What is Wire Forming and How Does It Work?

Before the wire goes through the wire bending machine for forming, it needs to be drawn. Wire drawing works by pushing a wire through a die and pulling it out of the other end. As a result, the thickness of the wire, or cross-section, is reduced.

Forging

Wire drawing changes the shape of metal with force, this process is also known as forging. Forging does not change any characteristic of the metal except for the shape.

Spooler

A spooler is a tool used at the end of the wire drawing process that winds or spools wires. Some wires are spooled and then used in the final form, whereas others still go through the wire forming process.

Coiler

Coilers are similar to spoolers but instead of just wrapping a wire around a spool, they coil the wire into an individual coil, such as a solenoid, or around a centerpiece.

Next in the wire forming process is wire straightening. The wire straightening process is exactly what it sounds like – a method for straightening out any defects in the wire. During straightening, disfigurements and deformities are rolled out manually or through a CNC machine. Once the wire is fully strengthened, it is then ready for wire forming.

Finally, step three is where the actual wire forming happens. There are a few processes of forming that are done with a manual or automated machine.

Manual

Manual wire bending machines get their name from the caveat that they require manual labor, even if they are partially automated. The manual process may be manually moving the machine, manually turning the wire, or manually adjusting throughout the procedure. With the accessibility of integrated and intelligent technology moving into the machining industry, manual wire forming is becoming outdated. This process is tedious, requires manpower, and takes exponentially longer than an automated method.

Computer Numerical Control (CNC)

CNC machines use a pneumatic or hydraulic method in conjunction with a computer numerical control system to form the wire. In other words, these machines utilize intelligent software for the control and movement of the machine. Since these machines work at a faster and more precise pace than manual machining, CNC wire bending machines are usually preferred over manual wire bending machines.

Four Slide

Four slide machines can use up to four machining processes for more efficient and cost-effective machining. Because of this factor, four slides are integral to the wire forming process because of the extra methods they can add to drawing and finishing.

Spring Wire Forming

Spring wire forming, also known as coil wire forming, is used for creating torsional and compression springs, as well as electrical coils. These springs and coils are wound very tightly, sometimes more than once.

Torsional Springs

Torsional springs are tightly wound coils with straight ends on each side. The straight ends are used for holding mechanical components in place for storing and releasing energy. These are used in items like chip clips, and door hinges.

Compression Springs

Compression springs compress and retract as force is added or taken away. An everyday example of compression spring is the spring in a pen or a mattress.

Roll Wire Forming

Roll wire forming works with flat and round shapes. This type of wire forming process needs additional finishing like hardening, rounding, and prefinishing.

Bend Wire Forming

Bend wire forming is the process of shaping wire into configurations after the wire is cut to the desired size. Using bend wire forming does not need extra finishing. For example, consider how a paper clip is bent into shape.

After forming, sometimes finishing is required for the final product. The finishing step in the wire forming process may involve one or multiple processes that affect a wire’s corrosion resistance, electrical conduction, appearance, or other qualities. Some examples of finishing processes include:

• Covering with plastic or rubber
• Cutting
• Galvanizing
• Electropolishing
• Powder coating
• Plating
• Shining

• Electrical wires
• Cables
• Light fittings

• Fasteners
• Aircraft frames

• Filters
• Hooks
• Racks
• Baskets
• Chairs

• Orthodontic brackets
• Syringes
• Surgery wires
• Orthodontic springs

• Suspension systems
• Steering systems
• Gear shifters
• Door handles

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