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ISSN 1913-0341 [Print]

Management Science and Engineering ISSN 1913-035X [Online]
Vol. 10, No. 1, 2016, pp. 14-20 www.cscanada.net
DOI:10.3968/8212 www.cscanada.org

Research on Key Technology of Wire-Bending and Equipment Development

TANG Wenxian[a],[b]; ZHU Hui[a],*; ZHU Mengxiu[a]; LI Qinfeng[a]; ZHANG Jian[a]

[a]
Jiangsu University of Science and Technology, Zhenjiang, China. China. As the common manufacturing process in the field
[b]
Jiangsu University of Science and Technology Industrial Technology of mechanism, wire- bending is widely used in aerospace,
Research Institute of Zhangjiagang, Suzhou, China.
*
Corresponding author.
automobile, shipping engineering, machinery and other
important fields (Liu, 2011).
Supported by the Plan Project of Science and Technology of Although, China is a large producer of wire products,
Zhangjiagang (BY2014080); the Plan Project of Science and Technology but its technical equipment is not advanced. Semi-
of Jiangsu (BY2015065-07).
automatic molding equipment is usually used to bend
Received 29 December 2015; accepted 2 February 201 wires. It often caused work pieces failure, as a result of
Published online 16 March 2016 the accuracy of bend wires are not high or residual stress
are oversize. And for equipment manufacturing industry,
Abstract the accuracy requirements of wires with complex shapes
In this paper, based on the wire-bending process, become higher and higher, while the product demand is
developing a DC wire-bending machine which is used to growing (Han, 2010). All of these urges a deeper research
bend the wire to any angle. The DC wire-bending machine and development of the equipment and processing which
with a higher integration and production efficiency is used to bend the wires. At present, the advanced
contained storing mechanism, straightening mechanism, equipment for wire forming in China is mainly imported
feeding mechanism and wire-bending mechanism. The from the technology developed countries such as
storing mechanism can be reset by itself without being Germany, France and Japan. While, most Chinese
adjusted manually when the feeding speed is different customers give up this way due to the fancy price and
from the receiving speed of the processing equipment. The inconvenience of maintaining (Ye & Chen, 2009).
wire-bending mechanism for double-heads can achieve Currently, Some Chinese manufacturers have also created
asymmetric bending. The clamping device of wire-bending such equipment, but they all failed to get improvement in
mechanism is more stable and higher rotational accuracy. these fields about the quality, the efficiency and the level
of maintenance. At the same time, the high manufacturing
Key words: DC wire-bending machine; Storing cost makes it lack of market competition (Barlat, 1991).
mechanism; Wire-bending mechanism; Clamping device
The common Automatic wire-bending machine
includes storing mechanism, straightening mechanism,
Tang, W. X., Zhu, H., Zhu, M. X., Li, Q. F., & Zhang, J. (2016). Research
cutting mechanism, feeding mechanism, bending
on Key Technology of Wire-Bending and Equipment Development.
Management Science and Engineering, 10 (1), 14-20. Available from: mechanism, etc.. But we don’t have equipment with a
URL: http://www.cscanada.net/index.php/mse/article/view/8212 higher integration and automatic production lines with
DOI: http://dx.doi.org/10.3968/8212 high and production efficiency at present (Lu, 2013). The
specific reasons are as follows.
Firstly, the traditional bending mechanism uses
single-head to bend (Masaki & Akihiko, 2006). But the
INTRODUCTION production efficiency is slow. Currently, there is some
In recent years, with the changes in the global economic bending mechanism with double-heads in the market. But
environment and the development of Chinese economy, it cannot achieve asymmetric bending, meanwhile, its
the machinery industry has been growing rapidly in efficiency is low and maintenance is inconvenient.

Copyright © Canadian Research & Development Center of Sciences and Cultures 14

 TANG Wenxian; ZHU Hui; ZHU Mengxiu; LI Qinfeng; ZHANG Jian (2016).
Management Science and Engineering, 10 (1), 14-20

Secondly, the wire-bending machine needs to be In order to solve above problems, the research is
equipped with the clamping mechanism which is used to based on the wire-bending process to develop a DC
clamp and whirl the wire (Webster, Romano, & Cowan, wire-bending machine which is used to bend the wire
2009). However, the existing clamping mechanism is to any angle. It is a fully automatic machine with
complicated, results in difficult maintenance, unstable storing, straightening, cutting, feeding and wire-bending
powertrain and lower rotational accuracy. mechanism to improve the integration, automation and
Finally, in the process of the mechanism which is precision.
used to store and feed the wire, the wire will be pushed
or the tension will be building up when the feeding speed
is different from the receiving speed of the processing 1. PROCESS ANALYSIS
equipment. In this situation, the mechanism which is The DC wire-bending machine consists of storing
unable to reset by itself needs to be adjusted manually. mechanism, straightening mechanism, feeding mechanism
This way not only reduces the production efficiency, but and wire-bending mechanism. The structure diagram is
also increases the labor costs. shown in Figure 1.

