the blast pattern. The parameters of the shot peening process, such as shot quantity, blast wheel speed/throwing velocity, the speed at which the work pieces rotate and the dwell time, can all be regulated to suit the requirements of a specific type of work piece. It is this definition of all treatment parameters that ensures process-safety at all times. Process parameters can be recorded in the control system and retrieved when necessary. A specific feature of the RDS Shot Peening System is its ability to handle coil springs in a wide range of dimensions including small parts and to treat them individually under uniform and defined conditions in a continuous process. With suitably adapted loading and unloading devices, the shot peening process can be integrated into continuous production lines. DISA Industries, Inc., www.disagroup. com. North America: tel. 630-820-3000, disasales @disaoswego.com.

Euroalpha srl Italy’s Euroalpha srl is a relatively new innovative company that designs and supplies wiredrawing equipment for nonferrous materials. It specializes in wiredrawing equipment for copper, aluminum and aluminum alloys. In addition to the traditional activities of production, sales

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Euroalpha’s Massimo Parise, l, and Massimiliano Bonomini by the company’s Multiwire system. and service, Euroalpha provides customers with preliminary technical advice and planning with a careful analysis of the technical production process. This is very important to determine the type of machinery that is more suitable for the customer. Euroalpha designs and manufactures rod breakdown lines, multiwire lines, intermediate lines, dynamic and static spoolers, automatic spoolers, static and automatic coilers, respooling automatic lines and different accessories for wiredrawing. The Euroalpha Multiwire is a versatile AC motor-powered machine that stands out in terms of high quality wire production,

ergonomic machine construction and flexibility. Power transmission to shafts is done by high precision gears that guarantee long life. Wire diameter can be changed under production based upon a PLC calculation. The die holder includes a “fast cleaning system” and the drawing capstans are in solid SPK ceramic for drawing copper wires.

There is individual drive for all the annealer contact pulleys for optimum speed adjustment to different diameters so a manufacturer can find the right speed that compensates for the wire dilatation due to heating, thus ensuring long life of the replaceable rings in contact with the wire and the best quality of wire surface. The absence of the belt reduces maintenance and provides the maximum accessibility for checking and changes of brushes.

Bonomini Massimiliano, tel. 39-335-1092839, bonomini@euroalpha.it, www.euroalpha.it.

GCR Eurodraw SpA At wire 2008, Italy’s GCR Eurodraw SpA exhibited one section of a CTR 630/6 strander, a machine designed for the production of wire ropes with different diameters. The complete stranding line consists of: an external spool payoff for DIN 630 spools, the CTR rotor with six 630 mm spool positions, a closing die and postformer, a double

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FEATURE

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and preformer are mounted at the outlet of the fourth rotor, to direct the strands to the closing die, which compresses the strand. The postformer is located at the outlet of the cover, where the strand is formed. It is mounted on a trolley that is moved longitudinally along the axis of the bench with a handwheel. A wire straightener is mounted on the same bench. GCR Eurodraw SpA, tel. 39-02-93963-1, gcr@gcrgroup.com.

A section of a tubular strander, model CTR 630/1+6, from GCR Eurodraw SpA. haul-off capstan and a take-up suitable for large-sized spools. The machine works with bright or galvanized steel wires having diameters of 1.27 to 6.35 mm and rope diameters up to 17.80 mm. The internal working structure is completely enclosed by a sound-absorbing cover. The structure consists of four shoulders that support the mechanically connected rotors, inside of which are mounted the rotating spool pay-off cradles and other machine organs. On each cradle, the spool is suspended between pneumatically operated tailstocks that hold it in place. The strander is driven by a motor located outside the back of the cover. Power is transmitted to the rotor shafts by a toothed belt and pulleys. A stranding layplate

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Jouhsen-bundgens Machinery Germany’s Jouhsen-bundgens Machinery, represented in North America by Jouhsen-bundgens USA, announces the launch of the MJE-2 high speed straighten and cutoff and end-working machine. The MJE-2 replaces conventional Swiss, turning and lathe machines, significantly outperforming them in both speed and efficiency. One MJE-2 can replace up to 10 conventional turning machines. Utilizing a double lever infeed, bushing cutoff, and computer controlled machining, the MJE-2 produces parts with various end geometries at speeds of up to 200 parts per minute. At these speeds, the MJE-2 offers the same performance as 10 conventional high speed metalworking lathes working with wire diameters from 2 mm to 6 mm, (0.0787” to 0.2362”), and part lengths from 25

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mm to 150 mm, (0.9842” to 5.9055”).

The versatility of the MJE-2 is shown through the rotating tooling units. The Jouhsen-bundgens Machinery Managing Director Dr. Bert Bosserhoff cutting units can work with the company’s new MJE-2 model. both ends of the parts at the same time, and consist of up to four machining/tooling units. The tooling units are universal, meaning that in most cases, MJE-2 customers can continue to use their current tooling. Cost wise, the MJE-2 can show a more rapid return on investment to manufacturers and a significant reduction in labor requirements to produce parts in large quantities. For larger customers with high output CNC turning centers, the savings can be significant bearing in mind that one MJE-2 replaces 10 CNC lathes. The

MJE-2 is a variation of the time-tested MJE machine platform that has been offered for more than a decade. As an industry benchmark, Jouhsen-bundgens has continued to push the envelope in machinery design, speed, and accuracy. Steve Van Duzen, Jouhsen-bundgens USA, tel. 770889-0689, steve@jouhsen.com, www.jouhsen.de.

Ernst Koch GmbH At wire Düsseldorf, Germany’s Ernst Koch GmbH & Co. KG displayed its innovative OTA wiredrawing technology that has seen more than two dozen models sold since the introduction of this new speed control technology two years ago. The OTA lines work without tuner and dancer rolls and thus ensure a linear wire passing from the first drawing block up to the spooler. This process guarantees an end product that stands out due to its particularly high quality and is especially suited for the production of high-quality wire products. The company has seen a continuously growing demand for the OTA machines. “With the OTA speed control technology we’ve managed the balancing act between improving the productivity of our drawing machines by means of higher drawing speeds and longer operation times of the drawing dies on the one hand and achieving better quality results on the other hand,” said Ernst Koch Managing Director

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Jochen Koch. The OTA lines can be delivered in different sizes and models and are suited for processing low- and high-carbon steel wires as well as stainless materials. Due to the high quality and constancy of the drawing results the machines are particularly suited for producing premium products like spring steel wires and music wire. Additional advantages of the OTA machines include its impressive drawing speeds as well as a An Ernst Koch GmbH compact design that is technician prepares an both user-friendly and OTA system. easy to maintain. Ernst Koch GmbH, tel. 49-2372-9-85-500, sales@ koch-ihmert.com.

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Maillefer SA Swiss-based Maillefer SA displayed several innovations at wire D端sseldorf, one of which was particularly significant: a section of a vertical CV line measuring nearly seven meters tall. Maillefer proposes both the vertical and catenary designs for its CV lines manufacturing MV, HV and EHV insulated power cables. The lines are characterized by their high production speeds and optimized curing capabilities. State-of-the-art technology makes it possible to produce cable with exceptional roundness and concentricity characteristics. Considering a traditional VCV line producing 130 kV EHV cable at 0.83 m/min., approximately 75 m of vertical heating and cooling tubes are needed. Height determines line speeds, product diameter and curing capacities and is a factor in terms of local building codes and public acceptance. Compared to a traditional VCV line, opting for state-of-the-art components brings about 40 to 50 % higher line speeds with the same tower height. One of the key contributions comes from the induction post heater. Positioned just after the extrusion head, it regulates conductor temperature so curing can begin from within. The result is full crosslinking, less mechanical stress and markedly improved roundness and concentricity. Control is improved too.

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Extrusion • Corrugation • Optical Fiber • SZ-Stranding

Nextrom & Rosendahl Enhanced Metal Tape Forming & Welding Technology Rosendahl, the market and technology leader in providing manufacturing solutions for the production of Microwave cables, has recently broadened the Metal Tape Forming & Welding product segment.

Applications • Microwave - RF Cable • Medium & High voltage power cable armouring • Metal Clad Cables • Specialty Tubes & Conduits

Microwave RF Cables • VSWR optimized equipment • Copper, Copper with reduced walls and Aluminium • 1/4“ to 1-5/8“ on one line • Low attunuation cable design

Technologies developed and optimized for this applications are: • Static and Roll formers for various materials • Laser or TIG welding processes - ensure perfect weld seams with minimal heat affected zones and best mechanical properties • High speed corrugators are available for Helical and Annular corrugation design for Copper, Aluminium or Stainless steel.

Nextrom & Rosendahl are globally known for our experience in the fields of Extrusion, Optical Fiber, SZ-Stranding and Forming, Welding & Corrugation. Customized product design, end product quality assurance which yields exact results, enables us to meet or exceed customer requirements.

Corrugation Rosendahl Nextrom Technologies • USA • Phone: +1 828 328 4319 • Fax : +1 828 328 4956 Rosendahl • Austria • Phone: +43 3113 5100 0 • Fax: +43 3113 5100 51 • www.rosendahlaustria.com Nextrom • Finland • Phone: +358 9 5025 1 • Fax: +358 9 5025 3003 • www.nextrom.com

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INTERNATIONAL

TECHNIC

AL

CONFERENCE

T E R R E Y

Photos courtesy of the Monterrey Department of Tourism.

M O N

Wire and Cable Technical Program • Tabletop Exhibits • Museum Tour • Networking

20–22 O CTOBER 2008 • M ONTERREY, N.L. M EXICO • C ROWNE P L AZA H OTEL

SPELLBINDING PRESENTATIONS ARE JUST A PART OF THE EXPERIENCE. Venture to a place where wire and cable best practices and technological answers are much more than theory. And leave with ideas you can put into place immediately. Join WAI and educational sponsor ANTAAC for the 2008 International Technical Conference that will leave you both informed and inspired.

Learn more at www.wirenet.org or contact WAI’s educational director, Marc Murray at mmurray@wirenet.org; Tel.: 001-203-453-2777, ext. 121.

Sponsored by:

The Wire Association International, Inc. and

ANTAAC

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A second-floor view of the vertical CV line displayed by Maillefer SA at wire Düsseldorf.

Immediate corrections of induction heating allow optimized curing while maintaining constant line and extruder speeds. The induction post heater together with splice box, x-ray measurement gauge, a curing calculation simulator and modern line controls were shown at wire 2008.

Since 1976 Maillefer has received more than 330 orders for its CV lines. Maillefer SA, tel. 41-21-694-4111, info@maillefer.net, www.mailleferextrusion.com.

At wire Düsseldorf, Germany’s Niehoff GmbH introduced multiple innovative equipment and devices including a new annealing and preheating technology for the inline production of data and telephone wires. The showcased line consisted of a newly redesigned cone type draw box, the MT200, with an integrated RI170.2 inductive annealer and preheater for tandem inline operation with an extrusion line. This technology was derived from the inductive annealers of the joint venture company Niehoff-Bühler GmbH NBM, which have been successfully proven for years in various annealing applications.

The simple and contactless annealing principle will considerably improve the quality of the conductor and therefore of the data cable, while reduction of operational and maintenance costs is achieved by eliminating slip rings and carbon brushes. The annealer is also available with an integrated calibration die which helps maintain closer tolerances of the mechanical properties of the conductor, a must for the stringent high quality data cable requirements. A non-contact temperature monitoring system controls the wire temperature between the drawing machine, annealer and extruder. An accurate dancer is used to control and synchronize the line with any existing types of

JULY 2008 | 55

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Niehoff GmbH

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Niehoff Endex North America, Inc., tel. 856-467-4884, sales@niehoffendex.com, www.niehoff-usa.com.

Pave Automation FEATURE

The Düsseldorf wire show, despite the economic climate and international credit crunch, was possibly one of U.K.-based Pave Automation’s busiest on record. The competition is always stiff at Düsseldorf with European

Niehoff GmbH’s MT200/RI170.2 drawing, annealing and preheating line. extruders. The new product generated a lot of interest at the wire trade show. The first MT200/RI170.2 line will be field-tested at a leading data cable manufacturer of high performance LAN Cat 8 cables. Another similar cable manufacturer intends to order a similar line shortly.

Niehoff GmbH & Co. KG, tel. 49-9122-977-0, info@niehoff.de, www.niehoff.de. In North America,

Pave Automation’s Silvio Perna with the company’s Panther X3 model.

