SYSTEM DESIGN AND PROTOTYPE MANUFACTURING FOR THE RECOVERY OF LUBRICANT POWDER USED IN WIRE DRAWING PROCESS
Abstract
Recycling processes have gained great importance for both environmental and economic sustainability and development. A prototype system was developed using physical separations including size sieving and magnetic separation for the recycling of solid die soaps used as lubricants in industrial wire drawing processes. The chemical composition of the waste obtained after the wire drawing process was elucidated by using X-ray fluorescence (XRF) analysis and extraction methods. The results showed that there was 67% reusable soap in the waste, and most of the remaining waste was made up of metals. Parameters such as particle size, sieve pore diameters, shaking time and magnetic field strength were optimized and an industrial scale prototype recycling system was designed. Finally, a prototype recovery system was established. Scanning electron microscopy (SEM), light microscopy, thermogravimetric/differential thermal analyzes (TGA/DTA), X-ray fluorescence spectroscopy (XRF) and Fourier transform infrared spectroscopy (FTIR) were used for the characterization. 88% of the soap in the waste was recovered, and the soap obtained was successfully used in wire drawing process without causing any deformation in the wire. These findings clearly demonstrate that offered system design engineered solution has a great potential to become a way out point for the waste recycling gain in the recovery and reuse of lubricant powder
Keywords
Supporting Institution
TÜBİTAK,
Project Number
3190313
Thanks
This study has been carried out within Hasçelik Cable Industry and Trade Incorporated Company R & D center. Thanks to Hasçelik Kablo Industry and Trade Incorporated Company and TUBITAK for its contribution to this work. Project number is ‘3190313’.
References
- Aristides, G., Martinez, S., Qian, W., Kabayama, L., K., and Prisco, U., (2020). Effect of Process Parameters in Copper-Wire Drawing. Metals, doi:10.3390/met10010105.
- Brard, D., (1991). Lubrication-Quality and Innevation, Wire Industry, 733-734.
- Byon, S.M., Lee, S.J., Lee, D.W., Lee, Y.H., Lee, Y., (2011). Effect of coating material and lubricant on forming force and surface defects in wire drawing process. Transactions of Nonferrous Metals Society of China, Volume 21, Supplement 1, March 2011, Pages s104-s110.
- Can, W., Ni Jing, Y., Paul, D. T., Lidan, Y., Xinglin L., (2023). Investigation of mixed hBN/Al2O3nanoparticles as additives on grease performance in rolling bearing under limited lubricant supply. Colloids and Surfaces A: Physicochemical and Engineering Aspects, Volume 659, 20 February 2023, 130811.
- Chengliang, H., Haitang, C., Wenlong, Z., Hironori, O., (2023). Enhancing the sensitivity of a tribological testing method to enable development of lubricants for cold forging. Tribology International, Volume 179, January 2023, 108156.
- De-Chun, X., Si-Yuan, Z., Hao-Yi, C., Awoke G., Hong-Cheng W., Jing-Long H., Cheng-Yan L., Ai-Jie W., (2020).
- Dove, A., Moritz, J., Smigel, W., (1980). Steel Wire Handbook, 372 s, U.S.A.
- Dubois, A., Lazzarotto, L., Dubar, L., Oudin, J., (2001). A multi-step lubricant evaluation strategy for wire drawing–extrusion–cold heading sequence. Wear. 249, 951-961. https://doi.org/10.1016/S0043-1648(01)00830-4
- Eickemeyer, J., Vogel, H.-R., Reichert, J., Rehm, M., (1996). Metal drawing by means of solid soap films. Journal of Materials Processing Technology. 61, 250-253. https://doi.org/10.1016/0924-0136(95)02185-X.
- EN 10270-1, (2011). “Steel wire for mechanical springs patented cold drawn unalloyed spring steel wire”. Gyucheol, J., Giate, H., (2010). Magnetic separator for removing oxidized steel from dry lubricant and recycling machine with the same. Patent No. KR101151382B1.
- Jeimin, R. Joshi, Khodidas, K., Bhanderi, J., Patel, V., (2023). Waste cooking oil as a promising source for bio lubricants-A review. Journal of the Indian Chemical Society, Volume 100, Issue 1, January 2023, 100820.
- Kim, S., H., Gyu-Chul, J., Chi-Wook, L., (2014). Development and Evaluation of Dry Lubricant Recycle Technologies for Wire Drawing Process. Journal of the Korean Society of Manufacturing Process Engineers, Vol.13 No.2, pp.35~40.
