Wire straighteners are also known as the wire straightening machines. As the name has suggested, this type of machine is used to make a wire straight. The straight wires are the fundamental components in manufacturing a number of products such as welding electrode, weld mesh, heat treated appliances, automobile spark plugs, exhaust valves and more. The wires need to be cut into specific required length and therefore the straightening of the wires is needed so that the precise length of wires can be guaranteed. The wire straightening machines can be automated machines that are controlled by a computer or they can be the manual wire straighteners that are operated by mechanists.
The manual wire straighteners are the manually operated wire straightening machines. The overall components that make a manual wire straightener are similar to those of a wire bending machine. They both have a set of roller dies and a wheel to drive the rollers rotating. Yet, the layout of the roller dies determines whether the wires are going to be bent or straightened. On a manual wire straightener, a crank is attached to the main driving wheel. The wires are forced through a set of roller dies as an operator turns the driving wheel. After the wires pass through the rollers, they are straightened. The manual wire straighteners are also called manual spiral machines.
Generally speaking, a manual wire straightener primarily contains a couple sets of roller dies. These roller dies are laid out in two rolls which set them into two groups: the top rollers and the bottom rollers. The top and bottom rollers are closely spaced in a series for the wire to pass through. The machine comes with a set of smaller rollers when the wire first enters the machine. These rollers make sure the wire is properly positioned before it passes the main driving roller.
The driving rollers are often significantly larger than other roller dies on a manual wire straightener. They connect to a crank which is turned by the operator of the machine. The driving rollers, or driving wheels, serve as the main driving force of the machine rather than the parts that are responsible for straightening the wire.
The wire is forced to the straightening roller dies by the driving rollers. The straightening rollers are a set of top roller dies and bottom roller dies. They are disposed of linearly in two rolls. As the wire goes through the roller dies, the rollers rotate and bend the wire. A wire straightening process is in fact a bending process which bends the wire in different sections at different angles so that it finally becomes straight.
A manual wire straightener is often incorporated with a wire cutter at the end of the process. For a wire straightening machine that processes a full-length wire, the wire cutting machine is a necessary component which is used to dissect the long wire into shorter wires in desired length. The wire cutter can be a mechanical press with cutting dies or an automated cutting machine which is hydraulically or pneumatically powered. After the wire is cut into shorter pieces, they can be used in the manufacturing of the end products.
To begin with, the wire to be straightened mostly comes from a wire coil. In a manual wire straightening process, the wire is uncoiled by the operator and fed into the pre-straightening roller dies manually by the operator too. As the wire passes through the driving rollers and enters the straightening unit. The internal stress in the wire is stabilized by bending it into plastic deformation. The displacement and rotation are the causes that result in the wire’s high degree of straightness.
During this process, the deformation, rotation and bending level are controlled by the straightening roller dies. The key to the high degree straightness is the even amount of rotation and bending on the surface of each and every section of the wire. A wire straightening machine is able to process wires with different diameters, strength, surface finish or of different materials by simply adjusting the settings of the machine or changing the roller dies.
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