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manufacturers fighting for their market share. It is through this competition that great things happen and great machines are built. Spirits were very high at the company as it was showcasing its new Panther X3 machine, the culmination of over 30 years of CNC wire bending machine experience. The major issues of straightening wire and delivering it to a CNC bending machine to manufacture a quality wire form have been addressed and the technology in this machine will again push the frontiers of what is achievable. Creating wire forms from 200 mm long to 3000 mm long in diameters from 2 mm-6.5 mm wire and using 9 axes to control the manufacturing process, the Panther’s accuracy is exceptional. It can accommodate up to 12 radii for forming. For complex automotive parts from rear seat cushion wires to door locking mechanism wires, the Panther X3 is a dream machine. The company looks forward to Interwire 2009 where it will show its finest equipment, led by the new Panther X3. Silvio Perna, Pave Automation, tel. 44-1733342518, sales@pave-wire.com.

Pourtier/Gauder Group How to produce a 37-wire concentric Cu/Al strand – 240 mm² at 500 rpm on only a 40-m long line without any breaks? That challenge was taken up by France’s

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A COS 1200 series model from Pourtier/Gauder Group.

Pourtier-Gauder Group, which designed an innovative multiwire concentric stranding line for screening of power cable, model COS 1200-37, that was displayed at Wire 2008. The machine, designed to produce high quality round or sectoral compacted strands of 7, 19, 37 or 61 copper (1.50–3.00 mm) or aluminum (2.00–3.50 mm) wires, is ideal for this typical application. The concentric

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Pressure Welding Machines Ltd, Bethersden, Kent England TN26 3DY Tel: +44 (0) 1233 820847 Fax: +44 (0) 1233 820591 E-mail: pwm@btinternet.com

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construction enables speeding up to 500 rpm (compared to 200 rpm with a traditional rigid stranding line) while keeping a short line length thanks to the multiwire process. Moreover, each bobbin is equipped with an individually driven tension control for prevention of wire breakage, optimization of the final section and therefore resistance of the cable. The 37-wire line is composed of six independent modules of two reels of three wires each, individually motorized by AC motors. Filling of the reels is by basket payoffs with individual capstans to pull the cable and to equalize the tension of each wire, reaching the best winding quality. The result is higher speed, less space needs, safer production, all in a flexible line that allows reduction of copper remainders. All the parameters are adjustable from the color touch screen control panel for a better process control. Philippe Letout, PourtierGauder Group, tel. 33-1-64-21-84-00, sales.pourtier @gaudergroup.com, www.gaudergroup.com.

Rosendahl GmbH At wire DĂźsseldorf, Austrian-based Rosendahl Maschinen GmbH introduced a ROEX Extruder-group, including special printing equipment, optimized for THHN wires. One ROEX 90 mm main extruder with 45

Rosendahl GmbH’s new ROEX Extruder-group. mm aux. extruder plus a ROEX 60 mm Nylon extruder were installed to illustrate a typical arrangement to produce PVC/PA insulated cores according to various standards such as THHN, THWN, AWN or MTW. The lines are usually configured to produce classical building wires, control cables or high-end XLPE/LS0H insulated conductors. The typical lines from Rosendahl are prepared for full continuous production and speeds up to 1200 m/min. By using a special pre-cooling unit and high end equipment, it is possible to run various products up to full production speed, including the printing. This multipurpose configuration enables cable producers to offer a major product range of different cables with topperformance in output and quality, and this by just investing in one line. Gerhard Jakopic, Rosendahl GmbH, tel.

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43-3113-5100-0, office@rosendahlaustria.com, www.rosendahlaustria.com

SAMP USA/SAMPSISTEMI FEATURE

At wire 2008, SAMP USA/SAMPSISTEMI displayed an automotive wire extrusion group for flame retardant cross-linkable materials (XLPE) with the curing process carried out by means of a horizontal vulcanization line.

The production of automotive wire requires a multitude of color changes for both stripe and base colors combined with the need to minimize the scrap level during those transitions. This problem is even more challenging when the insulating material is XLPE and the extrusion group is part of a horizontal CV line process. To respond to those challenges, SAMPSISTEMI has introduced a new extrusion technology especially dedicated to automotive XLPE and offering the capability to switch stripe colors without production interruption at full line speed while minimizing the scrap generated during the transition. The extrusion group is composed of: a main extruder, type TE 8020L; two semi-inclined auxiliary extruders, type TE 3525D; a crosshead including the cross-flow system for the stripe; and a continuous vulcanizing splice unit.

Both the main extruder and crosshead are water-

Genca Wire & Cable Extrusion.

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SAMP USA Managing Director Dominique Perroud by the company’s automotive wire extrusion group. cooled to maintain the low temperature profile necessary to extrude XLPE. Cross-flow valve and main extruder bypass are controlled by hydraulic systems to keep a compact head configuration and fast response time. This extruder group configuration is optimum for the production of XLPE automotive wire ranging from 24 awg to 10 awg at speed up to 2,800 ft/min for the smallest wire sizes. The vulcanization part of the line is composed of a straight steam section of 360 ft up to the autoclave. The back steam section from the autoclave is adjustable from to 0 to 80 ft with the final tube section consisting of water cooling up to 210 ft. Three levels are available to adjust the transition between steam and water. For this type of automotive wire application the tube diameter is 80 mm and the complete vulcanization tube system is designed to operate under pressure up to 24 bars. The complete extru-

No matter what type of wire or cable you may be extruding, Genca designs and manufactures everything you need for your extrusion process. From Crossheads and In-line Heads to Tips, Dies, Screws, Barrels, Breakerplates and more, Genca leads the industry with a complete line of innovative and highly productive extrusion products for your business. For more information, contact Genca at 1-800-237-5448 or online at www.genca.com

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sion group and vulcanization line system are controlled by means of a computerized system. On the HW side it is a combination of PC and PLC, PC for data, production and recipes management and PLC for the line logic and controls. SW was especially developed by SAMP to control all the automatic functions, sequences and safety requirements specific to this kind of line configuration.

Dominique Perroud, SAMP USA, tel. 301-223-8584, dperroud@sampinc.com, www.sampinc.com.

Schlatter AG Swiss-based Schlatter, a leading worldwide manufacturer of individual solutions in the field of resistance welding, presented its innovative System “MG 930 Quick Change” for industrial wire mesh production at wire 2008 in Düsseldorf, Germany. In many markets today, short reaction times to customer’s inquiries are of essential importance. The economical production of quality mesh panels in small quantities requires a welding plant which can be set for the next order within the shortest possible time and with a minimum amount of mechanical adjustments. Schlatter’s MG 930 Quick Change system offers new possibilities to reach this goal. Time consuming changeovers are eliminated

62 | WIRE JOURNAL INTERNATIONAL

A close-up Schlatter AG’s QF single gap-type cross wire feeder. by the use of modules with servo-motorized transport and positioning systems, which can be programmed through the process lead system. As shown on the picture, the new QF 12 single gap-type cross wire feeder with central adjustments facilities and large wire magazine can be changed over to a new production program within minutes. Other modules, such as the new LV 8 automatic line wire loading and feeding system are consequently designed to reduce operator intervention in set up of the machine. Changeover times, repeatability and accuracy are achieved due to the use

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of precision servo drives. The plant is applicable in a flexible way and allows an optimal adaptation to the needs of the market. A large variety of optional items allows the expansion of the plant and consequently the adaptation to changing market requirements. Schlatter’s System “MG 930 Quick Change” has been designed by the company to meet the customer’s demands for extremely short delivery time.

Herbert Wenker, Schlatter AG, tel. 41-44-732-7111, www.schlatter.ch.

Team Meccanica At wire Düsseldorf, Italy’s Team Meccanica, part of the Eurolls Group and represented in North America by Cortinovis Machinery America, displayed a wiredrawing line, model DSD 610/8, that offers innovative patented technological solutions that makes it simpler to use and maintain. The steel wire drawing line, which has a production range of 6.50 – 1.50 mm at 25 m/s, SAE 1004 - 1060, employs innovative patented solutions such as “plug & play” technology. The eight-block system has direct synchro drive with 45 KW synchronous motors that are directly connected to the capstans while a patented highefficiency wire cooling system uses closed-circuit water recirculation for the forming cassettes and motors. This design means that there is no need for gearboxes, belts,

64 | WIRE JOURNAL INTERNATIONAL

transmission means and lubrication oil, it said, noting that the drawing is done by roller forming cassettes or die boxes. The line, which has a prewired onboard electric board, can be installed without foundation bolts. The model comes Team Meccanica’s model DSD 610/8 with a fivewiredrawing system. year guarantee, with an extension up to seven years. Tony DeRosa, Cortinovis Machinery America, tel. 908-479-9818, cortinovis@ cortinovisamerica.com.

Teurema Italy’s Teurema, part of the Eurolls Group and represented in North America by Cortinovis Machinery America, displayed at wire Düsseldorf an automatic spooler, model EVM, for the production of precision laid wire coils with spools which can have a capacity of up to

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5 tons. This double automatic spooler is composed of two spool working stations which are the wire collection station and the wire strapping/unloading/loading station. It is complete with all necessary devices to ensure an automatic handling of the wire, the cutting and subsequent threading of the wire, and the securing of Teurema’s EVM automatic the wire tail. All these spooler. operations improve line efficiency specially when operating with large diameter wires. The combination of all these factors guarantees a drastic reduction in down times which are normally present during the spool changeover cycle. All parameters required for the formation of the pattern laid coil, as well as production information, are set on the spooler control pulpit Tony DeRosa, Cortinovis Machinery America, tel.

908-479-9818, cortinovis@cortinovisamerica.com.

TAK Enterprises U.S.-based TAK Enterprises offers a wire payoff designed for fine sizes. Fine wire is usually considered to be in the range of .010 in. to .020 in. while very fine wire is less than .010 in. in diameter. Handling fine or very fine wire, especially if it is of a precious metal like platinum, gold or silver must be controlled very carefully so as not to mark it or cause it to snap or break. The control factors are the same for other fine wires such as tungsten or tantalum but with the additional need to be able to A fine wire payoff from TAK stand up to the properties of the material. The Enterprises. paying off of fine and very fine wire of these types requires very specific equipment characteristics.

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PRINTING SOLUTIONS S-10 Guidance Guidance Station Station S-10

The TAK Enterprises Fine Wire Payoff (FWPO) has all of them covered and then some with these features: free floating guide arms that go where the wire is so the wire is not forced to a set point; “V” shaped plastic roller guides that all are on micro-bearings for low friction guidance; ceramic-coated guide wheels that withstand the abrasiveness of tough wires; controlled back tension that assists in the straightening process and precision feeding of the wire; a “snag” detector with auto-shutdown so crossovers or “kinks” are detected before they cause the wire to snap or break; four feet of under tension “pulled” reservoir to ensure a smooth payoff; motorized operation with auto-break so there is no “bird nesting”; and a wire range from .004 in. to .050 in., spooled or coiled. Norman Pierce, TAK Enterprises, tel. 860-583-0517, n_pierce @takenterprises.com, www.takenterprises.com.

Wafios AG Germany’s Wafios AG exhibited its new versatile CNC single-head bending and coiling machine BM 30. Featuring a new machine design concept including base panelling and a subtly tinted blue window in the enclosure, Wafios is pointing the way forward in the field of wire bending with its new BM 30 machine.

The BM 30 is the culmination of a symbiosis between innovative and proven machine features. The design encompasses the concept already familiar from the existing BM series of turning the wire rather than the bending head. The fixed

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position of the bending head offers a wealth of benefits in terms of performance, process reliability, Wafios AG’s BM 30 CNC bending and quality and coiling machine. service life.

One very practical example of these benefits is the method of energy supply: the wiring is safe and reliably secured against entanglement or wear. The bending head comprises four axes, including the lateral traversing axis, as a standard feature. Coiling processes are made possible by the continuously rotatable bending and mandrel axis, which also permits the production of closed loops without the need for any other optional attachments. The bending and cutting device are neither pneumatically nor hydraulically controlled, substantially reducing set-up times and making the system far less susceptible to faults. Together with the precise control of operating processes, these features provide a decisive range of benefits. All the popular tool types used on Wafios CNC single-head bending machines from 6 to 8 mm can also be used on the BM 30.

The focus on its development team was process reliability and quality, as can be seen by the capability for complete manual displacement of the infeed unit together with the straightener. The machine operator can choose any one of three positions, depending on the production range. The result: not only improved safety and quality, but also an increase in operating speed. The new BM 30 places Wafios firmly in the high-end sector, and provides impressive proof of what can be achieved using modern mechanical engineering, electronics and control systems today. Wafios AG, www.wafios.de. In North America, Wafios Machinery Corp., tel. 203-481-5555, sales@wafios.de.