Figure 1
The Structure of the DC Wire-Bending Machine
By analyzing the process of bending the metal wires, be cut by the cutting device. Afterwards the wire cut will
the bending process can be achieved: at first the wire be transmitted to the bending mechanism to be bend.
to be processed will be sent by the storing mechanism, Finally, the switch device will put the formed wire out
then it will be straightened and measured by the of the bending area. The bending process is shown in
straightening mechanism, after measured the wire will Figure 2.

Figure 2
The Process of the DC Wire-Bending Machine

15 Copyright © Canadian Research & Development Center of Sciences and Cultures

Research on Key Technology of Wire-Bending and Equipment Development

2. DESIGN CALCULATION the rotating device gets the signal. As the power of
the storing mechanism, the electric motor drive the
2.1 The Design of the Storing Mechanism stock supporting plate by the reducer, it made the wire
The storing mechanism consists of charging device roll from stock supporting plate to the stand, then
and rotating device. Its role is to store and feeding. to the straightening mechanism to straighten it. The
Sequence of actions is driving the charging device structure diagram of the storing mechanism is shown in
whirl and feeding wires to the next mechanism, when Figure 3.

Figure 3
The Structure Diagram of the Storage Module
The stand connects with the stand base by spring And then the angle transducer will send a signal to the
tension, and the angle transducer is equipped. Keeping electromotor to drive the stock supporting device to turn.
the stand up at a certain angle, when the straightening Finally, it will make the storing mechanism push the
mechanism feeds the wire, the angle between the stand wire forward. The overall layout diagram of the storing
and the stand base will be changed with the stand swings. mechanism is shown in Figure 4.

Figure 4
The Overall Layout Diagram of the Storing Mechanism

Design and Type-Selection. Known conditions: sheaf is 2,400 kg, the structure weight is 600 kg, the
The storing is plain round bar (hot-rolled low carbon aligning speed is 0.15 m/s, the mean radius is 0.3 m, the
steel wire rods GB/T701-2008), the weight of every responding time is 0.5 s.

Copyright © Canadian Research & Development Center of Sciences and Cultures 16

 TANG Wenxian; ZHU Hui; ZHU Mengxiu; LI Qinfeng; ZHANG Jian (2016).
Management Science and Engineering, 10 (1), 14-20

According to calculation, the design information can The pushing power of each wheel: FS=250 N.
be achieved: Therefore, the servomotor whose rated current is 2.0 A
Angular velocity: ω= 0.15 / 0.3= 0.5 r/s, is the best choice and hold the torque at 5.25 N∙ m. At the
Revolving speed: n =ω×60 / 2π= 4.8 n/min, same time, choose the retarder whose reduction ratio is 10
Rotational inertia: I = mr2 = 270 Kg∙m2, and the max output torque is 310 N∙ m.
Required torque: M = I×β= 270×0.5 / 0.5 = 270 N∙m. 2.2.2 The Design of the Straightening Device
Therefore, the stepping-motor whose rated current is The substantive role of the straightening device is to
2.0 A is the best choice and hold the torque at 5.25 N∙ m. apply a high-frequency periodic alternating stress to
At the same time, choose the retarder whose reduction make the wire exceed the limit of its elastic deformation.
ratio is 60 and the max output torque is 310 N∙ m. The deformation occurs alternatively in the opposite
2.2 The Design of the Straightening Mechanism direction. When the alternating deformation is looming
to a certain extent, its frequency will gradually decrease
The straightening mechanism includes: feeding device,
to 0 at a slower rate. Then the original bend will be
straightening device, measuring device and cutting device.
offset. The device of straightening machine adopts the
The functions of these are to feed, straight, and measure
mould straightening mode method. While the material
the length of the passed-wire. The action sequence: First
goes forward, the electric motor drives the mould to
the feeding device pushes the wire, then the straightening
rotate. This method makes the wire round and revises its
device straightens the passed-wire by rolling. The
straightness. After finishing it, the goal of straightening
measuring device will give back information to the
can be achieved. The drawing of partial enlargement of
electromotor of the last mechanism to stop feeding the
the straightening device is shown in Figure 6.
wire, when the length of the passed-wire reaches the goal.
It will also give feedback information to the cutting device
to cut the wire. The structure diagram of the straightening
mechanism is shown in Figure 5.

