How to Set and Rejust Enameling Dies
The main advantages of enameling dies are:
1. Adapt to enameled wire paint with high viscosity and high solid content, thereby saving solvent, reducing cost, and also helping to reduce environmental pollution;
2. The enameling dies can be reused, which reduces the cost;
3. In the case of reasonable mold matching, the mold method is more favorable than the felt method to make the coating uniform, and it is not easy to produce the eccentricity of the paint film, so as to ensure the stability of the enameled wire product quality.
1. Adapt to enameled wire paint with high viscosity and high solid content, thereby saving solvent, reducing cost, and also helping to reduce environmental pollution;
2. The enameling dies can be reused, which reduces the cost;
3. In the case of reasonable mold matching, the mold method is more favorable than the felt method to make the coating uniform, and it is not easy to produce the eccentricity of the paint film, so as to ensure the stability of the enameled wire product quality.
Enameling dies: It is a special process for enameling wire, which is used to control the amount of paint and finally ensure that the finished enameled wire reaches the specified paint film thickness. The mold for round wire enameling generally consists of two parts, the mold core, and the mold case. The entire mold should be made of materials that will not cause changes in the quality of the enameled wire paint and will not be corroded by solvents in various paints. The mold core must be tightly embedded in the mold sleeve so as not to fall off. When painting by the mold method, the coating thickness of each pass is determined by the core diameter of the mold in this pass. Therefore, the diameter of the core bearing area must reach the specified dimensional accuracy. At present, the commonly used enameled round wire painting molds include horizontal enameling machine enameling dies and vertical enameling machine enameling guide molds.
There are many aspects in the enameling process technology of the mold method, and the key link is mold matching, that is, to determine the mold aperture sequence used for each specific specification of the enamel. Die arrangement generally considers the following factors:
1. The solid content and viscosity of the enamel used;
2. The expected coating thickness and surface quality of the finished wire;
3. Comprehensive performance and special performance requirements to be met;
4. Pass the limit of enameling equipment.
The first coat of enamel should not be too thin or too thick. If it is too thin, it may cause oxidation of the bare wire. If it is too thick, it will affect the adhesion of the finished enameled wire coating film due to insufficient curing. The hole diameter of the second pass and subsequent passes is generally increased by 0.005mm in sequence. In order to ensure the uniformity and sufficient curing of the coating, under the conditions allowed by the equipment pass, the adjacent pass One or two passes use a die with the same aperture. When arranging the molds, the furnace temperature and line speed must be considered to avoid adverse effects on the curing of the coating or the surface condition of the finished enameled wire. Whether it is a horizontal enameling machine or a vertical enameling machine, the mold enameling must match the most suitable number of passes. Too few coats will inevitably make each coat too thick, resulting in too much curing of the enameling film and easy to produce eccentricity. Although the number of passes is beneficial to the curing of the enameling film, reducing the eccentricity and improving the surface condition, it will cause the wire to be thinned, which will increase the resistance and rebound angle of the enameled wire. The matching of molds needs to be formulated according to the situation of different models. For example, the enameling dies of the Mozart high-speed type horizontal enameling machine are generally arranged in 11-21 channels, and the vertical enameling machine enameling guides are generally arranged in 17-19 channels. It should be emphasized that, in order to ensure the stability of the quality of enameled wire products, the enameling system should be adjusted and cleaned before enameling. The parts of the enameled wire are in a straight line so that the enameling wire can be freely centered by the mold moving within a certain range to ensure the concentricity and adhesion of the enameling film of the enameled wire.
The solution to the situation where the quality of the enameled wire is affected by the factors of the enameling dies:
1. The outer diameter is too large or too small. This is mainly due to the fact that the enameling dies arrangement is too large or too small. The solution is to check the mold arrangement and adjust the mold arrangement process.
2. Disconnect. The reasons are that the mold arrangement is wrong, and the mold aperture is worn and scratched. The solution is to check the mold arrangement, check the inner hole of the mold, and replace the damaged mold.
3. Appearance quality problems such as rough surface, coke grains and bright spots. The main reasons are the wear and scratch of the mold aperture, the enameling leakage of the enameling dies, the dirt in the mold, and the rough inner hole of the mold. The solution is to check the enameling status, adjust the mold arrangement for poor baking, replace the leaking enameling dies, wear the mold, and clean the dirt in the mold.
There are many aspects in the enameling process technology of the mold method, and the key link is mold matching, that is, to determine the mold aperture sequence used for each specific specification of the enamel. Die arrangement generally considers the following factors:
1. The solid content and viscosity of the enamel used;
2. The expected coating thickness and surface quality of the finished wire;
3. Comprehensive performance and special performance requirements to be met;
4. Pass the limit of enameling equipment.
The first coat of enamel should not be too thin or too thick. If it is too thin, it may cause oxidation of the bare wire. If it is too thick, it will affect the adhesion of the finished enameled wire coating film due to insufficient curing. The hole diameter of the second pass and subsequent passes is generally increased by 0.005mm in sequence. In order to ensure the uniformity and sufficient curing of the coating, under the conditions allowed by the equipment pass, the adjacent pass One or two passes use a die with the same aperture. When arranging the molds, the furnace temperature and line speed must be considered to avoid adverse effects on the curing of the coating or the surface condition of the finished enameled wire. Whether it is a horizontal enameling machine or a vertical enameling machine, the mold enameling must match the most suitable number of passes. Too few coats will inevitably make each coat too thick, resulting in too much curing of the enameling film and easy to produce eccentricity. Although the number of passes is beneficial to the curing of the enameling film, reducing the eccentricity and improving the surface condition, it will cause the wire to be thinned, which will increase the resistance and rebound angle of the enameled wire. The matching of molds needs to be formulated according to the situation of different models. For example, the enameling dies of the Mozart high-speed type horizontal enameling machine are generally arranged in 11-21 channels, and the vertical enameling machine enameling guides are generally arranged in 17-19 channels. It should be emphasized that, in order to ensure the stability of the quality of enameled wire products, the enameling system should be adjusted and cleaned before enameling. The parts of the enameled wire are in a straight line so that the enameling wire can be freely centered by the mold moving within a certain range to ensure the concentricity and adhesion of the enameling film of the enameled wire.
The solution to the situation where the quality of the enameled wire is affected by the factors of the enameling dies:
1. The outer diameter is too large or too small. This is mainly due to the fact that the enameling dies arrangement is too large or too small. The solution is to check the mold arrangement and adjust the mold arrangement process.
2. Disconnect. The reasons are that the mold arrangement is wrong, and the mold aperture is worn and scratched. The solution is to check the mold arrangement, check the inner hole of the mold, and replace the damaged mold.
3. Appearance quality problems such as rough surface, coke grains and bright spots. The main reasons are the wear and scratch of the mold aperture, the enameling leakage of the enameling dies, the dirt in the mold, and the rough inner hole of the mold. The solution is to check the enameling status, adjust the mold arrangement for poor baking, replace the leaking enameling dies, wear the mold, and clean the dirt in the mold.