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WiTechs/Ernst Koch, GmbH At wire Düsseldorf, Germany’s Ernst Koch GmbH exhibited machinery from WiTechs, its new subsidiary that is co-owned by WTHK GmbH. The twin sanding head grinding system, model SEZ, has many advanced features. The extra long sanding belt is riding on three contact rolls. The tension roll and the access door are power-adjusted for safe and fast replacement of

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Jochen Koch, managing director of Ernst Koch and WiTechs, with WiTech’s twin sanding head grinding system. worn sanding belts. The SEZ can sand rod from 5.5 to 14 mm and allows a continuously adjustable belt speed as well as the usage of different belt types, depending on the finish product. The flyer speed is adjusted to the rod inlet speed to the drawing machine. In a majority of the applications the wire producer will also employ a WiTechs HSBE 3200 wire-cleaning and coating machine in between the SEZ sanding machine and the wire drawing machine. WiTechs offers parts and services for GSG and WTHK machinery. WiTechs, tel. 49-2372-985-500, www.witechs.de. ■

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TECHNICAL PAPERS

TECHNICAL PAPER The effect of thermal expansion of dies on dimensional accuracy in drawn bar and wire Experiments confirmed that controlling die temperature of the die was found to be effective at producing a consistently sized and accurate wire from drawn bar.

By Ryosuke Komami, Motoo Asakawa, Satoshi Kajino, and Hiroaki Kubota

Highly accurate drawn bars and wires are increasingly in demand for precision forging processes. There is a need for bars and wires to be manufactured with a higher dimensional accuracy of diameter for use in the office automation and automobile industries. In general, the drawing process produces highly accurate drawn bars and wires. However, the diameter of the drawn bar gradually increases during the actual drawing process. See Fig. 1.

The changing diameter is most likely caused by a combination of the approach semi-angle, mechanical properties of bar, reduction in area, back-tension, and thermal expansion of the die diameter1-3. Thermal expansion of the die diameter is the only variable in these factors. So this study focused on the effect of thermal expansion of the die diameter in drawing on the diameter of bars and wires.

Experimental method An increase in die temperature will cause an expansion in the die diameter. For that reason it is necessary to measure the die temperature, and consider the relationship between the diameters of drawn bars and die temperature.

Fig. 2 shows the wiredrawing machine that was used in these experiments. In order to measure the die temperature distribution, holes were bored in the dies and thermocouples were inserted into the holes. See Fig. 3 Hole A was placed 1.5 mm from the center of the bar, Hole B was placed 4.5 mm, Hole C was placed 11.3 mm and Hole D was placed 19.3 mm. Finally, a thermocouple was placed on the surface of the die. This was defined for the experiment as point E (See Fig. 4). Table 1 shows the thermal properties of the die.

Calcium carbonate was used as a lubricant, and SCM435 was used as the material in this study. See Table 2.

Experimental conditions Table 3 shows the experimental conditions. In order to investigate the effect of the approach semi-angle and drawing velocity on the die temperature and diameter of the drawn bar, the approach semi-angle was varied between 4 to 10°C and the drawing velocity from 10 to 110 m/min. Every test was carried out at reduction in area using the following information: Re = 11.6% (7.90 mm to 7.42 mm).

Calculation of thermal expansion of die diameter In order to investigate the thermal expansion of the die diameter and the diameter of drawn bar, the die diameter expansion was calculated from the measurements of die temperature. The following five points were assumed. • The die temperature was homogeneous. The average temperatures of Hole A and the surface temperature are used for this calculation;

Fig. 1. Diameter variation of drawn bar.

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• It is assumed that the chip was pressed into the case. The initial interference δo was set at 0.18 percent; • To calculate only thermal expansion, the contact pressure of the die-material interface was set at 0; • It was assumed that the case coefficient of thermal expansion was larger than that of the chip. Therefore, in effect of the decreasing contact pressure between the chip and the case was also considered; • and the end condition of die was not constrained.

Fig. 5 shows the die shape and parameters. The interference

δ(T) was calculated using Eq. (1).

Eq. (1) α1 and α2 indicate thermal expansion coefficient of the case and chip. Application of Eq (2) made it possible to determine the contact pressure, pm, between the chip and the case.

Fig. 2. Coil-to-coil drawing machine.

Table 1. Thermal properties of die.

Table 2. Chemical composition (mass%).

Table 3. Experimental conditions.

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ed from this contact pressure.

Eq. (3)

The thermal expansion of diameter of the chip was calculated with Eq. (4) u2 = α1 a T Eq. (4) Finally, the displacement of the die diameter was sum of the two values: u1 and u2.

Ur = u1+u2 Eq. (5) Hereinafter, “calculated value of diameter expansion, Ur” was computed with this method in this paper.

Fig. 3. Temperature-measuring die.

Eq. (2)

υ1 and υ2 indicate Poisson’s ratio and Ε1 and Ε2 indicate Young’s modulus of the case and the chip.

The displacement of the die diameter, u1, was then calculat-

Results and discussion Relationship between time, die temperature and diameter thickening ratio. Fig. 6 shows the relationship between time and die temperature. The approach semi-angle, α, was set at 7.5 degrees, and the drawing velocity, v, was set at 110 m/min.

The results indicated the die temperature increased rapidly for the first 2.5 minutes. After the first ten minutes, the die temperature became constant. The steady-state temperature of Hole A was 160°C, and the steady-state temperature of the surface was 110°C. Fig. 7 shows the relationship between the distance from the die-bar interface and the die temperature after a lapse of 0, 0.5, 1.5, 2.5 and 10 minutes. The die temperature has a radial gradient. As time passed, the temperature gradient decreased.

Here the diameter thickening ratio is defined as η and, where η denotes the thickening ratio from the die diameter. (See Eq. (6).

Eq. (6) (D = Die diameter, d = Diameter of the drawn bar). When

Fig. 5. Calculation method of die.

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Fig. 6. Relationship between time and die temperature.

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Fig. 7. Relationship between distance from contact point and die temperature.

η is positive, the diameter of the drawn bar is thicker than the die diameter. On the other hand, when the η is negative, the diameter of the drawn bar is thinner than the die diameter.

Then, ηd. ηd is defined obtained by subtractedη0 from the diameter thickening ratio, η (ηd =ηd - η); (η0 = Initial diameter thickening ratio).

The difference between the initial diameter and the steadystate diameter is an important issue in manufacturing.

Therefore it is important to define the diameter thickening ratio as ηd.

Fig. 8 demonstrates the relationship between the weight of the drawn bar and the diameter thickening ratio. As time passes, the diameter thickening ratio,ηd, increased. The steadystate diameter thickening ratio was 0.1%.

At this point the experimental results were compared with the calculated results. The experimental value, ηd, was 0.1%, and the value of calculated result was 0.07%. It was highly possible that the diameter thickening ratio was greatly affected by the thermal expansion of the die.

Fig. 9 shows the relationship between time and the change in the Hole A temperature after the drawing machine was stopped. Hole A temperature decreased and, therefore, the diameter thickening ratio decreased. When the drawing machine was reactivated, the Hole A temperature increased, which led to an increase in the diameter thickening ratio.

When the drawing machine was stopped, the diameter thickening ratio changed. It is a critical problem.

The effect of approach semi-angle on die temperature and diameter thickening ratio. Fig. 10 shows the relationship between the approach semi-angle and the steady-state temperature of Hole A. As the approach semi-angle was increased, the steady-state temperature at Hole A slightly decreased.

When the approach semi-angle was 10 degrees, the steadystate temperature at hole A was 160°C. Fig. 11 shows the relationship between the approach semiangle and drawing work. Drawing work varies with changes in the approach semi-angle4. Therefore, the die temperature will also vary with approach semi-angle. However. the die temperature is also greatly affected by frictional work.

Fig. 8. Relationship between and die temperature.

Fig. 9. The relationship between diameter thickening ratio and approach semi-angle α=5.5 deg. Drawing velocity v = 110m/min.

Fig. 10. Relationship between die semi-angle and HoleA temperature.

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Fig. 11. The relationship between the approach semiangle and drawing work.

Fig. 12. The relationship between the approach semiangle and diameter thickening ratio.

Fig. 12 shows the relationship between the approach semiangle and the diameter thickening ratio. As the approach semiangle increased, the diameter thickening ratio decreased.

When the approach semi-angle was 10 degrees, the diameter thickening ratio was 0.08%.

In the case when the approach semi-angle, α was 10 degrees, the die temperature was at its lowest in these four experimental conditions. Therefore, the thermal expansion of the die diameter was limited at the approach semi-angle α = 10 degrees.

The effect of drawing velocity on the die temperature and diameter thickening ratio. Fig. 13 shows the relationship between the drawing velocity and the steady-state temperature at hole A. As the drawing velocity decreased, the steady-state temperature at hole-A decreased. When drawing velocity was 10 m/min, the steady-state temperature at hole-A was 100 centigrade. It is likely that the frictional work and plastic deformation work per unit time decreased and corresponding-

Conclusion This paper investigated the effect of thermal expansion of the die diameter on the diameter of drawn bars. Drawing experiments at die semi-angels of α = 4, 5.5, 7.5 and 10 degrees and 10, 40, 70 110 m/min drawing velocity were carried out. The results were as follows:

Fig. 13. The relationship between the drawing velocity and hole A temperature.

Fig. 14. The relationship between the drawing velocity and diameter thickening ratio.

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ly the die temperature decreased.

Fig. 14 shows the relationship between the drawing velocity and the diameter thickening ratio. More than 80 m/min drawing velocity had a small effect on the diameter thickening ratio. As the drawing velocity was decreased, the diameter thickening ratio decreased. This inhibited the thermal expansion of the die diameter.

When the drawing velocity was 10 m/min, the diameter thickening ratio was approximately 0%. When the approach semi-angle was α = 10 degrees, the diameter thickening ratio was -0.1%.

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• The diameter thickening ratio, ηd was greatly affected by thermal expansion of the die diameter; • more than 80 m/min drawing velocity had a small effect on the diameter thickening ratio ηd; • as approach semi-angle, α increased, the diameter thickening ratio ç d, inhibited. However die semi-angle had a small effect on the diameter thickening ratio ç d; and • results confirmed that controlling the temperature of the die was effective in achieving a constant dimensional accuracy in the drawn bar.

References 1. W. Lueg and O. Pawelski, “Stahl und Eisen,” 80, 1960, pp. 343-350.

2. W. Lueg and A. Pomp, “Stahl und Eisen,” 61, 1941, pp.

1169-1172.

3. H. Kubota, Wire Expo 2006 Proceedings, pp. 112-123.

4. The Japan Society for Technology of Plasticity, Drawingfrom Fundamentals up-to-date Techniques, first edition, 1990, Coronoa Publishing Co., Ltd. ■

At the time this paper was written, Ryosuke Komami was a student in the school of science and engineering at Waseda University, Tokyo, Japan. Dr. Motoo Asakawa is a professor in the mechanical engineering department at the Waseda School of Science and Engineering. He came to the university 10 years ago from Sumitomo Metals Co. He has studied both the process engineering and materials engineering of the mechanical parts of cars, trains, aircraft and construction and electric devices. He earned a doctoral degree in bar and rod rolling from Waseda University in 1980.

He is a recipient of Japan’s Okochi Memorial Prize, the Society for Technology of Plasticity Prize, the Institute of Metals Prize, and Iron & Steel Institute Prize. Satoshi Kajino works at the National Institute of Advanced Industrial Science and Technology (AIST) in Japan.

He earned a doctoral degree in engineering from Waseda University. He is a recipient of the WAI Silver Certificate Award for best paper in the ferrous division for 2005.

Hiroaki Kubota is a graduate student in the School of Science and Engineering at Waseda University. This technical paper was presented at WAI’s 77th Annual Convention, Cleveland, Ohio, USA, May 2007.

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TECHNICAL PAPER Advanced semi-a automatic straightening technology Using the latest technology provides strategic advantages of mass customization that make it easier for manufacturers to make wire products at the increasingly high levels of quality demanded today by customers.

By Marcus Paech

Motivation From a global perspective, companies compete with similar constraints that have identical variables. However, there can be local differences that affect variables, such as labor, energy and raw material costs. Differentiation strategies are available that, based on advanced product manufacturing methods, can help offset such disadvantages. Some keys of these advanced manufacturing techniques include: the availability of process and setup data before the process begins; accurate, fast and reliable verification of setup data; and the ability to produce customer-specific products in small batches based on the rules of mass production (mass customization).

The roll straightening process Excellent process planning and optimization, intelligent, flexible machinery technology as well as advanced information and communications technology are absolutely essential

for the design of these production processes. An analysis of the production process in the wire industry shows that the rollstraightening process is one of the key production steps. In wire production and processing, the straightening process defines the engineering and business variables which determine success or failure. If, for example, finished products do not conform to geometric specifications as defined in standards such as EN 10218-2, it can take more time, material and labor to produce a product, making production inefficient. In addition to conformance to geometric specifications, there is increasing interest in other information and characteristics which are very important for the downstream production process. In this context, the wire straightening operation must evolve into a manufacturing process which makes it possible to continuously identify the properties of the process material and which is also capable of constantly maintaining specific

Fig. 1. Schematic diagram of roll straightening process showing key selected variables.

