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Introduction to Copper Wire Flattener Machine
The copper wire flattener machine converts round copper wire into flat or rectangular ones via cold rolling. As the core of copper wire flattening line, it is key to copper wire rolling process and flat copper wire manufacturing.
Integrating international advanced rolling technology and independent innovation, Sky Bluer Industries China’s flat copper wire manufacturing machine features high precision, stable operation and customization. Widely used in new energy, electrical, aerospace and motor fields, our copper wire rolling mill and copper wire flattening production line adapt to small-batch precision processing and large-scale production, covering various raw material specifications to realize seamless connection from oxygen-free copper rod rolling to finished flat wire forming.
What Is Copper Wire Flattening?
Copper wire flattening is a core cold rolling process that shapes round copper wires or oxygen-free copper rods into flat/rectangular wires via roll pressure at room temperature, relying on metal plastic deformation. Sky Bluer Industries uses multi-pass progressive rolling in a closed production line to avoid wire breakage and uneven deformation, producing high-precision, smooth flat copper wires. Unlike cutting, cold rolling preserves density and strength, improving conductivity and stability for high-performance copper products.
Working Principle of Copper Wire Flattener Machine
Based on metal cold rolling and plastic deformation theory, Sky Bluer Industries’ copper wire flattening machine forms flat/rectangular copper wires via precision rolls. Oxygen-free copper rods undergo multi-pass rolling, tension control and online correction to produce qualified products.
The machine features closed-loop force and speed control, servo-driven rolls, and online dimension monitoring for automatic adjustment. Its heavy-duty rolling mill is optimized for large-diameter oxygen-free copper rods, ensuring stable, continuous, and automatic production with high conductivity and quality.
Structure of Copper Wire Flattener Machine
Sky Bluer Industries China’s copper wire flattening machine and copper wire flattening production line adopt modular design, with five core interlocked parts ensuring stable copper wire flattening process and copper wire rolling process.
Feeding end of copper wire flattening line, stably releasing copper wire/oxygen-free copper rod coils. Hydraulic expansion reel adapts to different coil sizes; constant tension control avoids wire loosening/kinking. Guide device accurately feeds wire to next process—indispensable for copper wire flattening equipment and oxygen-free copper rod rolling mill.
Pre-straightening machine
Precision adjustment link, straightening bent/twisted wires via multi-roller vertical/horizontal structure, eliminating internal stress. Heavy-duty roller group for large-diameter oxygen-free copper rods ensures straightness, avoiding uneven thickness in subsequent rolling.
flat rolling mill
Core forming part of copper wire flattening machine, key to copper wire rolling mill series. Precision four-roll structure (2Hi/4Hi optional), tungsten steel rolls (HRC60) with micrometer-level servo adjustment for multi-pass rolling.
Edging rolls control width for rectangular copper wire manufacturing; integrated cooling lubrication reduces friction and prevents oxidation. Customizable for different raw material and finished product specifications.
Dancer system
Tension control core between rolling mill and takeup machine. Servo-driven floating roller adjusts tension in real time, avoiding wire slack/stretching. Interlocked with electrical system, it alarms and adjusts speed when tension is abnormal—ensuring stable copper wire flattening production line operation.
Winding end of copper wire flattening machine, winding finished flat/rectangular wires into neat coils. Servo precision winding synchronizes with rolling speed; automatic traversing ensures orderly arrangement. Coil pressing device and finished product detection improve efficiency and qualification rate of rectangular copper wire manufacturing.
Key Technical Features for flat copper wire manufacturing machine
Sky Bluer Industries China’s flat copper wire manufacturing machine and copper wire flattening equipment integrate advanced technology, with core features ensuring high performance:
Micron-level precision: Servo-driven roll gap adjustment and online laser detection control tolerance within ±0.01mm, meeting high-precision industry requirements.
High efficiency: Multi-pass progressive rolling, maximum speed 120m/min; 70% per-pass reduction rate for oxygen-free copper rod rolling mill.
Intelligent control: PLC system with touch screen for parameter setting, data storage and fault alarm; full automation reduces manual operation.
