Wire Forming Techniques and Processes

Wire forming is a metal forming technique that has been practiced since ancient times. Nowadays, it is used to forge a diverse range of products and metal parts. However, the basic principle of Wire forming stays the same even in this industrial age. However, the invention of machines, tools, and techniques of wire forming have undergone major changes.

Wireframing: A Simple Process to Manufacture Diverse Products

When it comes to forging metal products of various shapes and sizes, wire forming is a useful metal forming technique that is capable of producing metal products at a high volume with unparalleled efficiency.

Before a wire is formed, it must pass through a die that shapes it into the required configuration and measurements. The wire drawing die is a funnel-shaped tool that has a narrow opening. The die gently applied a force through its funnel shape. Too steep a funnel would apply too much pressure on the Wire, which would cause it to break or stretch and deform, so the Wire passes through multiple dies that gradually press it into the required diameter.

Once the Wire is of adequate dimensions and has passed through the die, the wire-forming process begins. In wire forming, the Wire passes through multiple rollers that bend and shape the Wire according to specifications.

In-Depth Look into Wire Forming Processes

The standard process of Wire forming involves applying pressure to bend Wire at various angles to make a shape. However, this is not the only procedure that is carried out since making top-quality products requires other operations that mold the Wire and give it the required strength and precise features. Let us take a look at these processes.

Upsetting

Deforming the Wire by applying compressing pressure to increase the wire width.

Extrusion

Forcing the Wire through a narrow opening that is less than the diameter of the Wire. This shapes the Wire further.

Swaging

This method involves a two-step process. The first procedure consists of pressing a die in an axial direction to press the Wire into the specific shape. The second step involves deforming the Wire by applying force through a tool at an angle of 90 degrees to the axial direction. This is known as side pressing.

Bending

This simply comprises applying force at different angles to bend a straight wire. In an automated process, this is achieved through a stamping machine.

Stamping

The bent Wire moves through a stamping machine, which applies forming tools known as dies for further bending and Shaping of the part.

Twisting

Wires are twisted to combine multiple lengths and make metal springs that have great tensile strength and elasticity.

Stretching

In this procedure, the Wire is increased in length and made thinner by applying opposite forces in a coaxial dimension. Wire can undergo a limited even stretching and narrowing, but if you keep stretching it, it starts to neck down. This means that the stretching and thinning become concentrated at a single spot, which weakens the Wire and eventually causes it to break.

Wire Forming Tools and Technology

Manual Wire forming: The traditional way of Shaping

When it comes to making things from Wire, manual wire forming is the simplest way to go. You basically bend and shape wires by hand. It can be as basic as not needing any tools, but in most cases, you'll see folks using hand levers and spinning things on a machine that's cranked by the operator.

Coil Wire Forming: The Go-To Technique to Make Springs

A typical wire form spring supplier, coil wire forming is what they use when they're making springs and coils for electronics. They take a wire, wrap it around a piece of metal, and snip it. This method can craft different types of springs, like the ones that twist, stretch, or compress. It's not just for springs, though; they also use it to make parts where the spring is just one piece of a bigger wire structure.

Fourslide Wire Forming: Automation For High-Volume Production

Foreside wire forming is like a fancy dance with a machine. This machine has several moving parts, kind of like slides, and it's actually called a 'foreside machine' because it has four of these slides arranged in a square shape. It often has extra slides for cutting, feeding, and other tasks. These slides do their thing based on some clever cams controlling their timing and movement. Each slide has a tool, and together, they shape the wire step by step in a specific way.

Back in the 20th century, these four-slide machines were the go-to for making lots of wire forms quickly. They're super versatile and can handle wires as wide as 3 inches, although they're usually used for smaller ones.

But here's the catch: Fourslide machines are great for long races and high production volume. To set them up with the right tools and cams is a big investment, which makes them not as suitable for smaller production runs.

CNC Wire Forming: A Blend of Unparalleled Precision and Seamless Automation

You know those fancy CNC wire-forming machines? They're like the tech wizards of wire bending. They can make all sorts of wire shapes in 2D and 3D, and they do it all with computer smarts.

The best part is that you can design what you want on your computer in 3D, and the machine follows your lead. There is no need for setting up cams and tools like with those four slide machines. This makes CNC wire-forming machines a more budget-friendly choice when you're crafting unique wire forms.