Photo 1. An example of advanced semi-automatic straightening technology.

Editor’s Note Due to space limitations, it was not possible to present all the text and figures in this paper. The complete original paper can be found at wirenet.org by clicking on “Wire Journal Extra” and then “Paech.”

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material characteristics. and dmax are relevant parameters for round wire and are Given the level of complexity, it is difficult to understand shown in Eq. (1) as follows: why the acceptance and utilization of semi-automatic straightening technology in the wire industry has not kept pace with Eq. (1) the available options. An analysis of insular solutions in practical applications1,2 reveals that, from the list of characteristics The number of rolls which are needed in a straightener above, only verification of setup data has actually been impledepends on the elongation limit Rp and the range of the radius mented. The remaining characteristics are not used in combiof curvature Δ r using the maximum (rmax) and minimum nation with semi-automatic straightening technology in pracradius of curvature (rmin) as shown in Eq. (2). tical application. Potential suppliers as well as the users of semi-automatic straightening equipment are both to blame for this situation. On the user side, management is focused excluEq. (2) sively on short-term profitability. It lacks creativity and does not have the courage to take risks. Despite the associated competitive disadvantages, managers are unwilling to invest in The rule of thumb is that to achieve good finished product innovation which is nothing other than creativity that has quality, the number of rolls needed increases as the elongation become reality3. The level of investment is insufficient, limit and the range of the radius of curvature increase. because the persons making the decisions are reluctant to Fuzzy logic is used to determine the number of rolls n. spend what they perceive to be large sums. Usually no attempt Knowledge based on empirical data can be formulated in veris made to weigh up the investment costs against the engineerbal rules for input into a fuzzy logic system. The knowledge ing and business benefits. Suppliers can help raise the level of base consists of linguistic terms (membership functions) for investment if they offer advanced semi-automatic straightenthe input and output variables, the rule base and the inference ing technology which is cost-effective and suitable for the and defuzzification functions5. The rule base creates a link application and if they find ways of communicating the between the range of the curvature of radius Δr and the elonadvantages of the technology in a way that the users can readgation limit Rp as the input variables and the number of rolls ily understand. See Photo 1. In taking up the challenge, a new n as the output variable. approach was used rather than relying on existing strategies.

The use of an appropriate inference mechanism and a speStraightening is primarily needed to modify or remove curcific defuzzification method finally produces a specific transvature in process material. Curvature is induced by mechaniformation pattern. Thus a set of sharply defined input cal and thermal effects, and it can be desirable or undesirable. variables can be used to generate a sharply defined output As a secondary effect, the straightening process affects the variable. Table 1 shows some discrete values for the number mechanical properties of the process material such as elongaof rolls n, which were derived from the input variables elontion limit Rp, tensile strength Rm, modulus of elasticity E and gation limit Rp and range of the radius of curvature Δr. residual stress potential WE. The shape curve of a process Deformation power requirements material, which is not exposed to external forces and Power is needed to deform process materials using straightmoments, is based on the equilibrium of internal forces and ening rolls. The amount of power required depends on key moments. variables of the straightening device and the process material A straightener, which has straightening rolls arranged in two as well as the type and speed of roller adjustment. alternating rows, can effectively modify or eliminate one Translation or rotation that is converted to translation can be dimensional curvature4. The positioning of the adjustable used to make the best individual roll adjustment. Adjustment straightening rolls ai causes alternate elastic/plastic deformascrews or spindles, which act as gear units with good selftion which forms the basis for changes to the geometric and locking and convert torque MiG into adjustment force FiA, are mechanical properties of the process material. Fig. 1 shows selected process material and straightener variables for a process which is used to straighten a wire with diameter d.

Every straightener has a specific straightening range Δ, which is determined by the spacing T (the distance between straightening rolls) and the diameter of the straightening rolls D (Fig. 1).

Depending on these variables, the straightening range Δ has a minimum and maximum limit and a maximum crosssectional dimension of the process materiTable 1. Values for the number of straightening rolls n based on fuzzy al which can be straightened. The minilogic. mum and maximum wire diameter dmin

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popular solutions. The variables that apply to these gear units are thread flank diameter diF, mean helix angle αim, and friction angle ρ’i. The angular velocity ϖiG and respectively the spindle speed niG can be used in Eq. (3) to calculate the minimum power Pi which is required to adjust roll i.

Eq. (3)

The adjustment force FiA results from the deformation of the process material in the area which is affected by straightening roll i. It is equal to the amount of straightening force |FiR| Eq. (4), which is applied at the point where process material contacts the straightening roll in correlation with reaction forces.

FiA = |FiR|

Fig. 2. Reaction forces Fir and Fit, resulting straightening force FiRes, components Fiver and Fihor and the graph of the non-dimensional bending moment M*i = f(x).

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Eq. (4)

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Analysis of the quasi-static case allows one to ignore external forces and the tangential reaction force Fit. The radial reaction force at the straightening roll is equal to the resulting straightening force (Fig. 2 a).

If one ignores the spacing which has changed by ΔT, then the straightening force FiR is only made up of the vertical component of the resulting straightening force Fiver (Eq. 5, Fig. 2 b).

FiR = Fiver

Eq. (5)

Calculation of the amount of non-dimensional straightening force |F*iR| using Eq. 6 is based on equilibrium analysis which includes the bending moments at the rolls (Fig. 2 c) and the spacing.

Eq. (6)

The use of non-dimensional values (indicated by an asterisk) simplifies the calculation6. Eq. 7 is used to calculate the adjustment force FiA (Eq. 4) or the actual straightening force |FiR|.

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row’s advanced manufacturing scenarios.

Instead of using simple tools to adjust straightening rolls, advanced semi-automatic straighteners are equipped with actuators which have a motor and a gear unit. These actuators work in conjunction with automation equipment and software to determine and set the target position of the straightening rolls based on the desired finished product quality. This type of design leads to: guaranteed high actuating forces; remote operation; minimized operator error; minimized time, human resources and volume of process material needed to achieve the desired product quality; and precise, automatic setting at specific tool positions which is appropriate for a particular process material and tool geometry.

Subsystem types The conceptual design of the advanced semi-automated straightener contains three sub-systems. The mechanical, electrical and software subsystems (see Fig. 3) are based on lean design principles, means that the component count is kept to a minimum.

Mechanical subsystem. The servomotor (M), planetary gear (G), spindle adjustment mechanism and slide as well as the roll axis and straightening rolls are located in the mechanical system power train (Fig. 4). The combination of all of these elements on a single module is the revolutionary new feature of this design. Because the system is modular, customer-specific versions of the straighteners can be produced quickly and efficiently while still adhering to the laws of mass production and the applicable pricing guidelines (mass customization = mass

Eq. (7) The analysis presented above shows that calculation of the bending moments M(i-1)v, Miv and M(i+1)v is needed to determine the power which is required to achieve deformation.

Simulation of the straightening process6 can be run to generate numeric bending moment/curvature graphs. The analysis uses iteration to calculate the curve for bending moment M* = f(x) (Fig. 2 c), curvature K* = f(x) and the bending line of the process material y = f(x) for a given roll adjustment. With the bending moment curve also the non-dimensional values for the bending moments for calculating the amount of power required are known.

Concepts The section on motivation described important characteristics of an advanced production process. Conventional straighteners do not possess these characteristics. The straightening rolls, which are the tools on straighteners, can be adjusted, but the adjustment is not defined and reproducible, because the equipment which would be required to do so such as instrumentation is lacking. Tools such as wrenches or screwdrivers are used to move the adjustment screws until the process material has the right curvature at the outlet or other quality criteria are met. Conventional straighteners have a static design. There is no way for the user to expand the application horizon to handle alternative cross-sectional geometries or materials. As a result, they are not suitable for tomor-

Fig. 3. Conceptual design of advanced semi-automatic straightening technology with mechanical, electrical and software subsystems.

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Fig. 5. Menu for the synchronous positioning of rolls.

Fig. 4. Modular mechanical subsystem.

production + customization7).

Straighteners with a specific number of straightening rolls n and specific spacing T can be produced cost-efficiently at short notice on customer request. Advanced straightening technology uses process simulation6 to determine optimal spacing T and maximum straightening range Δ see (Eq. 1). Optimization of spacing T is based on the level of finished product quality that the customer wants as well as the material characteristics.

Modular design also offers the advantage that modules with actuators can be paired with modules that have non-adjustable straightening rolls. Customers can maintain the functional profile at a lower investment cost. From the user’s point of view, advanced straightening technology based on mass customization offers the advantage that products can be made in small lots using a mass customization process. This approach is feasible if the straightening equipment offers variable spacing T. Users can adjust roll spacing on site (see Fig. 3) to create perfect conditions for handling special materials or cross-sections (wire, tube, etc.). Theoretical and practical results demonstrate the significant influence which spacing T has on finished product quality and the required roll adjustment accuracy8.

With the exception of the motor and the gear unit, the elements in the mechanical subsystem are mounted on a high-precision base which can be subdivided along the axis of the roll shaft. This ensures high power density. The calculation used to determine the power needed to deform the process material and to position the rolls is based the applicable rules. The initial version of the straightener is suitable for round wire in the 5-15 mm diameter range. It can also be used for elastic/plastic

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deformation of profile wire, flat wire or tubing.

Pretension on the spindle adjustment mechanism can be set to increase positioning accuracy. There are two holes in the slide to hold at least one roll shaft. The roll shafts and straightening rolls can be customized to meet customer needs. Series FT roll shafts, for example, can be a good choice if there is a need to quickly change straightening rolls without tools or to use long-wearing straightening rolls which feature a special design and materials such as ceramics or hard alloy.

Electrical subsystem. Conventional positioning systems consist of an industrial control unit, inverters and sensors which are embedded into hierarchical or distributed control systems.

Serial communication and power cabling is usually connected to the control unit using a star topology. These discrete designs require elaborate cabling design and significant implementation effort which can easily become quite costly.

An alternative electrical system, which contains nothing more than servo converters and a touch-screen HMI (human machine interface), has been developed for advanced straightening technology. A servo converter, which communicates with the higher-level HMI via the CAN data bus, is allocated to each module (see Fig. 4). Up to 32 modules can be run in a cluster, and energy management has been designed to support synchronous positioning of the rolls on all 32 modules.

The modular design and topology support genuine plug and play functionality. An actuator and servo converter can be swapped without any additional effort because all communication settings and initialization of new components are performed in the factory. The system can be regenerated by changing components without any loss of information.

No proximity switches or sensors are used to detect end of travel or for travel to the home position on advanced semiautomatic straightening equipment, because intelligent routines in the software sub-system reliably perform these functions. Elimination of the need for a higher level controller (e.g. a PLC or computer) helps keep the component count down.

The HMI, software and the servo converters provide an alternative solution.

Software subsystem. Software implemented on the HMI

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manages communications with the module inverter or the servo inverters if more than one module is used. The software subsystem contains all of the routines that are needed to support advanced semi-automatic straightening technology.

Following are the routines provided for a module (see Fig. 3):• parameterization (module specific zero line, wire diameter); calculate the wire-specific zero line; calculate the absolute roll position; move to home position without sensors or proximity switches; adjust in inching mode (teach-in); display set point data records; select, modify, save, delete or send set point data record (recipe management); adjust to set point defined in a data record; show actual adjustment position; adjustment limit; spindle play compensation; overload protection; status display; access management (password); change language; and help Fig. 5 shows the menu for a routine realizing a synchronous positioning of the straightening rolls (RECIPE). It uses socalled set point records or recipes. They contain the adjustment position ai and wire diameter d for every module. The user can select, create, edit or delete records on the HMI at any time.

Once a record has been selected, the next step is to send setup information ai, which is stored in the record, to the inverters.

This allows, for example, to adjust the zero line considering the actual wire diameter, a quick opening or an accurate roll adjustment in seconds.

The roll adjustments, which are needed to produce straight process material, are based on simulation of the straightening process6 which is run using SimDATA software9. SimDATA is a simple program which uses binary coded equipment libraries that contain information about the roll positions which are needed to achieve a defined finished product quality.

The availability of SimDATA fulfills another advanced production criterion, because setup data for the advanced semi-automatic straightening equipment is available before the process commences. A version of the software can be supplied which can for example be used to calculate setup data in ad-vance for production of process material with defined curvature.