- Mariana, T. D., Rogério, C., Branco, C. L., Benilde, S., (2021). A review on alternative lubricants: Ionic liquids as additives and deep eutectic solvents. Journal of Molecular Liquids, Volume 333, 1 July 2021, 116004.
- McNulty, M. 2006. Spotlight on Drawing Machines, Wire and Cable Technology, 54 – 56.
- Moon, C. S., Kim, N., (2012). Study on dimensional change in wire product during wire-drawing process, Journal of KSME. Vol. 36, pp.723-730. DOI: 10.3795/KSME-A.2012.36.7.723.
- Mun, B., Kyung-ho, S., (2011). Dry Drawing Lubricant Recycling Machine For steel Wire. Patent No. KR101380168B1.
- Murakawa, M., Jin, M., Hayashi, M., (2004). Study on semidry/dry wire drawing using DLC coated dies. Surface and Coatings Technology. 177, 631-637. https://doi.org/10.1016/j.surfcoat.2003.08.057
- Sarma, R. Narayana, Vinu, R., (2022). Current status and future prospects of biolubricants: properties and applications. Lubricants, 10 (4) (2022), p. 70, 10.3390/lubricants10040070
- Toru, Y., (2005). Wire drawing dry lubricant recycling machine. Patent No. JP2006289196A.
- Tripp, I., (1998). Health and Safety Concerns for the Wire Drawing Industry, Wire and Cable Technology, 55-56.
- Wire-drawing process with graphite lubricant as an industrializable approach to prepare graphite coated stainless-steel anode for bioelectrochemical systems. Environmental Research, Volume 191, December 2020, 110093.
- Wright, R.N., (2011). Wire Technology-Process Engineering and Metallurgy, doi:10.1016 / B978-0-12-382092 1.00002-6, UK.
- Zhendong, C., (2011). Automatic lubricating powder recovery device. Patent No. CN102172651A.
TEL ÇEKME PROSESLERINDE KULLANILAN TOZ SABUNUN GERI KAZANIMI İÇIN SISTEM TASARIMI VE PROTOTIP İMALATI
Abstract
Günümüzde geri dönüşüm süreçleri hem çevresel hem de ekonomik sürdürülebilirlik ve kalkınma için büyük önem kazanmıştır. Bu çalışmada, endüstriyel tel çekme işlemlerinde yağlayıcı olarak kullanılan katı kalıp sabunlarının geri dönüşümü için eleme ve manyetik ayırmayı içeren fiziksel yöntemler kullanılarak yeni bir yöntem ve prototip sistem geliştirilmiştir. Tel çekme işlemi sonrasında elde edilen atığın kimyasal bileşimi X-ray floresan (XRF) analizi ve ekstraksiyon yöntemleri kullanılarak görülmüştür. Elde edilen sonuçlar, atıkta %67 oranında yeniden kullanılabilir sabun bulunduğunu ve kalan atığın çoğunun metallerden oluştuğunu göstermiştir. Geri dönüşüm için partikül boyutu, elek gözenek çapları, sallama süresi ve manyetik alan gücü gibi parametreler optimize edilmiş olup optimum koşullar kullanılarak endüstriyel ölçekli bir prototip geri dönüşüm sistemi tasarlanmıştır. Son olarak optimum koşulları içeren bu veriler ışığında bir prototip kurtarma sistemi kurulmuştur. Bu çalışmada, analizler için elektron mikroskobu (SEM), ışık mikroskobu, termogravimetrik/diferansiyel termal analizler (TGA/DTA), X-ışını floresan spektroskopisi (XRF) ve fourier transform kızılötesi spektroskopisi (FTIR) kullanılmıştır. Sonuçlar, atıktaki sabunun %88’ inin geri kazanıldığını ve elde edilen sabunun telde herhangi bir deformasyona neden olmadan tel çekme işleminde başarıyla kullanıldığını göstermiştir. Bulgular, önerilen sistem tasarımı çözümünün, yağlayıcı tozun geri kazanılması ve yeniden kullanılmasında atık geri dönüşümü kazanımı için bir çıkış noktası olma konusunda büyük bir potansiyele sahip olduğunu açıkça göstermektedir.
Keywords
Project Number
3190313
References
- Aristides, G., Martinez, S., Qian, W., Kabayama, L., K., and Prisco, U., (2020). Effect of Process Parameters in Copper-Wire Drawing. Metals, doi:10.3390/met10010105.
- Brard, D., (1991). Lubrication-Quality and Innevation, Wire Industry, 733-734.
- Byon, S.M., Lee, S.J., Lee, D.W., Lee, Y.H., Lee, Y., (2011). Effect of coating material and lubricant on forming force and surface defects in wire drawing process. Transactions of Nonferrous Metals Society of China, Volume 21, Supplement 1, March 2011, Pages s104-s110.