Figure 6
Figure 5 The Drawing of Partial Enlargement of the
The Structure Diagram of the Straightening Mechanism Straightening Device
1. Feeding roller, 2. Pinch roller, 3. Spring, 4. Synchronous belt, 5. Design and Type-Selection. Known conditions:
Straightening device, Those data that measured from the scene:
6. Measuring device, 7. Cutting device, 8. Electricmotor, 9. Frame
Straightening torque: M=40 N∙ m,
2.2.1 The Design of the Feeding Device Revolving speed: n=850 n/min,
The function of the feeding device is to push the wire Straightening speed: v= 0.15 m/s.
from the storing mechanism to the straightening device. Therefore, the servomotor with brake whose rated
As the capstan, the feeding roller is driven by the electric current is 2.0A is the best choice and hold the torque at
motor. After the pinch roller finishing the compression, 5.25 N∙ m. At the same time, choose the retarder whose
it will cooperate with feeding roller to move the wire to reduction ratio is 15 and the max output torque is 55 N∙ m.
straighten device through the friction force. 2.2.3 The Design of the Measuring Device
Design and Type-Selection. Through measuring, the The substantive role of the measuring device is to measure
max resistance of the wire can be obtained, and its value the passed material and give feedback signal to the storing
is 912.616 N. So the value of feeding resistance can be set mechanism, the feeding device and the cutting device. The
at 996 N and the diameter of the pinch roller is 160 mm. model diagram of the measuring device is shown in Figure
According to calculation, the design information can 7. When the wire goes through the measuring roller and the
be achieved: pinch roller, the encoder starts to work. If the wire reaches
Torque: M=75 N ∙m, the set length, the device will return signal and then the
Revolving speed: n=19.1 n/min, storing mechanism and the feeding device will stop at once.
The pressure on each wheel: FN=5000 N, At the same time, the cutting device will cut the wire.

17 Copyright © Canadian Research & Development Center of Sciences and Cultures

Research on Key Technology of Wire-Bending and Equipment Development

feeding device, and then it will be sent to the center

clamping device after turned over by the turn-over
device. The model diagram of the feeding mechanism is
shown in Figure 9.
2.4 The Design of the Wire-Bending Mechanism
The wire-bending mechanism includes the bilateral
bending device on the left and right and the center
clamping device. Its function is to make bilateral bending
device and the center clamping device joint to bend the
wire. The action sequence of the mechanism is in the
following order: First, the center clamping device will
clamps the wire, then bilateral bending device move to
the first location to start the first bend. Second, the rotate
gear of the center clamping device will rotate to the
perspective of presupposition, then the bilateral bending
Figure 7
The Model Diagram of the Measuring Device device move to the next location to bend the wire again.
1. Rotary encoder, 2. Pinch roller, 3. Measuring roller Third, the rotate gear once again rotates to the perspective
of presupposition and continues to loop until the bend
2.2.4 The Design of the Cutting Device
finished. After finishing it, the switch device will put the
The function of the cutting device is to cut down the
wire out of the bending area. The front view of the link
measured material when it receives the returning signal
bend module is shown in Figure 10.
from the measuring device. The way is used to cut off oil
cylinder through the hydraulic. The model diagram of the
cutting device is shown in Figure 8.

Figure 10
The Front View of the Wire-Bending Mechanism
1. The left side of the bilateral bending device, 2.Center
Figure 8 clamping device, 3. The right side of the bilateral bending device
The Model Diagram of the Cutting Device
1. Guiding device, 2. Blade, 3. Cutting oil cylinder 2.4.1 The Design of Bilateral Bend Device
2.3 The Design of the Feeding Mechanism The bilateral bending device include the holding device,
The feeding mechanism includes: lathe bed, feeding the movable die, the stationary die, the sliding seat,
device and turn-over device. The function is to hold the synchronous pulley retarder, the horizontal driving
wire and turn-over to feed. Its action sequence is in the electromotor, the vertical driving electromotor, the
following order: The wire cut off is put into the blank electromotor of movable die and the electric motor of
to be machined after cutting. First it will be held by the stationary die. The structural diagram of the left side of
the bilateral bending device is shown in Figure 11.
Design and Type-Selection
a) Electromotor of stationary die
Known conditions:
Material: steel 20,
The nominal diameter of steel: Φ8.
According to calculation:
The needed moment to reach the yield limit:
M0=K1×δs×w=21 N∙m.
The needed moment after strain hardening:
Figure 9 M=[K1+K2×d/(d+r)]×δs×w=24.6 N∙m.
The Model Diagram of the Feeding Mechanism
1. Cylinder, 2. Power arm, 3. Driving belt, 4. Hexagonal steel, 5. The needed moment to bend: M 1=[(M 0+M)/2] ×K=
Feeding stand, 6. Manipulator, 7. Buffer 24 N∙m.