Summary The power requirements for the process material deformation process are based on the working principle and the main characteristics of the straightening process. A simulation program, which uses a virtual model of the straightening process, is available to support the assessment of the power requirements. Simulation in turn is based on a theoretical model of alternate elastic/plastic deformation and the relationship between bending moment and curvature during bending operations. This article describes advanced semi-automatic straightening technology. The equipment consists of mechanical, electrical and software subsystems, and it meets advanced manufacturing process criteria. Advanced straightening technology features a modular design, minimal component count, a user-friendly HMI and the availability of process and setup data prior to the start of the process. The flexibility of the design and the ability to manipulate the number and spacing of the rolls, which are the main variables, produce a system which can be used to make customer specific products in small lot

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sizes. Users benefit from the strategic advantages of mass customization, which enables producers to supply ex-actly the product and quality which their customers are looking for.

Photo 1 shows the mechanical subsystem and one electrical subsystem component on the CS EASY 5-15.0 LE version.

References 1. H. Schneidereit and M. Schilling, “Straightening unit with electronic position control,” Wire, 47, 1997, 2, pp. 34-37.

2. R.T. Hübner, “Modern straightening machines,” Wire, 49, 1999, 6, pp. 18-19.

3. K. Linneweh, Mut zur Muße – Innovation als persönliche Herausforderung, www.linneweh.com, Vortrag vor der TÜV Rheinland Group, 2005.

4. M. Paech, “Roller straightening process and peripherals,” Wire, 51, 2001, 2, pp. 76-82.

5. J. Kahlert, “Fuzzy Control für Ingenieure,” Vieweg, Braunschweig/Wiesbaden, 1995.

6. W. Guericke, M. Paech and E. Albert, “Simulation of the wire straightening process,” Wire Industry, 8, 1996, pp. 613620.

7. J.B. Pine II, Mass Customization: The New Frontier in Business Competition, Boston, Havard Business School Press, 1993.

8. M. Paech, “Custom-tailored straighteners,” Wire, 52, 2002, 4, pp. 22-24.

9. M. Paech, “The Positioning of Straightening Rolls,” Wire, 52, 2002, 4, pp. 82-83 ■

Marcus Paech is technical managing director at Witels Apparate-Maschinen Albert GmbH, Berlin, Germany, a position he has held since 2002. Prior to that he was research and development manager at Witels-Albert. He previously was a member of the scientific staff in the Paech department of machinery and drive engineering at Ottovon-Guericke University of Magdeburg, Germany. He studied engineering at Ottovon-Guericke University of Magdeburg. This paper was presented at WAI’s 77th Annual Convention, Cleveland, Ohio, USA, May 2007.

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TECHNICAL PAPER Thermodynamic wire transformation process in the manufacture of steel tire cord A new approach, the Thermodynamic Wire Transformation (TWT) Process, has been found to better control the wire cooling process by altering the quenching method to produce wire that has a fine pearlitic microstructure and more desirable drawing properties.

By Thomas W. Tyl

Overview A newly developed quenching and soaking technique, Liquid Quenchant Fluidized Bed Technology (LQF), U.S. & PCT Patent Pending, uses the Thermodynamic Wire Transformation (TWT) process to precisely quench and soak steel during strand patenting. The TWT process allows for an infinite number of heat transfer coefficients by changing media composition depending upon thermodynamic wire requirements at any specific time. This process is motivated by the tire industry’s desire to decrease conversion costs by replacing low-strength, normal tensile (NT) and high tensile (HT) cable with higher strength cables like super tensile (ST), ultra tensile (UT)

Fig. 1. Controlled cooling, media temperature.

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and mega tensile (MT). Gains for tire manufacturers lie not only in higher-strength, lower-weight cord but reductions in the amount of rubber top-coat compound using ST, UT and MT tensile strengths that permit the production of smaller diameter cables.

Steel tire cord manufacturers with less advanced technology can produce normal, high and even some simple super tensile products using old patenting techniques. These sacrifice patented tensile strength, work hardening ability and ductility for patenting throughput using slow quenching rates and high soaking temperatures, resulting in large patented diameters. These patented large diameters may require 25 or more wet drawing dies, slower wet drawing

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speeds and an eventual chemistry limit for acceptable twisting performance. To remain competitive in emerging and future ST, UT and MT tire cord markets, shortcomings of molten lead and sand fluidized beds have been addressed by using the TWT Process’ innately efficient quenching to near the appropriate TTT curve nose and precise thermodynamic soaking by altering the quenchant chemistry. The resulting fine pearlitic microstructure with a lack of microconstituents at grain boundaries is desirable for drawing to high strength and true strains, while maintaining torsional stability and high fatigue properties.

History Strand annealing or patenting for the manufacture of steel tire cord consists of two steps: transformations for austenization and transformations for controlled cooling.

This paper will discuss details of controlled cooling to produce a microstructure suitable for subsequent drawing, namely a purely fine pearlitic microstructure without presence of upper bainite or “degenerative pearlite,” and a lack of proeutectoid microconstituents at grain boundaries.

Further, it will discuss controlled cooling for hypereutectoid steels where suppression of the proeutectoid cementite reaction is essential for control of draw ability, high strength, delamination free filament torsion and high filament and subsequent cable fatigue.

Although hypoeutectoid and eutectoid steels benefit from properly controlled cooling, controlled cooling for higher carbon and microalloyed steels is far more critical.

Austenization is governed by the difference in temperature of wire and furnace as well as convective and radiant heat transfer rates related to the furnace atmosphere, very different mechanisms of conventional and new controlled cooling technologies.

Cooling Theory After austenization, controlled cooling heat transfer rates are governed by Newton’s Law of Cooling (or Newton’s Law of Forced Convective Cooling): Q = A * h * ΔT where Q is the heat transfer rate to the surrounding media, A is the wire’s surface area, h is the forced convective heat transfer coefficient, and ΔT is the temperature difference between wire (Tw) and media (Tm). In the practice of reality, the only component that need be fixed in Newton’s equation is A, the wire’s surface area, although older technologies fix all components of the equation except Tw from the ΔT term.

Old technologies like molten lead and fluidized sand without a quenching section prior to soaking set the process so that when ΔT = 0 the wire and media will at some time in the soaking process equilibrate at the desired soaking temperature; the driving force for heat transfer terminates when wire and media temperature are equal and at the desired soaking temperature. Mathematically, the temperature of the wire and media never equilibrate, just as mathematically two trains heading toward each other on the same track never meet. Although this “fuzzy math” does not apply to reality it illustrates the fact that as the wire and media temperature become close together the rate of heat transfer, Q, declines sharply and linearly to near zero since the only variable in the described processes is Τw. See Fig. 1.

Even with the high heat-transfer rate of lead, promoted by lead’s relatively low vapor pressure, cooling rates to the preferred soaking temperature for these operations can be menacingly slow. Some more advanced air fluidized sand technologies employ a quenching section prior to the soak-

Fig. 2. Controlled cooling, two media temperatures.

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Fig. 3. Controlled cooling, two media temperatures exothermic reaction.

ing section where ΔT is purposely set to a large value to more quickly cool wire to the desired soaking temperature.

Although this common technique helps cool the wire more quickly there are issues with the technique that make it difficult to control and commonly introduce maintenance issues that can outweigh advantages of large differences in temperature. See Fig. 2.

The models used for Figs. 1 and 2 assume that the wire generates no heat, which is not realistic since the transformation from austenite to pearlite is exothermic and skewed parabolic under the previous limitations. This means that below about 725°C and after about 0.7 seconds for eutectoid steel quenched to the TTT “nose,” the wire gives off heat which changes the curve’s shape. A more realistic curve shape accounting for exothermic pearlite formation after the wire passes the TTT “nose” is shown in Fig. 3.

Accounting the initial rapid quench from the austenitizing

temperature of about 1010°C for a 1090 steel and the exothermic reaction related to transformation from unstable austenite at about 565°C to pearlite, it can be shown that the wire temperature and Newton’s Forced Convective Heat Transfer Rate both change during the exothermic reaction under the constraints of constant media temperature alone.

This means that the initial soaking temperature of 565°C can be obtained but that the constant media temperature causes wire temperature to increase significantly. This results in a coarsened pearlitic microstructure that is likely unsuitable for high drawing strains and filament strengths with reduced filament torsional stability and lower filament fatigue. See Fig. 4.

The TWT Process Simply stated, the Thermodynamic Wire Transformation (TWT) Process asserts that an alternative to constant media temperature that effectively controls Newton’s Forced

Fig. 4. Controlled cooling, two media temperatures exothermic reaction.

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Fig. 5. Grain boundary precipitation versus chemistry and temperature.

Convective Heat Transfer Rate “Q” during cooling is to manipulate the forced convective heat transfer coefficient “h” in Newton’s Law of Cooling: Q = A * h * ΔT. With Conventional Process Controls, “Tm” from ΔT = (Tw-Tm) can be controlled two different ways: it can be controlled to one value for liquid lead or air fluidized sand beds without a quench and controlled to two values for air fluidized sand beds with a quench. By contrast, with the TWT Process Controls, “h” is controllable to an infinite number of values at any point in the process.

Using modern quenchants, the initial rapid cooling rate from the austenitizing temperature to a temperature near the intended soaking temperature can easily be obtained.

The difference between austenitizing temperature and the A3 or Acm (or A1 in the very specific case of a eutectoid steel) temperature is about 255°C, but the exact required cooling rate is a function of chemistry as defined by the phase diagram.

This cooling rate must be kinetically sufficient to avoid precipitation of undesirable microconstituents at prior austenite grain boundaries while passing through the appropriate two-phase region on the Fe-Fe3C phase diagram: heat removed between the austenitizing temperature and A3 or Acm is “unimportant” as long as the amount of time to reach these temperatures is brief.

Consider the three cases for steel: Hypoeutectoid: two phase (A3 -> A1 on the phase diagram) ferrite plus austenite region.

Eutectoid: A1 single phase region.

Hypereutectoid: two phase (Acm -> A1 on the phase diagram) cementite plus austenite region.

• for a 1070 steel the A3 line is not crossed until about 735°C; • for a eutectoid steel the A1 line is crossed at about 725°C; • for a 1080 steel the A3 line is not crossed until about 730°C; and

Fig. 6. Pearlite transformation rates.

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• for a 1090 steel the Acm line is not crossed until about 755°C. The goal of the controlled cooling process while quenching through the appropriate two phase region is to consistently remove thermodynamic heat, leaving the wire at a desired temperature near the nose of the TTT curve in a severely unstable state without proeutectoid precipitates.

Jeopardy of grain boundary precipitation for these steels is avoided when crossing the A1 line which lies at about 725°C: unstable austenite is formed prior to transformation to one of the other phases (ferrite or cementite). So, for 1070 steel there is about a 10°C region of concern, for 1080 steel the region is about 5°C and for a 1090 steel it is about 30°C. The larger region of 30°C for 1090 steel is one reason that ST, UT and MT steels require a more aggressive quench, as illustrated in Fig. 5. A second reason is that the grain boundary precipitate is hard and brittle cementite which is much more damaging to material properties like drawability and filament strength, torsion and fatigue than grain boundary ferrite found in hypoeutectoid steels. See Fig. 5.

After crossing A1 and reaching the appropriate soaking temperature requirements of Newton’s Law of Forced Convective Cooling, “Q” changes dramatically as the exothermic heat of transformation replaces the amount of heat necessary to reach the desired soaking temperature from the austenization, A3 or Acm temperature. This heat can be estimated by estimating pearlitic transformation kinetics and applying thermodynamics to the results.

Using results from several austenite to pearlite transformation studies and normalizing them for time and temperature yields the results shown in Fig. 6: Considering the thermodynamics of the process of cooling from the austenitizing temperature and holding through completion of the pearlitic transformation temperature requires the use of Kirchhoff’s law:

Fig. 7. Estimated incremental energy transformation to pearlite.

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ΔCp is of the form: A + BT – CT-2 An example of this can be seen in that the following temperature ranges of interest (pure iron and Cementite): • Austenization temperature (1010°C for 1090 steel) • 910°C = Transformation from Δγ to α • 760°C = Curie Temperature • A3, Acm and A1 Temperatures • 565°C = Soaking Temperature In this example, ΔCp enthalpy changes for iron and cementite yield about 9228 cal/mole for the described conditions. ΔHt enthalpy transformation changes yield about 721 cal/mole for the described conditions. The ratio of ΔCp to ΔHt enthalpy changes is about 12.8. For typical 1090 steel tire cord using the ratio ΔCp/ΔHt of 12.8 leads to the following graph for the transformation of pearlite. See Fig. 7.

The area under the curve shown above is equal to ΔHt = 1, which shows graphically the energy of transformation of unstable austenite into fine pearlite suitable for steel tire cord. For typical 1090 steel tire cord using the ratio ΔCp/ΔHt of 12.8 leads to the following graph for cooling of stable austenite at 1010°C to unstable austenite at 565°C. See Fig. 8.

