Frank Alkanes India Pvt Ltd

FRANK DRAW TW-2

INTRODUCTION:
FRANK DRAW TW-2 is intended for an accelerated hot dipZinc Phosphating on steel and zinc
Surfaces to facilitate wire and tube drawing.

WIRE & TUBE DRAWING
This Process involves grain dislocations /boundary transformations and subsequent work hardening depending on the alloying constituents. the efficiency of the process depends not only on the ductility of the material drawn ,Die design but greatly on the lubrication.
Considering the speeds employed, the lubrication is put to greatest tests. These tests include Critical under high pressure & temperature. The lubrication, hence is required to meet the following requirements.

1.To ensure no metal to metal contact is present throughout during drawing.
2.To have optimum amount of lubricant coating ,to reduce carry over and eventual pick up at die boxes.
3. Absolutely smooth to avoid chattering
4.Highly uniform, highly adherent, high performance lubricative coatings.
5.Corrosion resistance for longer storage life after/before drawing.

The choices are a substrate chemically bonded, corrosion resistant coated with a performance lubricant.
Zinc stearate coatings easily meet these requirements.

ZINC PHOSPHATING AS A SUBSTRATE
Phosphate coating acts as a fool proof substrate to lubrication if the following requirements are met.

FEATURES
1.Very good Reactivity with stearate to produce fine, smooth, highly adherent, highly lubricative, Corrosion resistant and chemically bonded Zinc stearate coating.
2.Provides corrosion reistance and arrests, creeping incase, the local physical damages occur thus Prolonging the storage life.
3.The phosphate coating itself is very smooth, fine grained and rich with phosphohyllite and forms as an Excellent foundation for subsequent lubrication.

Produces Strongly adherent coatings which have excellent wear resistance to retain the lubricant during cold working resulting in increased tool life.
Designed to tolerate higher load ratios and hence very little control is needed.
Special accelerators and refiners produce highly refined, heavier coatings in a very short time

Coating weight of 15-20 gms/Sq.m is easily achieved.
Produces highly corrosion resistant coatings.
Single Chemical is used for Bath make-up and replensishment.

PHOSPHATING BATH MAKE-UP
FRANK DRAW TW-2 : 60 Litres for every 1000 litres of bath capacity
Bath Pointage : 30-35
Temperature : 80°-85° C
Treatment Time : 10-20 Minutes
Iron Content : 0.05-0.4%
Normally a bath pointage of 30 is optimum but a higher or a lower pointage may be required

because of local line conditions. Whenever a portion of the bath is discarded or lost by sludge removal the volume should be restored with the same proportion of FRANK DRAW TW-2 and water as used in the orginal bath.

IRON CONCENTRATION
During Process ,ferrous iron is formed in the bath.Wher the bath is not heavily loaded ,or is used intermittently,the ferrous iron concentration remains constant at 0.05-0.4 % and need not be controlled .If the bath is heavily loaded @ 1 sq.ft/litre of bath per hour,the ferrous iron concentration may need controlling.

ESTIMATION OF IRON IN THE BATH
The ferrous iron concentration is to be checked by titration as follows:
1.Pipette 10ml of the bath solution into a beaker and dilute to about 100 ml with distilled water
2.Add about 2 ml of 50% sulphuric acid and titrate with 0.1 N potassium permanganate (3.16gm/lit) until a permanent faint pink colour is obtained.The no. of ml. of potassium Permanganate added is measure of the ferrous iron in the bath.
% of IRON = Titration Value × 0.056
If the ferrous iron content should build up ,the coating reaction will slow down and chalky or loose Coatings may be produced.The bath can be restored to its normal condition by discarding a portion of the bath,replenishing it with fresh water and adjusting the strength with FRANK DRAW TW-2
Alternatively ,the following procedure may be adopted to reduce iron content by 0.05 % ,For Every 1000 litres of bath capacity.

METHOD-1 :
1.Take about 500 g of caustic soda and dissolve in about 5 lit of water.
2.To this add about 600 ml of 100 Volumes (30%) Hydrogen Peroxide and mix thoroughly.
3.Without much delay pour this solution in to the bath
4.Mix thoroughly and only after allowing the sludge to settle,the work should be processed.

METHOD-II :
1. Take about 200g of FRANK TONE and dissolve in about 1 litre of water and pour slowly in to the bath
2. Take about 500gm of caustic soda and dissolve in about 5 lit of water and pour slowly in to the bath
3. Mix thoroughly and only after allowing the sludge to settle,the work should be processed.

DESLUDGING :
A FRANK DRAW TW-2 bath will accumulate sludge on use .Sludge formation is a natural Phenomenon of the coating formation .Being inert, the sludge will not affect the chemical balance of the FRANK DRAW TW-2 bath but with excessive accumulation it may touch the work causing improper coating.It is therefore ,necessary to desludge the FRANK DRAW TW-2 bath at regular intervals. The simplest way of desludging the FRANK DRAW TW-2 bath is to allow the bath to settle overnight and Pump the top clear liquid to adjacent rinse tank earlier empited.The slude is removed and the tank walls Scrubbed and flushed with water.
The solution is now returned to the tank and the volume restored to the operating level with water And FRANK DRAW TW-2 according to the proportion of the original bath make up.

AFTER TREATMENT
After the work has been coated with FRANK DRAW TW-2 it should be thoroughly hose rinsed or dip Rinsed with water and then dipped in a hot neutralizer bath (70-90°C) containing 1 kg of Frank Neutralizer per 1000 Litres of rinse bath. The work which will dip lubricated should go straight in to the FRANK LUBE FL-1bath after rinsing.

NO	PROCESS	CHEMICAL	CONC	TEMP	TIME
1	DEGREASING	SURFALEAN-FX	5-8%	85-90°C	15-20 MTS
2	RINSING	====		AMBIENT	FLASH
3	DESMUTTING	CAUSTIC SODA KMnO ====	20% 7%	70-80°C	5-10 MTS
4	RINSING	HCL		AMBIENT	FLASH
5	DERUSTING		10-15%	AMBIENT	5-10 MTS
		=====
6	RINSING	======		AMBIENT	FLASH
7	RINSING	FRANK DRAW TW-2		AMBIENT	FLASH
8	PHOSPHATING	=====	6%	80-85°C	10-20 MTS
9	RINSING	FRANK NEUTRALIZER		AMBIENT	FLASH
10	NEUTRALISING	FRANK LUBE FL-1	0.10%	AMBIENT	FLASH
11	LUBRICATION		3-8%	75-95°C	5-15 MTS

HANDLING PRECAUTIONS
FRANK DRAWE TW-2 is slightly acidic and clothing should be protected if there is any possibility of splashing with the solution. Wash off any splashes at once with cold water. If the solution gets in the eyes wash out with liberal quantities of water and obtain immediate medical attention.