A wire is a single, usually cylindrical A cylinder is one of the most basic curvilinear geometric shapes, the surface formed by the points at a fixed distance from a given straight line, the axis of the cylinder. The solid enclosed by this surface and by two planes perpendicular to the axis is also called a cylinder. The surface area and the volume of a cylinder have been known since, string of metal. Wires are used to bear mechanical loads In structural design, assumed loads are specified in national and local design codes for types of structures, geographic locations, and usage. In addition to the load magnitude, its frequency of occurrence, distribution, and nature are important factors in design. Loads cause stresses, deformations and displacements in structures. Assessment of and to carry electricity Electricity is a general term that encompasses a variety of phenomena resulting from the presence and flow of electric charge. These include many easily recognizable phenomena, such as lightning and static electricity, but in addition, less familiar concepts, such as the electromagnetic field and electromagnetic induction and telecommunications Telecommunication is the transmission of messages, over significant distances, for the purpose of communication. In earlier times, telecommunications involved the use of visual signals, such as smoke, semaphore telegraphs, signal flags, and optical heliographs, or audio messages via coded drumbeats, lung-blown horns, or sent by loud whistles, for signals. Wire is commonly formed by drawing Drawing is a metalworking process which uses tensile forces to stretch metal. It is broken up into two types: sheet metal drawing and wire, bar, and tube drawing. The specific definition for sheet metal drawing is that it involves plastic deformation over a curved axis. For wire, bar, and, tube drawing the starting stock is drawn through a die to the metal through a hole in a die A die is a specialized tool used in manufacturing industries to cut or shape material using a press. Like molds and stencils, dies are generally customized to the item they are used to create. Products made with dies range from simple paper clips to complex pieces used in advanced technology or draw plate A draw plate is type of die consisting of a hardened steel plate with one or more holes through which wire is drawn to make it thinner. A typical plate will have twenty to thirty holes so a wide range of diameters can be drawn. Standard Standardization or standardisation is the process of developing and agreeing upon technical standards. A standard is a document that establishes uniform engineering or technical specifications, criteria, methods, processes, or practices. Some standards are mandatory while others are voluntary. Voluntary standards are available if one chooses to sizes are determined by various wire gauges Wire gauge is a measurement of how large a wire is, either in diameter or cross sectional area. This determines the amount of electric current a wire can safely carry, as well as its electrical resistance and weight per unit of length. Wire gauge is applicable to both electrical and non-electrical wires, being important to electrical wiring and to. The term wire is also used more loosely to refer to a bundle of such strands, as in 'multistranded wire', which is more correctly termed a wire rope Wire rope is a type of rope which consists of several strands of metal wire laid into a helix. Initially wrought iron wires were used, but today steel is the main material used for wire ropes in mechanics, or a cable A cable is two or more wires running side by side and bonded, twisted or braided together to form a single assembly. In mechanics cables, otherwise known as wire ropes, are used for lifting, hauling and towing or conveying force through tension. In electrical engineering cables used to carry electric currents. An optical cable contains one or more in electricity.
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History
In antiquity Ancient history is the study of the written past from the beginning of recorded human history in the Old World to the Early Middle Ages in Europe, jewellery Jewellery or jewelry (see American and British English spelling differences) is a form of personal adornment, manifesting itself as necklaces, rings, brooches, earrings and bracelets. Jewellery may be made from any material, usually gemstones, precious metals or shells. Factors affecting the choice of materials include cultural differences and the often contains, in the form of chains and applied decoration, large amounts of wire that is accurately made and which must have been produced by some efficient, if not technically advanced, means. In some cases, strips cut from metal sheet were made by pulling them through perforations in stone beads. This causes the strips to fold round on themselves to form thin tubes. This strip drawing technique was in use in Egypt Egypt (pronounced /ˈiːdʒɪpt/ ; Arabic: مصر Miṣr, pronounced [misˤɾ] ( listen); Arabic: مِصْر Miṣr [ˈmisˤɾ]; Egyptian Arabic: مَصْر Maṣr [ˈmɑsˤɾ]; Coptic: Ⲭⲏⲙⲓ, kīmi; Egyptian: 𓆎𓅓𓏏𓊖 Kemet), officially the Arab Republic of Egypt, is a country mainly in North Africa, with the Sinai Peninsula by the 2nd Dynasty The Second Dynasty of ancient Egypt is often combined with the First dynasty under the group title, Early Dynastic Period of Egypt. It dates approximately from 2890 to 2686 BC. The capital at that time was Thinis. From the middle of the 2nd millennium BC Its first half is dominated by the Middle Kingdom of Egypt and Babylonia. The alphabet develops. Indo-Iranian migration onto the Iranian plateau and onto the Indian subcontinent propagates the use of the chariot. Chariot warfare and population movements lead to violent changes at the center of the millennium, and a new order emerges with Greek most of the gold Gold is a chemical element with the symbol Au (from Latin: aurum, "shining dawn", hence adjective, aureate) and an atomic number of 79. It has been a highly sought-after precious metal for coinage, jewelry, and other arts since the beginning of recorded history. The metal occurs as nuggets or grains in rocks, in veins and in alluvial wires in jewellery are characterised by seam lines that follow a spiral path along the wire. Such twisted strips can be converted into solid round wires by rolling them between flat surfaces or the strip wire drawing method. The strip twist wire manufacturing method was superseded by drawing Wire drawing is a metalworking process used to reduce the diameter of a wire by pulling the wire through a single, or series of, drawing die. There are many applications for wire drawing, including electrical wiring, cables, tension-loaded structural components, springs, paper clips, spokes for wheels, and stringed musical instruments. Although in the ancient Old World sometime between about the 8th and 10th centuries AD.[1] There is some evidence for the use of drawing further East prior to this period.[2]