The area under the curve shown above is equal to

which shows graphically the energy required to cool stable austenite at 1010°C to unstable austenite at 565°C suitable for steel tire cord. Placing austenite cooling and pearlite transformation incremental energy on the same graph demonstrates the difference in magnitude of the two enthalpic reactions shown in Fig. 9.

The energy requirement can be shown with its relationship to patenting by superimposing the incremental energy

Fig. 8. Estimated incremental energy cooling of stable austenite to unstable austenite at 565°C.

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X 20 on a TTT curve for 1090 steel. See Fig. 10.

The difference in magnitude between the energy required to controllably cool austenite to unstable austenite at the desired transformation temperature has been shown to require dramatically different forced convective cooling rates. It has further been shown that during cooling from austenitizing temperatures to soaking temperatures requires critical control in the appropriate two phase region of the phase diagram, for the diagrams above between Acm and A1.

An improved result to conventional methods of patenting like liquid lead or air-fluidized sand with a quenching region, which control the media temperature, can be achieved by utilizing more than one forced convective heat transfer coefficient “h”: a high coefficient to quench from the Acm temperature and one or more very low coefficients to maintain wire temperature during exothermic transformation from unstable austenite to fine pearlite.

One process that utilizes different forced convective heat transfer coefficients is Bekaert’s “Near Water” steel patenting process (US Patent 6228188) that relies on a large “ΔT” and two disparate forced convective heat transfer coefficients, one a liquid close in temperature to boiling water and the other a gas close to still air. The patent claims that a vapor barrier forms between the hot wire and liquid quenchant during cooling from the austenitizing temperature or when the quenchant is used during the transformation process.

It is hypothesized that the barrier protects the wire from under cooling below the desired transformation temperature. According to the patent, at certain points after reaching the transformation temperature the wire is alternatively subjected to still air or additional liquid quenchant depending on the actual wire temperature. Although this process undoubtedly uses a more advanced quenchant, there appear to be similarities to this process and “liquid spray” processes abandoned in the 1960s.

Liquid Quenchant Fluidized Bed Technology (LQF – US & PCT Patent Pending) differs by allowing an infinite number of forced convective heat transfer coefficients “h” during the transformation process after reaching the desired transformation temperature and includes that of a liquid quenchant to cool wire from the austenitizing temperature to the desired transformation temperature. The forced convective heat transfer coefficient “h” is a function of many variables related to the quenchant like: chemistry, velocity, vapor pressure and viscosity. In the TWT Process “h” can be altered by dynamically changing the quenchant chemistry during the soaking process without affecting the quenchant either upstream or downstream of the dynamic change and without the possibility of quenchant contamination. While the TWT Process sounds difficult to control it is uncomplicated in practicality since it utilizes the proprietary RichardsApex, Incorporated quenchant, RAQTWT2, which uniquely extracts heat through combined phases built into the liquid’s chemistry.

Fig. 9. Estimated incremental energy austenite cooling and pearlite transformation at 565°C.

Fig. 10. 1090 steel TTT & relative forced convective heat transfer rate.

Summary The Thermodynamic Wire Transformation (TWT) Process applies the thermodynamics and kinetics of heat transfer during controlled vigorous cooling from the austenitizing temperature to the appropriate transformation temperature.

The TWT Process also utilizes an infinite choice of forced convective heat transfer coefficients, “h” in Newton’s Law of Convective Cooling, to help ensure that the wire remains at the appropriate temperature during the entire transformation. Some advantages of the TWT Process utilizing the Liquid Quenchant Fluidized Bed Technology (LQF – US & PCT Patent Pending) are: high control ability of exothermic transformation; very low energy consumption; no diameter concurrency limitations; no chemistry concurrency limitations; nontoxic; and low maintenance.

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Acknowledgments The author would like to thank RichardsApex, Incorporated of Philadelphia, Pennsylvania, USA, for leading the development of a quenchant suitable for the Thermodynamic Wire Transformation (TWT) Process and Thermcraft, Incorporated of Winston-Salem, North Carolina, USA, for technical support developing the technology for a bench scale model to develop the data to confirm and understand the Thermodynamics of Liquid Quenchant Fluidized Bed Technology (LQF).

References 1. T.W. Tyl, “Control of strengthening mechanisms in the manufacture of steel tire cord,” Wire Journal International, February 2006, pp. 122-128.

2. R.P. Schenk and T.W. Tyl, “Control of wet drawing lubricant in the manufacture of steel tire cord,” Wire Prague 2005, Czech Republic, October 2005.

3. T.W. Tyl, “Control of cable twist in the manufacture of steel tire cord,” Wire Journal International, October 2006, p. 88.

4. Thomas W. Tyl, “Liquid Quenchant Fluidized Bed Technology in the Manufacture of Steel Tire Cord,” WAI’s 2006 International Technical Conference, New Delhi, India.

5. S.E. Offerman et al., “In-situ study of pearlite nucleation and growth during isothermal austenite decomposition in nearly eutectoid steel,” Acta Materialia, 51-2003, 3927-3938.

6. “The Making Shaping and Treating of Steel” edited by Harold E. McGannon, United States Steel, 9th Edition, 1971.

7. T. Hamada et al., “Development of a numerical model for predicting the temperature of a steel wire threaded through a fluidized bed for patenting treatment,” Wire Journal International, June 2001, p. 74.

8. Mamora Murahashi, et al., “The influence of material and process factors on the drawability of mechanically descaled high carbon steel wire rod,” Wire Journal International, November 1993, p. 50.

9. Ikuo Ochiai et al., “Effects of metallurgical factors on strengthening of steel tire cord,” Wire Journal International, December 1993, p. 50.

10. Stanislav Antolin, private conversations, December 2006.

11. M. Zelin, “Microstructure Evolution in Pearlitic Steels During Wire Drawing,” Acta Materialia, 50-2002, 4431. ■

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Thomas W. Tyl is the principal of Tire Wire Technology (TWT), LLC, Siler City, North Carolina, USA. He retired from the Goodyear Tire & Rubber Company where he had worked for 15 years in steel reinforcement.

He holds a master’s degree in metallurgical engineering and Tyl materials science from Carnegie Mellon University, an M.B.A. degree in manufacturing management from the University of Pittsburgh and a B.S. degree in materials science from North Carolina State University. This paper was presented at WAI’s 77th Annual Convention, Cleveland, Ohio, USA, May 2007.

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PRODUCTS & MEDIA PRODUCTS Next-generation model can now measure XL-diameters as well Germany’s Sikora AG represented in the U.S. by Sikora International, reports that its well-known X-RAY 8000 system for measuring wall thickness, eccentricity and the diameter and ovality of high-voltage cables, has been further improved.

The X-RAY 8000, which had been optimized for profitability and technological progress to create the X-RAY 8000 NXT, provides optimum quality control for producing MV-, HV- and EHV-cables in CCV-,VCV- and MDCVlines, a press release said.

The newest model of the X-RAY 8000 NXT line utilizes the technological advantages of the X-RAY 8000 with regard to the practical application in the field of EHV-cable (Extra High-Voltage cable) production, the release said. “(This) ‘measuring giant’ is perfectly suitable for

extremely big cable diameters of up to 7.09 in. (180 mm) for CCV-lines and 8.66 in. (220 mm) for VCV-lines,” the release said, noting that the measuring system can provide the highest degree of accuracy and repeatability while demonstrating the flexibility and safety of the basic system.

The newest addition to the X-RAY 8000 NXT line requires only one scan to calculate all measuring values, meeting all requirements for rapid centering of the extrusion tools as well as optimum control of the production line, the release said.

Contact: Jeff Swinchatt, Sikora International, tel. 770486-1233, sales@sikora-usa.com.

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System excels at producing steel fiber Eurolls SpA, part of Italy’s Eurolls Group and represented in the U.S. by Cortinovis America LLC, notes that its IFO 60 system for producing steel fiber provides a high and continuous production of steel fiber that, with the appropriate tools, can be preset for the production of any type, shape and dimension.

The design enables the system to provide superior performance while maintaining the simplicity of operation, a press release said. One system innovation is tolerance range of the inlet wire material, which is so broad that it permits the transformation of wire that would be rejected from other processes into a final product that carries a high market value, it said.

Technical specifications are as follows: wire diameters, 0.6 - 1.2 mm; wire tolerances, ± 0.3 mm; max number of wires, 60; installed power, 24 Kw; working speed, 2 m/sec; production rates, 0.8 t/h – 3.3 t/h; working coil weight, per client’s specifications; working coil dimensions, per client’s specification.

Contact: Eurolls SpA, www.eurolls.com. Tony DeRosa, Cortinovis America LLC, tel. 908-479-9818, cortinovis@cortinovisamerica.com.

Welding head offers quick set-up times for reduced operation costs At wire Düsseldorf, Ideal/Clifford displayed its latest self-adjusting welding head, a technology advance that it said can reduce operation costs for mesh welders.

The QSEA mesh welders can drastically reduce setup times via the new welding head, a press release said. The technology excels at automatically positioning according to the operator program, drastically reducing setup times and making the system ideal for short volume runs, it said.

The QSEA welders are suitable for engineering mesh, reinforcing mesh and fencing mesh. The new head can weld up to .500 in. wire diameters and is infinitely variable from 2 in. line wire centers, it said. Each head has its own welding

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transformer, offering improved weld quality and control.

Contact: Scott Liebenberg, Ideal Welding Systems, tel.

815-874-4349, scott@idealweld.com, www.idealweld.com.

Insulation offers advantages for lowvoltage cable, offers quick set-up times At wire Düsseldorf, Austria-based Borealis AG introduced Visico FX, which the companty described as “a unique high-productivity, low-voltage cable insulation material that will help boost the competitiveness of cable manufacturers.”

The new Visico FX LE8823 grade delivers all-round advances in productivity and cost efficiency, resulting in higher output and increased profitability at the manufacturing stage and knock-on benefits for grid owners and installers, a press release said. It explained that Visico FX is an innovative base material for low-voltage, moisturecured XLPE cables, which enables faster production of high-quality cables. Its outstanding cross-linking speed is twice that of traditional Visico material and typically more than five times that of grafted XLPE materials, it said.

By removing bottlenecks from XLPE production, Visico FX shortens lead times, reduces manufacturing complexity and lowers the potential for handling-related errors, the release said. It delivers the environmental and cost-related benefits of reduced energy usage and minimized handling and production space requirements and improves productivity by delivering a consistent, high-quality product with less downtime required for cleaning, it said.

Contact: Borealis AG, tel. 43-1-22-400-302, www. borealisgroup.com.

Economical new cord line works as a replacement for Neoprene U.S.-based Autac Inc. reports that it has introduced a new line of retractable cords that represent a good alternative to using Neoprene.

The cords, which are UL listed and CSA certified, have Thermoplastic Rubber (TPR) waterproof jackets that offer high environmental performance, a press release said. The TPR cords, it said, are also oil, chemical, abrasion and UV resistant and RoHS compliant, and represent an economical replacement to Neoprene.

The cords, which come in stock lengths of 12 in., 24 in., 36 in. and 48 in., can extend to a 1:5 ratio if needed, the release said, adding that variations for

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special applications can also be designed and made to order. The company notes that it can manufacture custom cables to customer specs and can design and build “almost any type of cord that meets UL, CSA, RoHS and other industry standards.”

Contact: Autac Inc., tel. 203-481-3444, info@autacusa.com, www.autacusa.com.

Motorized pull tester can measure multiple products in different modes The PullTester 20 from U.S.-based Schleuniger, Inc., is a motorized, bench-top unit designed to measure pulltest forces in pounds, newtown or kiloponds for a variety of applications.

A press release said that the pull-test system is a low-cost device that is most commonly used for wire crimp and ultrasonic metal welding connections, although the design makes it possible to create cus-

tom fixtures for many others. Standards such as IEC and SAE, it said, specify that the device pulls at a consistent rate, and the Tester 20 comes with a speed-controlled motor, ensuring consistent pull rates throughout the measuring range which means repeatable and accurate data.

The model’s standard 12-position terminal holder can accommodate a wide variety of terminals to suit most applications, the release said. A variety of terminal holders are available upon request. The machine can test pull forces up to 110 lb (500 Newtons) and is specially suited for quality assurance in a production environment, it said.

Other features include a simple LCD-display for easy digital pull force read out, two selectable pulling rates and a RS 232 interface for curve analysis and export to Microsoft EXCEL software.

Contact: Schleuniger, Inc., tel. 603-668-8117, www.schleuniger-na.com

These tools are able to fashion wire for sweet music and more U.S.-based Xuron Corporation has introduced a new tool kit that features a cutter for hard music wire, a shear for guitar strings and electronics wire and a long-nose plier.

