Wire Manufacturing Process

Wire Drawing Process

The initial step in wire manufacturing is wire drawing. Copper rods, which are initially supplied in thick forms, need to be reduced to the desired thickness for flexible wire production. This is accomplished by drawing the rods through a series of progressively smaller dies, gradually reducing the rod's diameter until it reaches the required size. Once the wire has been drawn to the appropriate thickness, it undergoes further refinement.

Wire Bunching Process

Following the drawing process, the next step is wire bunching. During this stage, multiple copper wires are twisted together to form a cable. The number of individual wires that are combined determines the nominal cross-sectional area of the final cable. Bunching smaller, thinner wires together offers greater flexibility compared to using a solid wire of the same size, making it ideal for applications where flexibility and maneuverability are crucial.

Stranding Process

Stranding is a process similar to bunching, with a key distinction. While bunching involves twisting bare copper wires together, stranding refers specifically to the twisting of insulated cables. In the case of certain flexible cords, insulated wires are twisted together along with cotton yarn to enhance the cable's durability and flexibility. After this, the bundled wires go through a final extrusion process, where additional layers are applied to provide further protection and ensure the cable meets the required specifications.

Extrusion Process

Extrusion is the process used to apply insulation to bare copper cables. During this stage, the cables are coated with a protective material that ensures safety and functionality. Depending on the specific product requirements, the cables may undergo multiple extrusion cycles. For instance, if the cables need additional sheathing on top of the initial insulation, they will be extruded again to apply this extra layer, enhancing the cable's overall durability and performance.

Coiling and Packing Process

The final stage of the manufacturing process is coiling and packing. In this phase, the finished cables are carefully coiled and cut to the required packing length. Depending on the order specifications, the cables are then packed onto drums or wound into individual rolls. Once coiled, the cables are securely wrapped, labeled, and stored, ready for shipment to customers.

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