It is impossible to undervalue or dismiss the relevance of high-quality wires and cables used in industrial and commercial settings. We often read about horrible fire accidents in industrial and commercial buildings/establishments that not only cause the loss of human life but also cause enormous damage to the surrounding premises, equipment, and machinery. When these terrible accidents are investigated, it is discovered to everyone’s surprise that the short circuit in the inferior wires and cables was the cause.
Electric conductor insulation eventually reaches a point of rapid degradation, necessitating a quick replacement, as is now scientifically established. The lifespan of their insulation does not last as long as anticipated in many cases even though the wires and cables produced by a reputable manufacturer survived short-term testing extremely well. Therefore, the quality of the wires and cables utilized needs to be of very high quality.
The foundation is laid even before the manufacture of high-quality wires and cables starts. The methods and tools used are important in the manufacture of cables. This particularly applies to those utilized in industrial settings. This is because they have a considerable influence on the overall quality and performance of cables. When cables have excellent insulation, all types of cables are thought to be of the greatest quality. This is made possible by utilizing the proper cable extrusion machine and extrusion technology.
Overview of extrusion methodology
Manufacturers all around the world utilize the extrusion method to produce a broad variety of products having a defined cross-sectional form. The material is pressed into a die with the desired cross-section during this operation. Both hot and cold methods of carrying out this treatment are acceptable. Additionally, the molten substance (intended to be plastic) is poured evenly around the wire’s perimeter, causing it to adhere to the wire or cable’s shape and structure. One of the most popular techniques for creating the outer sheath of the cable and effective and efficient wire covering is extrusion. The extrusion process as well as equipment is tailor-made to suit different materials and more or less remains the same be it including LSZH cable extrusion or any other variant of cable and wires.
Thermoplastics and thermosetting are two of the most in-demand materials
In the process of extruding wire and cable using high-quality rubber extruder machine, raw materials are transformed into a continuous profile to offer the required protection to wires and cables against all forms of damages brought on by various external sources and physical wear. There are many other ways to accomplish the same thing, but the market’s demand for a certain chemical is the key factor. The most often processed materials are thermoplastic and thermosetting, which are completed or partially finished using an internal machine friction (barrel) and an external heat resistor. By pressing it into a die, the raw material is given the desired form.
A look at the drawing down and pressure extrusion
The insulation and sheathing material is drawn by a mathematical model used to select the right tools.It makes use of the tensile strength of the material in a highly tactical way to perform the necessary pulling motion through the die. However, with sketching, there are very few opportunities for several adjustments to be made at once. Drawing only has uses for simpler shapes, which often require varying degrees of size minimization.
Tool design and selection of tooling
The overall quality of insulation or sheathing is greatly influenced by the design and choice of tooling. The instruments must be created in a way that eliminates any possibility of material standstill throughout the whole cycle. There may be many other techniques, but Supermac Industries India Limited, a top producer and supplier of extrusion machines chooses a consistent and straight-angle strategy to get the job done perfectly the first time.
Advantages of using the right kind of tooling selection
● The top surface becomes smooth
● Much better eccentricity and ovality
● There is no approximation, and dimensions are as per calculations
● The right selection of tooling leads to the excellent quality of the end product
● Controlled consumption of material
● Lower cost of production
● Better process control done by a proper system
● Repeat orders
● Higher line speed- higher productivity
● Improper tools lead to defects in insulation or sheathing.
Choosing the right extruder
Seeking a statement of output versus the size of the extruder from various manufacturers and suppliers in line with the criteria is a perfectly fair course of action in this respect. When selecting an extruder the following factors should be taken into account:
● Horse power-requirement
● Extruder size
● L/D ratio, and
● Screw-design.
The selection of the following is also equally important:
● Reduction gearbox
● Thrust gearbox, and
● Right drive and PLC.
Types of screws
The screw, which is made to produce a fully melted polymer with high output, is regarded as the extruder’s “heart.” For a wide range of applications, Supermac Industries India Limited produces technologically sophisticated extruders. The most common screw types include the following:
● Basic Metering Screw– Simple 3-zone PVC screw
● Maddock Mixing
● Pin mixing – Shear pins – Distributive mixing
● Compression Relief – Used for high L/D 34:1
● Vented screw
● Barrier Screw- Two channels – Melt and Barrier.
The company’s R&D division has a wealth of expertise in designing screws for a variety of materials and applications.
Concluding Remarks
Supermac Industries is the world’s one of the top leading manufacturers of production systems, process technologies, cable coiling machines, and cable extrusion machines in India. The company takes pleasure in adhering to stringent quality control standards, and it has received ISO 9001-2018 accreditation for the entirety and supremacy of its product line. The wide range of extrusion machines, crossheads, caterpillars, capstans, screws and barrels, and pay-offs, haul off caterpillar machine, Rubber ,HV and special extruder machine are only a few of the numerous products offered by Supermac.
Modern production facilities for Supermac are located in Manesar (Haryana), Dharuhera as well as New Delhi. These facilities, which have a combined size of 95,000 square feet, are outfitted with the greatest machinery in the world to carry out the production process in accordance with the customer’s unique needs.