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A press release said that the kit is especially developed for musicians, but can be used for other purposes as well. The three tools, it said, are suited for use with virtually all types of acoustic and electric string instruments and power accessories. Included is the Model 2193 Hard Wire Shear for music wire up to 0.040” dia., Model 2175 Maxi-Shear™ Flush Cutter for soft wire up to 14 AWG, and the Model 485 Long Nose Plier for locating and holding.

Designed initially as ergonomic hand tools for industry, Xuron’s Music Trio of Tools all have Xuro-Rubber™ cushioned hand grips, a Light-Touch™ return spring, are made from a tough, alloyed steel, and have a non-glare black finish which is easy on the eyes and helps make the wires more visible, the release said.

Contact: Xuron Corporation, tel. 207-283-1401, sales@xuron.com, www.xuron.com.

WIRE & CABLE EXTRUSION

Increase Productivity!

Improve Throughput!

Optimize Product Quality!

When you need expert solutions for your Wire & Cable Extrusion Processes, you need Canterbury Engineering.

Canterbury’s vast design and manufacturing capabilities offer a complete line of custom designed Crossheads, In-line Heads, Screws, Barrels, Breaker Plates and more. Plus, Canterbury offers the best in Rebuilds, Relines, Repairs, and all OEM Replacements. For more information, contact Canterbury at 1-800-241-7650, or online at www.cec75.com

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Power bar strip is meant to be used in the most rugged of environments U.S.-based Coleman Cable, Inc., notes that its new Workshop Power Bar is a heavy-duty power strip designed to withstand the rigors of the workshop, garage or other rugged environments.

The Power Bar’s four-ft metal housing contains 12 outlets, purposely spaced apart to allow for larger adapter sized plugs for even the biggest projects, a press release said, noting that the outlet covers keep out dust and debris. The power strip has a 6-ft 14/3 gauge power cord, features a combination on/off circuit breaker switch for safety and comes with the necessary hardware for mounting, it said.

“The Power Bar makes it easier and safer to power tasks, no matter how rough the work environment,” said Cathy Schaufenbil, Coleman Cable market manager.

Contact: Coleman Cable, Inc., www.colemancable.com.

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Lubricant line with proprietary technology is designed for aluminum rod drawing, more U.S.-based Etna Products, Inc., has introduced a recently developed series of aluminum rod breakdown and wire drawing products in its MASTERDRAW® product line.

The 5100 Series Product includes: MASTERDRAW 5129, for slow to high speed breakdown and intermediate drawing; MASTERDRAW 5127, for high speed breakdown and Intermediate drawing; MASTERDRAW 5124, for fine wiredrawing; and MASTERDRAW 5122, for ultra-fine drawing and cabling.

The series employs a proprietary lubrication package that enable high quality drawing of even the most difficult of aluminum alloys over a wide range of diameters and speeds, a press release said. It noted that the series has a high viscosity index and shear stability properties from the series’ unique synthetic frictional that provide unparalleled lubrication throughout an extensive sump life.

Together, Etna’s new Masterdraw® aluminum wiredrawing series and Etna-Bechem Lubricants’ Unopol and Kubitrac brands offer nonferrous wire manufacturers the most robust lineup of breakdown and drawing lubricants available from one source, a press release said.

Contact: Etna Products, Inc., tel. 800-229-3862, etna@etna.com, www.etna.com.

Nylon slotted loom is good choice to help drain moisture from cable assemblies U.S.-based Del City reports that its new line of nylon slotted loom is designed to drain any excess moisture from cable assemblies.

The slit loom, a press release said, is perforated with small holes along the entire length to enable moisture to drain. It can be used for applications such as marine, construction, agricultural or other areas where high moisture is a concern. The product is available in IDs of .5 in., .750 in. and 1.0 in., and in a variety of lengths ranging from 50 ft to 8,500 ft, it said.

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The slotted loom, which is made from nylon material for high heat resistance, and has an operational temperature range of -40º to 300ºF (-40º to 149ºC), the release said. It also has a high ridge design for greater flexibility and slit separation avoidance, it said, adding that Del City “offers a variety of loom accessories, wire and tools to complement this new slotted loom.”

Contact: Del City, tel. 800-654-4757, www.delcity.net.

MEDIA Upgraded website highlights range of ferrous consulting firm’s capabilities U.S.-based Tire Wire Technology, LLC (TWT), which specializes in manufacturing technology for the steel tire cord and bead wire industries, has revised and streamlined its web site.

At www.tirewiretechnology.com, the company states, “Our goal is to help improve performance of your plant using common measurable metrics like output per dollar compensation (lbs/$Comp or kg/$Comp) or useable product per hour (lbs/hr or kg/hr).” Thomas Tyl, principal of TWT, notes that his consulting firm is the only one that works exclusively with Type-1 wire and equipment companies. TWT’s business plan includes introduction of at least one new technology per year and the company has applied for three wire-related patents in the past three years, he said.

The website, Tyl said, includes news about its ties with OEMs, development of its Liquid Quenchant Fluidized Bed technology and what it can do to further develop higher strength steel tire cord products for clients.

Contact: Tire Wire Technology, LLC, tel. 919-6633323, tom_tyl@yahoo.com, www.tirewiretechnology. com.

Website provides more solutions for cable wrapping tapes, components U.K.-based Scapa Cable Solutions recently launched its new Cable Solutions website to make it easier for companies to understand the range of its dedicated cable wrapping tapes and components for the cable industry.

The website, besides offering a new categorized product search facility, provides customers with more information on each company product as well as downloadable technical data sheets and up-to-date product literature, a press release said.

“As part of the Scapa Group with production sites all around the world, and approaching 90 years experience in this field, we have a wealth of technical and manufactur-

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ing knowledge to call upon in the area of cable wrapping tapes and components.

This means we offer the most extensive range available from one supplier.”

Contact: Scapa Cable Solutions, tel. 44-870-871-3131, sales@scapacable.com, www.scapacable.com.

Company launches customer-focused website with more practical details U.S.-based PolyOne Corporation has launched a revamped global web site that features advanced search capabilities, simplified navigation and access to the company’s complete library of polymer solutions literature and technical information.

Designed to serve customers and prospects, the content and layout of the new site is based on extensive research which benchmarked customer needs and expectations with web and industry best practices, a press release said.

Site users will find an easy to use search function that delivers well organized, categorized and targeted results along with quick links that direct visitors to data sheets and marketing literature, it said.

An early testimony to the effectiveness of polyone.com has come from Microsoft Corporation, which has featured the site in a case study of best practices.

“Customers … told us they wanted to be able to quickly find product and technical information and assistance. As a result, we feature this information prominently. We also simplified the navigation and incorporated a robust site search that delivers organized, targeted results,” said David Honeycutt, director of marketing and eBusiness, who led the redesign.

Contact: PolyOne Corporation, www.polyone.com. ■

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

days after receipt. 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 Wire Journal International 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.

DEADLINES: Copy is due a full month in advance, i.e., it must be received by March 1 for publication in the April issue. Classifieds booked on-line, run for at least one-month on-line, from the date of booking. Wire Journal International “Print classifieds” booked on-line as an “add-on” to an “online classified” booking will run in the next available issue of the WJI.

BLIND BOX INFO: Blind box numbers assure the confidentiality of the advertiser in both the WJI and the on-line publication. Responses are mailed out within two business

PAYMENT POLICY: All ads must be pre-paid.

CAREER OPPORTUNITIES

required. Please send resume to sales@abcwire.com.

SALES AGENTS. Midwest Wire & Cable manufacturer is seeking for commission-based agents. Previous experience in insulated and bare copper

REGIONAL SALES PERSON. Sumiden Wire Products Corp (est 1979) is a leading manufacturer of

seven wire prestressing steel strand with a well established customer base.

We are seeking to hire a regional sales person to cover the Western U.S. market. The person will be responsible for maintaining existing accounts and

COMMISSION BROKERS, INC. EQUIPMENT SPECIALISTS TO THE ELECTRICAL WIRE & CABLE INDUSTRY APPRAISERS • COMMISSION BROKERS • INDIVIDUAL PIECES OR ENTIRE PLANTS

FOR SALE 1 - WMCA 37-Wire, 6+12+18, 16” Planetary Line 1 - NEW ENGLAND BUTT 12-Head 16” Planetary Cabler 1 - WATSON 6-Head 16” Planetary Cabler 1 - WATSON 36” Rotating Cabler Line 1 - NORTHAMPTON ST1000 Cabler, 1999 1 - NIEHOFF M15 Wire Drawer, Annealer, SG45 Spooler 1 - D/S 4.5” 24:1 L/D Extrusion Line 1 - D/S 2.5” 24:1 L/D Nylon Extruder 1 - D/S 2” 30:1 L/D Hi-Temp Extrusion Line 1 - D/S 1.25” 30:1 L/D Hi-Temp Extruder 1 - D/S 2” 24:1 L/D Extruder 4 - DAVIS STANDARD, ENTWISTLE 50” Shaftless Payoffs 1 - DAVIS ELECTRIC 36” Shaftless, Model POS18-36 1 - TULSA 30” Payoff, Model PSPO-1, 1000lb cap, 8/90

1 - 30” Core Neutralizer Payoff 1 - NEB 61-Wire 22” Rigid Strander Line 1 - D/S 36” H.S. Dual Reel Take-up, twin Motors 1 - ENTWISTLE 36” Dual Reel Take-up, Model THE 24/36 4 - D/S 30” Dual Reel Take-ups 1 - DAVIS ELECTRIC Model TAP30 Parallel Axis Dual Take-up 7 - CLIPPER Model SP16 Dual Spoolers 2 - BARTELL 72” Shaftless Take-ups 1 - DAVIS ELECTRIC 36” Shaftless, Model TUS36 3 - TULSA/KENRAKE Model WTR-656 Respoolers 1 - ADVANTAGE Chiller, Model MK-25AM41HBX, 9/98 1 - IMAJE Model Jaime 1000 S4 Ink Jet Printer, 10/96 41 - 48” x 32-1/4” ID x 25” Barrel x 3” Arbor Toroidal Reels

Contact: Martin Kenner

COMMISSION BROKERS, INC. P.O. Box 8456 • Cranston, RI 02920-0456 • Tel. (401) 943-3777 • Fax: (401) 943-3670 WEB: www.commissionbrokers.com • E-MAIL: marty137@aol.com

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CLASSIFIEDS

WIRE JOURNAL INTERNATIONAL CLASSIFIED AD INFORMATION NAME _________________________________________________________________________TITLE _________________________________________________ COMPANY ____________________________________________________________________________________________________________________________ ADDRESS ___________________________________________________________________________________________________________________________ CITY ________________________________________STATE _______________POSTAL CODE _____________________COUNTRY _______________________ PHONE ______________________________FAX________________________________EMAIL _______________________________________________________ AD CATEGORY____________ ISSUE YOUR AD BEGINS___________E-mail Please e-mail the requested information to: WAI’s Cindy Kirmss at ckirmss@wirenet.org.

For more details, you can call her at 203-453-2777, ext. 116.

NUMBER OF ISSUES RUN _______LAST ISSUE ________________RUN TILL FURTHER NOTICE? YES____ NO ____ FULL RUN (WJI & ON-LINE) YES____ NO ____

BLIND BOX? YES____ NO ____

WAI MEMBER? YES____ NO ____ WAI MEMBERSHIP # ______________________ (Applies only to “Position Wanted”)

developing new sales opportunities.

50% travel will be required. Please e-mail jfeitler@sumidenwire.com.

PERSONNEL SERVICES “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 thousands of key individual contributors, managers and executives. For corporations we provide recruitment, outplacement, and salary assessment functions. For the professional exploring a new opportunity, we provide career evaluation and guidance. Our services are performed in absolute confidence.

E-mail Peter Carino or Jack Cutler pcarino@wireresources.com or

jcutler@wireresources.com www.wireresources.com.

EQUIPMENT

Wire Resources, Inc., 522 E. Putnam Ave, Greenwich, CT 06830, 203-6223000 or 800-394-WIRE.

BEST WARRANTY-LOWEST PRICES on high quality Rolling Ring Traverses. YR Products phone/fax: 708672-5007 or e-mail kamoline@ comcast.net.

DIES

WWW.URBANOASSOCIATES. COM. For New & Used Wire & Cable Equipment. Tel. 727-863-4700; fax 727-863-4711; or by e-mail at urbassoc@verizon.net.

MOLONEY DIE COMPANY. Low prices on all sizes of new, used and recut carbide dies. We also recut tapered nibs. Fast turn-around. Quality service since 1985. Tel. 904-388-3654.