Durable components: Tungsten steel rolls and international brand accessories ensure long service life and low maintenance cost.
Strong adaptability: Customizable for different raw materials, specifications and production capacity; suitable for multiple copper materials and industries.
Integrated cooling lubrication: Real-time lubrication reduces friction; circulation filtration saves costs.
How to Select a Copper Wire Flattener Machine?
To select a suitable copper wire flattener machine for production and manufacturing, Sky Bluer Industries China recommends focusing on four core factors:
Input wire diameter
Determines rolling mill model. Our equipment covers φ0.5mm-φ5mm round wires to φ8mm-φ20mm oxygen-free copper rods. Adjustable rolling mills are available for multi-specification processing.
Final width & thickness
Our machines process 0.1mm-5mm thick, 1mm-12mm wide flat wires; customizable rectangular wire aspect ratios. High-precision requirements require micron-level adjustment and online detection.
Required tolerance
Industry-specific: ±0.01mm (new energy/aerospace) or ±0.05mm (general electrical). Choose ordinary or high-precision equipment accordingly.
Production capacity
Ranges from small-batch (annual output <500 tons) to large-scale (up to 5000 tons). Large enterprises select high-speed automatic copper wire flattening line; small-medium enterprises.
choose compact models
Sky Bluer Industries China provides full-cycle services (pre-sales consultation, customization, after-sales support) to ensure equipment stability, creating value for enterprises with copper wire rolling mill and oxygen-free copper rod rolling mill solutions.
Frequently Asked Questions
What type of copper material is suitable for flattening?
Our machine typically processes ETP copper, oxygen-free copper (OFC), or alloy copper in round wire form. Material hardness, purity, and prior drawing condition significantly affect rolling force, surface quality, and final tolerances.
What is the typical reduction ratio in a single pass?
Single-pass reduction depends on copper wire properties, input diameter, tensile strength,surfacing condition and roll capacity. For soft copper, a width-to-thickness ratio up to about 8:1 can often be achieved in one pass, while harder materials may require multiple rolling stages, also drawing machine will be required.
How are dimensional accuracy and stability controlled?
Precision in flat copper wire production mainly depends on accurate roll gap setting, stable tension control, proper lubrication, and consistent temperature conditions during rolling. The rigidity of the mill stand and the quality of the rolls also play an important role in maintaining dimensional stability. When the machine is correctly adjusted and operating under steady conditions, high-precision copper wire flattening mills can typically achieve thickness tolerances within ±0.005 mm while maintaining good surface finish and edge shape.
Why is corner radius (R) control important?
The corner radius affects electrical performance, insulation behavior, and winding quality. Transformer and CTC applications often require specific R values to prevent insulation damage and ensure proper packing density.
Is online annealing necessary for flat copper wire production?
Online annealing is recommended when soft temper wire is required. It restores ductility after cold deformation, reduces residual stress, and improves suitability for enamel coating, paper covering, or tight winding processes.
What factors influence surface quality of the flattened wire?
Surface finish depends on roll polishing quality, lubrication cleanliness, incoming wire condition, alignment, and debris control. Poor conditions may cause scratches, oxidation, edge cracking, or roll marks.
How to install a copper wire flattener?
Installation should be performed on a rigid, level foundation. Key steps include:
- Positioning and anchoring the machine securely
- Precision leveling of the mill base
- Aligning payoff, rolling mill, dancers,and take-up units on the same centerline
- Connecting electrical power, cooling water, lubrication, and pneumatic systems
- Installing rolls and setting the initial roll gap
- Performing no-load test runs and safety checks before production
- Feeding the raw material to test run
- Use a laser diameter gauge or a contact diameter gauge to measure the width and thickness of copper flat wire.
Conclusion
At Sky Bluer, we manufacture high-quality copper wire flattener machines and copper wire flattening mills. We not only supply the equipment but also provide professional guidance on the flattening process to ensure optimal performance and product quality. Partner with us to get a complete solution tailored to your copper wire production needs.
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