Assomac Machines Ltd.

Bulandshahr Road Industrial Area, Ghaziabad, Uttar Pradesh

The fabrication of a Flux Cored Electrode begins by slitting steel coiled sheet into strips. The strips are passed through rollers that form it into a U-shaped cross-section. In the same operation, the formed strip is filled with a measured amount of core ingredients. The U-shaped strip is passed through closing rolls, forming it into a tube and tightly compressing the granular core material.
The tube is then passed through drawing dies that reduce the diameter and compress the core ingredients to prevent any movement within the tube.

Equipments Required

Rewinding line composed of :

• Strip Coil Pay Off.
• Strip Butt Welding
• Strip Washing Unit
• Strip Spooling Machine

Forming and Pre Drawing Line Composed of :

• Spool Pay Off.
• Tube Forming, filling and closing unit.
• Wire Drawing machine
• Spooler

Redrawing Line Composed of :

• Spool Payoff
• Wire Baking oven.
• Wire drawing machine.
• Lubrication unit.
• Spooler

Layer Rewinding Line composed of :

• Motorized spool payoff.
• Pneumatic dancer synchronizer
• Layer winder for steel baskets or plastic spools.

Flux Core Wire Advantages :

The Flux Cored Wire (FCW) offers many advantages, including excellent weld metal quality, high deposition rates, and ease of operation. Labour and overhead are the most expensive factors in any welding operation, usually comprising 80 to 85 percent of the total cost. Welding with high deposition FCW electrodes provides an immediate means of cost reduction without a major investment in specialized equipment.

• Excellent weld quality due to deep penetration and lower root opening of the joint.
• All position versatility with the right filler metals (the consumable electrode) with or without gas shielding reduces setup time and requirement of special fixtures.
• Shielding gas not necessarily needed making it suitable for outdoor welding and/or windy conditions.
• A high-deposition rate process because of the relatively high current density (speed at which the filler metal is applied).
• Less post cleaning of metal required as weld joints are smooth with almost no ripples and very little spatter.
• Metallurgical benefits from the Flux such as the weld metal being protected initially from external factors until the Flux is chipped away.

Straight Line Wire Drawing Machines were developed for straight or deflection free drawing of wire to provide better drawability, lower frictional contact and lower operator interference. Theoretically there is no limit as far as the wire material or wire diameter is concerned to be drawn on these machines.
ASSOMAC has pioneered to indigenously develop the Straight-Line Wire Drawing Machine Technology in India. Presently the range available is capstan diameter 900mm, 750mm, 600mm, 550mm, 500mm, 460mm, 400mm and 300mm for inlet wire diameter 16mm down to 0.5mm. Line speeds upto 25 Mtrs / Sec. These heavy Straight Line Wire Drawing Machines provide remarkable drawing performance for Low, Medium and High Carbon Steel Wire, Stainless Steel Wire and special Alloy Steel Wire and Non-Ferrous Alloy Steel Wire.

This machine has a sensor roller between the drum and the next die such that the wire passes in contact with this roller. These rollers have sensors to detect the position of the arm and maintain tension on the wire by regulating speed of the drums. The drums of this machine are inclined to the vertical axis to effect fill on the drums. Principally this machine is best suited for thick wires.

Features of Straight Line Wire Drawing Machine:

• Machines are built on modular structure, in combination of Blocks and do not require any special foundation.
• Better productivity due to higher drawing speeds, twist-free operation & better cooling.
• Easy operation and faster threading.
• High pressure Narrow gap, internal water cooling for high efficiency cooling of wire.
• High degree of reliability, low downtime due to lower no. of wear parts.
• Much better finish wire quality due to a gentler handling of the wire during the drawing process (less wire deviations, low torsion etc.) as well as an optimized wire cooling.
• Highly effective pneumatic braking system in case of emergency.
• Better environmental conditions due to increased dust protection.
• Greater flexibility and lower current consumption due to modern AC drive technology and efficient power transmission system.
• PLC based control with profibus digital communication and fault diagnostic system.

Optional Fitment:

• Stripper Block
• Rotating Die Boxes
• Motorized Soap Applicator Die Boxes
• Die less drawing trough Rolling Cassette
• Laser wire diameter measurement system
• Dust Suction System
• Online Modem based PLC support