Wire forming is a method for applying force to change the contour of wire by bending, swaging, piercing, chamfering, shearing, or other techniques. The various techniques for wire forming can produce any type of shape, form, or configuration. The process starts with coiled wire that is straightened before being formed.
Common metals used for wire forming include steel, brass, stainless steel, copper, aluminum, and a variety of different alloys. The diameters of wires vary from 0.5 mm to 6.5 mm, or 1/64th of an inch to a quarter inch and can produce 2 and 3 dimensional wire forms.
The types of equipment to complete wire forming vary between manual crafting to advanced CNC programmable machines. The process includes options for coating and protecting final products for use in harsh conditions.
Though there are several types of equipment used to perform wire forming, in most cases, wire forming machines are manually or automatically operated. Manual machines include ones that are operated by manual force and ones that are electronic but manually loaded. Automatic machines have advanced computer numerically controlled (CNC) programming and complete production without manual involvement.
Wire forming is performed using several different processes each designed to achieve a different shape, pattern, or configuration. The methods of wire forming are used for other part production but have been adjusted for wire forming.
The oldest method for wire forming is manually operated machines, which involves a hand lever and spindle. Manual machines can be drawn or rotary die and have gears that increase the applied bending force.
Coil, or spring wire forming, involves winding wire around a metal blank. It is also used for the manufacture of electrical coils where a conductive wire is evenly wound around a ferromagnetic core. Coil winding takes different forms depending on the final product. Electrical coils have to be more precisely wound than springs and can require more than one winding.
Roll forming is a cost efficient method for the production of flat, round, and other shapes of wire parts. The process can manufacture undercuts, knurls, pointing, chamfers, grooves, surface finishes, collars, and threads. Roll formed wire parts have extra strength after being hardened, having rounded edges, and being prefinishing.
In the wire bending process, wire can be shaped into unlimited configurations to fit any application. Diameters of 0.4 mm to 16 mm, or 0.016 in to 0.625 in, can be easily formed. Since the bend in the wire is made prior to the wire being cut, the process has no scrap or waste and does not need secondary finishing.
CNC wire bending machines can be pneumatic or hydraulic for efficient and rapid production. They can bend and shape rebar to 180o using single or double wire. The machine straightens the bar prior to the bending process. CNC machines have exceptional accuracy and cut wire to the exact required dimensions. The types of wire a CNC machine can be programmed to shape includes music, hard drawn, basic or coated metals, 300 series stainless steel, brass, and beryllium copper. Wire diameters vary between 0.008 in to 0.250 in or 0.0203 mm to 6.35 mm.
Contact Acme Wire Products today to answer your questions and provide you with a custom quote today.
Acme Wire Products has designed, recommended and manufactured custom wire components for customers in many diverse markets. We offer the benefit of our almost 50 years’ experience in the manufacture of component parts for hardware, medical & lab equipment, cable management, sporting goods, firearms, furniture, guarding, HVAC, pharmaceutical, automotive, optical and food service and processing industries.
Acme Wire’s designers work with our customers to create a wire component that will provide the greatest functional value. The design of wire products such as levers, handles, supports, rings, guards, baskets, trays, grids, frames, shelves are limited only by one’s imagination (and the limitations of technology).
Contact Acme Wire Products to assist you in determining the wire product best suited to your requirements! Call Acme Wire Products at 1-800-723-7015 to get started.
Acme Wire Products Co., Inc. – Mystic, CT
https://www.acmewire.com
860-572-0511
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Many auto parts need wires that are bent into certain shapes. There’s an art to bending wire. The wire needs to be bent beyond its yield strength, but within its tensile strength. In other words, the wire needs to be bent to achieve the desired angle without breaking it or letting it rebound back to its original shape. There are several different ways to achieve this:
Let’s explore each option and discuss how these options differ from each other.
Wire forming is a broad term that describes shaping wires into a specific configuration. For example, turning a piece of wire into a spring. This term is normally used to describe an automated wire forming process used by machines.
At Intran, we use CNC wire benders to bend wires up to 1 1/2” in diameter. Our use of these machines allows us to bend a large amount of wire in a short amount of time. Read on to learn how the CNC wire bending process works.
CNC bending stands for “computer numerical controlled” bending. It’s a unique process that uses the following parts:
The computer sends the specifications to the machine. Next, the robotic arm pushes the wire through the servo-driven rollers. This step bends the wire into preprogrammed configurations. This creates wires with the right shape and dimensions every time.
Wire forming is a versatile process. It can bend a wire in any direction: up, down, left, or right. It can bend a wire in pretty much any angle. It can even create coils out of wires.
Hand bending is a manual wire forming process. It requires physical labor. The process works like this:
This is a pretty labor intensive process that’s only practical for small orders. It is not as precise as CNC wire forming, but also has less set up cost.
The air bending process is the similar to the hand bending process. The only difference is the roller pin is air powered. The process still involves a physical labor, but it is easier for the operator. Because the roller pin is air powered, an operator can form a larger diameter wire than they could with a purely manual process. Like hand bending, air bending is only practical for small orders.
With all three methods, the idea is the same, which is to bend wires. Execution is quite different between wire forming and hand or air bending. Wire forming involves robotic arms and computers, making it more automated. Hand bending and air bending are much more manual processes.
Wire forming is a much better method than hand bending and air bending for mid to high volume production. It’s automated, and it doesn’t require any extra tooling. This means:
Wire forming requires more sophisticated equipment than hand bending and air bending. It’s important to find a good wire forming manufacturer that uses the latest equipment and technologies. At Intran, we offer wire forming services. Please contact us with any questions about our wire forming services.