- Can, W., Ni Jing, Y., Paul, D. T., Lidan, Y., Xinglin L., (2023). Investigation of mixed hBN/Al2O3nanoparticles as additives on grease performance in rolling bearing under limited lubricant supply. Colloids and Surfaces A: Physicochemical and Engineering Aspects, Volume 659, 20 February 2023, 130811.
- Chengliang, H., Haitang, C., Wenlong, Z., Hironori, O., (2023). Enhancing the sensitivity of a tribological testing method to enable development of lubricants for cold forging. Tribology International, Volume 179, January 2023, 108156.
- De-Chun, X., Si-Yuan, Z., Hao-Yi, C., Awoke G., Hong-Cheng W., Jing-Long H., Cheng-Yan L., Ai-Jie W., (2020).
- Dove, A., Moritz, J., Smigel, W., (1980). Steel Wire Handbook, 372 s, U.S.A.
- Dubois, A., Lazzarotto, L., Dubar, L., Oudin, J., (2001). A multi-step lubricant evaluation strategy for wire drawing–extrusion–cold heading sequence. Wear. 249, 951-961. https://doi.org/10.1016/S0043-1648(01)00830-4
- Eickemeyer, J., Vogel, H.-R., Reichert, J., Rehm, M., (1996). Metal drawing by means of solid soap films. Journal of Materials Processing Technology. 61, 250-253. https://doi.org/10.1016/0924-0136(95)02185-X.
- EN 10270-1, (2011). “Steel wire for mechanical springs patented cold drawn unalloyed spring steel wire”. Gyucheol, J., Giate, H., (2010). Magnetic separator for removing oxidized steel from dry lubricant and recycling machine with the same. Patent No. KR101151382B1.
- Jeimin, R. Joshi, Khodidas, K., Bhanderi, J., Patel, V., (2023). Waste cooking oil as a promising source for bio lubricants-A review. Journal of the Indian Chemical Society, Volume 100, Issue 1, January 2023, 100820.
- Kim, S., H., Gyu-Chul, J., Chi-Wook, L., (2014). Development and Evaluation of Dry Lubricant Recycle Technologies for Wire Drawing Process. Journal of the Korean Society of Manufacturing Process Engineers, Vol.13 No.2, pp.35~40.
- Mariana, T. D., Rogério, C., Branco, C. L., Benilde, S., (2021). A review on alternative lubricants: Ionic liquids as additives and deep eutectic solvents. Journal of Molecular Liquids, Volume 333, 1 July 2021, 116004.
- McNulty, M. 2006. Spotlight on Drawing Machines, Wire and Cable Technology, 54 – 56.
- Moon, C. S., Kim, N., (2012). Study on dimensional change in wire product during wire-drawing process, Journal of KSME. Vol. 36, pp.723-730. DOI: 10.3795/KSME-A.2012.36.7.723.
- Mun, B., Kyung-ho, S., (2011). Dry Drawing Lubricant Recycling Machine For steel Wire. Patent No. KR101380168B1.
- Murakawa, M., Jin, M., Hayashi, M., (2004). Study on semidry/dry wire drawing using DLC coated dies. Surface and Coatings Technology. 177, 631-637. https://doi.org/10.1016/j.surfcoat.2003.08.057
- Sarma, R. Narayana, Vinu, R., (2022). Current status and future prospects of biolubricants: properties and applications. Lubricants, 10 (4) (2022), p. 70, 10.3390/lubricants10040070
- Toru, Y., (2005). Wire drawing dry lubricant recycling machine. Patent No. JP2006289196A.
- Tripp, I., (1998). Health and Safety Concerns for the Wire Drawing Industry, Wire and Cable Technology, 55-56.
- Wire-drawing process with graphite lubricant as an industrializable approach to prepare graphite coated stainless-steel anode for bioelectrochemical systems. Environmental Research, Volume 191, December 2020, 110093.
- Wright, R.N., (2011). Wire Technology-Process Engineering and Metallurgy, doi:10.1016 / B978-0-12-382092 1.00002-6, UK.
- Zhendong, C., (2011). Automatic lubricating powder recovery device. Patent No. CN102172651A.
Details
| Primary Language | English |
|---|---|
| Subjects | Engineering, Chemical Engineering, Material Production Technologies |
| Journal Section | Materials Science and Engineering |
| Authors | |
| Project Number | 3190313 |
| Publication Date | June 3, 2023 |
| Submission Date | November 29, 2022 |
| Published in Issue | Year 2023 |