Wire flattening Plants
The high precision wire flattening mill is shown
here is used for rolling fine wire into flats &
shapes as desired. The mill consists of pay-off
unit, capstan, and two sets of tungsten roll
assembly, two mills stands, rewinder &
PAY-OFF: Motor driven pay-off with state of the
art drive to precisely control the back tension.
This variable tension controller is used to
increase or decrease the back tension depending
upon the inlet size of the wire. The die box &
capstan is provided to achieve exact inlet
diameter. Straighter or stress killing unit is
provided prior to the inlet to first mill. The
capstan is master drive, which is synchronized
with both the mills drive thru. PLC based
system. The precise tension & look are
maintained by the sets of dancer provided
between capstans & of course mill & between 1st
& the 2nd mill. The capstan & all the dancer
pulleys are with ceramic ring to achieve best of
the surface finish. The mills have same drive
unit i.e. of Capstan. The helical gearbox in the
mills ensures high torque. The construction of
mills is highly rigid & compact, which ensures
vibration free operations, culminating into high
dimensional accuracy in product being produced.
The rolls are made of tungsten carbide sleeves
having hardness of about 70 HRC, ground & lapped
to very high precision. The screw down mechanism
is provided with state of the art specially
designed gearbox driven by high torque step
synchronous motor. This facilitates the
displacement of torque rolls as low as 0.1
The pass line of the material produced is fixed
& mill can be moved across. The wire is guided
thru. specially designed tungsten carbide guide.
The coolants sprayed at roll bite using American
make nozzle & spraying system. The chiller unit
is provided to maintain the coolant temperature
at 20º C at the time during operations.
Since the path of the wire is fixed, the spool
moves on transversing shaft of 36mm diameter.
This state of the art ball screw provided to
facilitate backlash free traverse of the spool.
The traverse motion is synchronized with
rotational movement. The pitch can be adjusted
from 0 to 5 mm as desired. The rewinder unit is
driven with variable tensions of control drives.
The whole electrical system is PLC based. All
the variables frequency tension drives are
synchronized. Dual operating system is provided.
The mill can be also operated thru. touch
We have recently supplied this mill to M/s. Ruby
Mica Co. Pvt. Ltd. M/s. Ruby Mica Co. Pvt. Ltd.
is engaged in production of Nichrome ribbon. The
ribbon was rolled with very close tolerance. The
tolerance achieved was thickness ± 2 micron &
width ± 10 micron.