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Ceramic Guide Rollers

To benefit from ceramics wear resistance and light weight, wire drawing machine parts use ceramics in capstan rollers and wire guide rollers. With XYC unique ceramic precision machining technology, formed material is cut, ground and lapped after sintering to required shapes.
These products are used for their unrivaled performance in sliding parts as general structural members, precision jigs and tools, in wear and chemical resistant sliding parts and also in electromagnetic fields and chemical solutions

Background

How much do you know about ceramic guide Rollers?

The Guide wheel plays the role of transmission and direction change in the whole system, so it has extremely high requirements on its wear resistance. If use ceramic guide wheel, not only can the quality of the wire rod be improved, but also the replacement frequency of the roller can be reduced.



Generally, guide wheels are usually made of metal, but due to the resume wires, the surface of the guide wheels is lead to poor surface roughness.

The rough and thick guide wheels will damage the metal when they come into contact with the metal wire. To reduce the quality of the product, if the guide wheel is replaced with a high-hardness ceramic material, the wear and scratches on the surface of the guide wheel can be reduced.



Overview

Guide rollers as shown in the figure are used in the process of manufacturing metal wire. Since the wire travels at high speeds, high levels of tension act on the guide rollers and wear down their surfaces. As a result, there was a need to frequently replace components. This therefore requires that guide rollers have a high degree of hardness as well as have smooth surfaces.


Challenge

Quality of the metal wire degrading due to guide roller surface wear

Metal components had conventionally been used in guide rollers. However, since their surfaces tend to wear easily through contact with the metal wire, surface roughness would worsen. This surface roughness on the guide rollers would then scratch the metal wire when coming in contact, thus affecting product quality.


Solution

Use hard ceramics in guide rollers

To be able to manufacture metal wire of high quality over the long-term, we switched from metal as the material used in guide rollers to high-hardness ceramics to achieve higher wear resistance.


Result

Improved long-term metal wire quality

By switching to ceramics, which are harder than metals, there was less occurrence of scratching as a result of guide roller surface wear. This resulted in less scratching from contact between the metal wire and guide rollers, contributing to higher quality production. Furthermore, with improved wear resistance, rollers required less frequent replacement, alleviating maintenance work.


* Structures in the pictures and animation have been simplified.

* Material property can change depending on operating conditions.