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 TANG Wenxian; ZHU Hui; ZHU Mengxiu; LI Qinfeng; ZHANG Jian (2016).
Management Science and Engineering, 10 (1), 14-20

Therefore, the servomotor with brake whose rated modulus is 2, the teeth is 30, the pitch diameter is 60 mm.
power is 400 W and rated speed is 3,000 r/min is the According to calculation:
best choice. At the same time, choose the retarder whose Starting thrust: F=m×a+m×g×sin (20°)=872.3 N,
reduction ratio is 25. Starting torque: M=F×r=26.2 N∙m.
b) The horizontal driving electromotor Therefore, the servomotor whose rated power is
Known conditions: The responding time is 0.5 s, the 900W and rated speed is 1000r/min is the best choice. At
movement speed is 0.5 m/s, the moving mass is 650 kg; the same time, choose the retarder whose reduction ratio
arameters of the selected pinion and rack mechanism: The is 6.

Figure 11
The Structural Diagram of the Left Side of the Bilateral Bending Device
1. Movable die, 2. Stationary die, 3. Holding device, 4. Driven synchronous pulley, 5. Electomotor of stationary die, 6. Vertical
driving electromotor, 7. Horizontal driving electromotor, 8. Electromotor of movable die, 9. Vertical sliding seat, 10. Driving
synchronous pulley

c) The longitudinal drive motor

Known conditions:
The responding time is 0.5 s; the movement speed is
0.25 m/s; the moving mass is 650 kg; parameters of the
ball screw that is selected: the nominal outside diameter
is 20 mm, the lead is 20 mm, the stroke is 150 mm, the
rotating speed is 750 n/min, the maximum moving mass is
170 kg.
According to calculation:
Starting thrust: F=m×a+m×g×sin(20°)=663 N,
Starting torque: M=4.7 N∙m.
Therefore, the servo motor with brake whose rated
power is 400 W and rated speed is 3,000 r/min is the
best choice. At the same time, choose the retarder whose
reduction ratio is 4.
d) The vertical sliding seat Figure 12
The Front View of the Center Clamping Device
Therefore, the air cylinder whose travel is 145 mm, 1. Box, 2. Rotate gear plate, 3. Driving device, 4.Transmission
working pressure is 0.7 MPa and cylinder diameter is 15 device, 5. Clamp device, 6. Switch device, 7. Switch arm, 8. Switch
mm is the best choice. oil cylinder

2.4.2 The Design of Center Clamping Device 360°. The pitch diameter of the gear 1 that meshes with
The center clamping device includes: clamp device, the center gear is 80 mm; the pinion diameter of the
transmission device and the switch device. The front view gear 2 that meshes with the gear 1 is 60 mm; the pinion
of the center clamping device is shown in Figure 12. diameter of the center gear is 220 mm. According to
Design and Type-Selection calculation:
a) Rotate gear plate Starting torque: T=I×B=0.4 kN·m.
Known conditions: The mass of the rotate gear plate Therefore, the servomotor with brake whose rated
is 12.13 kg, the distance between the center and the mass power is 400 W and rated speed is 3,000 r/min is the best
center is 19.5 mm, and the speed accelerated to 30 r/min choice and choose the retarder whose reduction ratio is
in 0.1 s. The range of the positive and negative rotation is 20.

19 Copyright © Canadian Research & Development Center of Sciences and Cultures

Research on Key Technology of Wire-Bending and Equipment Development

b) Transmission device base will be changed when the straightening mechanism

Known conditions: the recommended preload is 65N; feeds the wire, then the angle transducer will send a signal
the max rotation rate is 30 r/min; the transmission ratio is to the electromotor to drive the stock supporting device to
110; the weight is 12.13 kg; the friction coefficient is 0.2; turn. Make the storing mechanism push the wire forward
the distance of the center and the mass center is 19.5 mm, to the straightening mechanism.
the speed is accelerated to 30 r/min in 0.1s. Secondly, the bilateral bending device and the center
According to calculation: clamping device of the wire-bending mechanism joint to
Friction moment: M = m·g·μ·r = 0.7 N·m, bend the wire. The bilateral bending device with double-
Torque: T =I·β= 2.5 N·m, heads can achieve asymmetric bending on two sides at the
The needed power with the max angular velocity: P = same time to bend the wire to any angle.
T × ω = 10 w. Finally, the rotate gear in the center clamping device
So the synchronous pulley is selected. The two pulleys will rotate to the perspective of presupposition makes
have the same diameter and the pitch diameter is 75 mm. the wire-bending mechanism more stable and higher
There are two closed rings on two sides. The thickness rotational accuracy.
of the pulley is 17 mm, its type is XL (light load and low
speed type); the electricmotor whose rated power should
be 100 W, the rated speed is 3,000 r/min; and the retarder REFERENCES
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