CAST MACHINE PARTS. Specializing in Arbor Dies. Dutile iron & Bronze. Excellent price, delivery & Engineering help. JESTREITMAN LLC. Phone & Fax 704-882-2167.

E-mail-jes1930@aol.com.

APOLLO DIA-CARB COMPANY. Buy & sell new/used Natural & PCD DIAMOND DIES. Fair prices & excellent lead times. Contact Paulette, Owner-Sales, by telephone at 1-508226-1508 or by e-mail at apollodie@wmconnect.com.

WIRE JOURNAL

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AUGUST 2008: WIRE EXPO WRAPUP & ITC 08 PREVIEW It’s show time and the perfect time to tell the industy about your products and services with a display ad in the August issue of Wire Journal International where we’ll put the finishing touches on Wire Expo and preview WAI’s International Technical Conference in M

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Call WJI’s Bob Xeller or Anna Bzowski today to get your message in the limelight. Tel.: 001-203-453-2777 | E-mail: bxeller@wirenet.org or abzowski@wirenet.org

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MEDIA FERROUS WIRE HANDBOOK. The most recent in a series of handbooks published by WAI, this comprehensive hard-cover book is a new, definitive industry resource for ferrous wire written by members of the Association and edited by former WAI President Robert M. Shemenski. It is a modern-day reference tool for those working directly in the steel wire or manufacturing, engineering, or operations sectors of the industry. At 1,168 pages, the publication’s comprehensive 36 chapters cover a broad range of topics including many of the equipment types, processes, and specialty applications of steel wire manufacturing. The book begins with a history of the steel industry and includes the evolution of ferrous steel manufacture, appendices and a complete index. List Price is $235, $195 for WAI members. To purchase, go to wirenet.org and click on The WAI Bookstore.

WIRE BREAKS, by Horace Pops and Julie Steininger, 2003, 49 pages.

Breakage of copper, steel, or aluminum wire is one of the most common and costly problems facing the wire industry today. To help minimize the number of breaks, drawing personnel must first be able to recognize and identify the type and cause of material failure. With this need in mind, the following reference manual was prepared. It contains

pictures of the most frequent examples of broken wires found in the wire mill and at the customer’s facility. Although some of these photographs were taken at high magnification with a scanning electron microscope, adequate visual examination of the broken ends can be made in the plant using either a magnifying glass or a low power stereomicroscope. In addition, many pictures of cross-sections are included that were obtained in the laboratory using metallographic techniques The photomicrographs do provide useful supplemental information that helps to confirm and explain the nature of the wire breaks.

List Price: $15, WAI Member Price: $10. To purchase, go to wirenet.org and click on The WAI Bookstore.

ELECTRICAL WIRE HANDBOOK. Focusing on the special needs of the insulated wire and cable industry, this three soft-cover book set examines materials, equipment and products.

They include sections on electrical conductors, insulating materials, extrusion equipment, power transmission, building wire, flexible cords and cables, control and signal cables, communication cables, magnet wire, heater wire and more. Part 1 is Wire and Cable Production Materials, Part 2 is Wire and Cable Production Processes and Part 3 is Types of Cables. The new format allows for more frequent future updates when necessary. Parts 1 and 2 are now available, but the original handbook

will still be available until Part 3 is published separately. The handbooks, produced by the WAI’s Electrical Management Committee, are a valuable reference tool for members of the industry to help keep up with today’s rapidly changing technology. List Price: $99, WAI Member Price: $59.

To purchase, go to wirenet.org and click on The WAI Bookstore.

INTRODUCTION TO EXTRUSION SET (DVD). This video series (total running time of 1 hr., 45 min.) by extrusion expert Tom Black includes Part 1, Materials & Equipment (50 min.), and Part 2, Extrusion Processing (55 min). List Price: $425, WAI Member Price: $325. To purchase, go to wirenet.org and click on The WAI Bookstore. ■

Serving the non-ferrous and ferrous industries since 1983

JULY 2008 | 95

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ADVERTISERS’ INDEX

ADVERTISERS’ INDEX ADVERTISER . . . . . . . . . . . . . .PAGE

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

AIM Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Eurolls Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 4

AXIS Computer Systems Inc . . . . . . . . . . . . . . . . . . . . . . .52

George Evans Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

Anbao Wire & Mesh Co Ltd . . . . . . . . . . . . . . . . . . . . . . . .43

FMS USA Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Bergandi Machinery Co . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Fine International Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

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

Fort Wayne Wire Die Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Bongard Trading GmbH & Co KG . . . . . . . . . . . . . . . . . . .29

Mario Frigerio SpA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Caballe SA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

GCR Eurodraw SpA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Canterbury Eng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

Genca . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Carris Reels Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

W Gillies Technologies LLC . . . . . . . . . . . . . . . . . . . . . . . .66

Cemanco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Gimax Srl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-18

CM Furnaces Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Howar Equipment Inc/GMP Slovakia . . . . . . . . . . . . . . . . .10

Commission Brokers Inc . . . . . . . . . . . . . . . . . . . . . . . . . .93

Howar Equipment Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Davis-Standard LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Huestis Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Domeks Makine Ltd Sti . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

International Fastener Machinery & Suppliers Association . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Durant Tool Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Eurolls Group/Cortinovis Machinery America . . . . . . . . .15

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

NORTH AMERICA

EUROPE

Robert J. Xeller Anna Bzowski Wire Journal International 1570 Boston Post Road P.O. Box 578 Guilford, CT 06437-0578 USA Tel: 203-453-2777 Fax: 203-453-8384 sales@wirenet.org

U.K., France, Spain, Holland, Belgium, Denmark & Scandinavia Jennie Franks David Franks & Co. 63 St. Andrew’s Road Cambridge CB4 1DH, England Tel/Fax: 44-1223-360472 franksco@btopenworld.com

96 | WIRE JOURNAL INTERNATIONAL

Joe Tools Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

SALES OFFICES ASIA/WAI INDIA OFFICE Germany, Austria, & Switzerland Dagmar Melcher Media Service International P.O. Box 103 D-82402 Seeshaupt Germany Tel: 49-8801-914682 Fax: 49-8801-914683 dmelcher@t-online.de

Anand Bhagwat Wire & Cable Services Pvt. Ltd. (WCS) Mobile 91-98-508-38467 abhagwat@wirenet.org

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

Kinrei of America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Properzi International Inc . . . . . . . . . . . . . . . . . . . . . . .56-57

Lesmo Machinery America Inc . . . . . . . . . . . . . . . . . .31, 87

PS Costruzioni . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Locton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Queins & Co GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Maillefer SA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Reel-O-Matic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44, 49

Mathiasen Machinery Inc . . . . . . . . . . . . . . . . . . . . . . . . . .95

Rockford Manufacturing Group FELM . . . . . . . . . . . . . . .55

Micro Products Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Rosendahl Maschinen GmbH . . . . . . . . . . . . . . . . . . . . . .53

Niehoff GmbH & Co KG . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

SAMP USA Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Numamerica/Numalliance . . . . . . . . . . . . . . . . . . . . . . . . .26

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

Paramount Die Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Schlatter Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Pittsfield Plastics Eng Inc . . . . . . . . . . . . . . . . . . . . . . . . .20

Sikora International Corp . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Power Sonics LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

Sjogren Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Pressure Welding Machines Ltd . . . . . . . . . . . . . . . . . . . .59

Skaltek AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 2

RECENT PURCHASES EXRL35 (2)4 1/2” D.STD Therm III 20:1 Rubber Ext w/Rollerfeed, water cooled, 150 HP Drive, (1989) EXRL36 3 1/2” D.STD Therm III 20:1 Rubber Ext w/Rollerfeed, water cooled, 100 HP Drive, (1999) EXRL34 2 1/2” D.STD Therm II 15:1 CV Line w/D.STD. DR-30 Dual Take up, (2) 24” BW Capstans, autoclave, 3 yr old drives.

EXP858/859 (2) 4 1/2” D.STD. Therm III. 24:1, EXP834/835 (2) 2” D.STD. 24:1. EXP864/864 (2) 3” D.STD. 24:1.

EXP853 6” D.STD. 24:1 Therm III w/250 HP DC motor, panel.

CBR977 ENTWISTLE COOK SC-48 S.T. Cabler (1983).

CBR980 (2) 760mm LESMO D.T. Buncher, DTO-760MB (1998).

CBR981 760mm SAMP D.T. Buncher, BM-760D. (1995) CBR965 - 50 Pair 500mm CABALLE Group Twinning Line Yr. 1992, w/ 84” rot. take up 5 head OSC/binder.

CBR967 - 52 PAIR 500mm CEECO Group Twinning Line, Yr. 1992, w/1.6m Pourtier rot. take up, 7 head OSC/binder, (2) SZ OSCbinder, (2) 1.6m Ceeco portal trav. T/U. CBR968 - 84” CEECO Cabling Line w/(29) 64” S/L payoffs, (2) conc binders.

CBR966 - 50 Pair 500mm POURTIER Line with 1.6m Pourtier rotating take up, 10 head osc/binder. O.A. binder.

CBR949 - NEXTROM 18 Bobbin (6+6+6) Ribbon Strander, 450mm bobbins CBR927 - (10) 560mm WATSON/KINREI D.T. Twinners, 20” Dual Driven payoffs, 1998.

CBR923 - 1250mm POURTIER Drum Twister, 12-630mm Neutralizing Payoffs, Rotating Caterpuller, 1.25m Rotating Payoff.

CBR948 - 48” TEC Drum Twister w/(2) Conc. Tapers.

CAT420 BARTELL 48” belt caterpuller.

TKU1068 CLIPPER PA-16 Dual Parallel S/T Take up.

TKU1060 D.STD. DR-30 dual Take up w/AC Vector drive, mot.

Traverse.

TKU1061 (2) 60” BARTELL S/T take ups.

TKU1062 AFA 84” take up.

TKU1050 30” D.E. TAP-30 Dual take up w/ controls.

TKU1043 36” CLIPPER Dual Reel Take up, PS-36 Recently rebuilt.

PAY1420 HALL 72” driven S/L payoff.

RWD360 CLIPPER SP-18 Dual Rewinder RWD445 CLIPPER SP-16.Dual shaft rewinder, NOKIA DUAL TAKEUPS - (2) EKP-5 2001, EKP-50 1998, EKP-100 1995.

WRD835 ENDEX 18” Drop Coiler with Turntable.

WRD837 (4) NIEHOFF M30 Intermediate Wire Drawing w/VG_30 annealer, 75 kw DC motor, controls.

BIN131 (2) CABALLE 18 Position Kevlar servers, RKCR-250-18, 250 RPM, Year 2000, Siemens S7/300 PLC. LATE MODEL HIGH QUALITY (BRAND NAME US & EUROPEAN) WIRE, CABLE & OPTICAL CABLE MANUFACTURING MACHINERY EX-STOCK FROM (6) USA WAREHOUSES

JULY 2008 | 97

ADVERTISERS’ INDEX

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SOMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Wire Lab Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Sweed Machinery Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Woodburn Diamond Die Inc . . . . . . . . . . . . . . . . . . . . . . . .65

TAK Enterprises Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

Wyrepak Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Talladega Machinery & Supply . . . . . . . . . . . . . . . . . . . . .24

Zumbach Electronics Corp . . . . . . . . . . . . . . . . . . . .Cover 3

Tubular Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

US Synthetic Wire Die . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

WIRE ASSOCIATION INTERNATIONAL ADS

Ultimation Machines Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Ferrous Wire Handbook . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Wafios Machinery Corp . . . . . . . . . . . . . . . . . . . . . . . . . . .98

WAI Membership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39-40

Wire & Plastic Machinery Corp . . . . . . . . . . . . . . . . . . . . .97

WAI 2008 ITC: Monterrey, Mexico . . . . . . . . . . . . . . . . . . .54

Tulsa Power LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

98 | WIRE JOURNAL INTERNATIONAL

connexia

Impossible is nothing STEEL FIBER PRODUCTION MACHINE The machine guarantees a high and continuous production of steel fiber and, with the appropriate tools, can be preset for the production of any type, shape and dimension.

The particularity of this machine is the introduction of a new concept that combines the simplicity of operation with high performance and production.

Another essential innovation is the tolerance range of the inlet wire material: it is so broad that it permits the transformation of the wire, rejected from other processes, into the final product with high market value.

EUROLLS S.p.A. - via Malignani, 14 - 33040 Attimis (UD) ITALY Phone: +39 0432 796511 - Fax +39 0432 796501 - www.eurolls.com The Eurolls Group Companies are exclusively represented in North America by: Cortinovis America, Inc. - 1014A Route 173 Bloomsbury New Jersey 08804 Phone: 908-236-0400 - e-mail: cortinovis@cortinovisamerica.com - www.cortinovisamerica.com