Square and hexagonal wires were possibly made using a swaging Swaging is a forging process in which the dimensions of an item are altered using a die or dies, into which the item is forced. Swaging is usually a cold working process; however, it is sometimes done as a hot working process technique. In this method a metal rod was struck between grooved metal blocks, or between a grooved punch and a grooved metal anvil. Swaging is of great antiquity, possibly dating to the beginning of the 2nd millennium BC in Egypt and in the Bronze The Bronze Age of a culture is the period when the most advanced metalworking in that culture used bronze. This could either have been based on the local smelting of copper and tin from ores, or trading for bronze from production areas elsewhere. Many, though not all, Bronze Age cultures flourished in prehistory and Iron Ages In archaeology, the Iron Age is the prehistoric period in any area during which cutting tools and weapons were mainly made of iron or steel. The adoption of this material coincided with other changes in society, including differing agricultural practices, religious beliefs and artistic styles in Europe for torches A torch is a portable source of fire used as a source of light, usually a rod-shaped piece of wood with a rag soaked in pitch and/or some other flammable material wrapped around one end. Torches were often supported in sconces by brackets high up on walls, to throw light over corridors in stone structures such as castles or crypts and fibulae A Fibula is an ancient brooch. Technically, the Latin term fibulae refers specifically to Roman brooches, however, the term is widely used to refer to brooches from the entire ancient and early medieval world. Unlike modern brooches, fibulae were not only decorative, they originally served a practical function: to fasten clothes, including cloaks.
Twisted square section wires are a very common filigree Filigree is a delicate kind of jewel work made with twisted threads usually of gold and silver or stitching of the same curving motifs. It often suggests lace, and in recent centuries remains popular in Indian and other Asian metalwork, and French from 1660 to the late 19th century. It should not be confused with ajoure jewellery work; while both decoration in early Etruscan jewellery.
In about the middle of the 2nd millennium BC a new category of decorative tube was introduced which imitated a line of granules. True beaded wire, produced by mechanically distorting a round-section wire, appeared in the Eastern Mediterranean and Italy in the seventh century BC, perhaps disseminated by the Phoenicians. Beaded wire continued to be used in jewellery into modern times, although it largely fell out of favour in about the tenth century AD when two drawn round wires, twisted together to form what are termed 'ropes', provided a simpler-to-make alternative. A forerunner to beaded wire may be the notched strips and wires which first occur from around 2000 BC in Anatolia Anatolia is a geographic and historical term denoting the westernmost protrusion of Asia, comprising the western two-thirds of the Republic of Turkey. The region is bounded by the Black Sea to the north, Georgia to the northeast, the Armenian Highland to the east, Mesopotamia to the southeast, the Mediterranean Sea to the south and the Aegean Sea.
Wire was drawn Wire drawing is a metalworking process used to reduce the diameter of a wire by pulling the wire through a single, or series of, drawing die. There are many applications for wire drawing, including electrical wiring, cables, tension-loaded structural components, springs, paper clips, spokes for wheels, and stringed musical instruments. Although in England from the medieval period. The wire was used to make wool cards and pins, manufactured goods whose import was prohibited by Edward IV Edward IV (28 April 1442 – 9 April 1483) was King of England from 4 March 1461 until 3 October 1470, and again from 11 April 1471 until his death. He was the first Yorkist King of England. The first half of his rule was characterised by violence, but he overcame the remaining Lancastrian threat at Tewkesbury to reign in peace until his sudden in 1463.[3] The first wire mill in Great Britain was established at Tintern Tintern is a village on the west bank of the River Wye in Monmouthshire, Wales, close to the border with England, about 5 miles north of Chepstow. It is popular with tourists, who visit for the natural scenery and the ruined Tintern Abbey in about 1568 by the founders of the Company of Mineral and Battery Works, who had a monopoly In economics, a monopoly (from Greek monos / μονος + polein / πωλειν (to sell)) exists when a specific individual or an enterprise has sufficient control over a particular product or service to determine significantly the terms on which other individuals shall have access to it. (This is in contrast to a monopsony which relates to a on this.[4] Apart from their second wire mill at nearby Whitebrook,[5] there were no other wire mills before the second half of the 17th century. Despite the existence of mills, the drawing of wire down to fine sizes continued to be done manually.
Wire is usually drawn of cylindrical form; but it may be made of any desired section by varying the outline of the holes in the draw-plate through which it is passed in the process of manufacture. The draw-plate A draw plate is type of die consisting of a hardened steel plate with one or more holes through which wire is drawn to make it thinner. A typical plate will have twenty to thirty holes so a wide range of diameters can be drawn or die A die is a specialized tool used in manufacturing industries to cut or shape material using a press. Like molds and stencils, dies are generally customized to the item they are used to create. Products made with dies range from simple paper clips to complex pieces used in advanced technology is a piece of hard cast-iron or hard steel, or for fine work it may be a diamond In mineralogy, diamond is an allotrope of carbon, where the carbon atoms are arranged in a variation of the face-centered cubic crystal structure called a diamond lattice. Diamond is less stable than graphite, but the conversion rate from diamond to graphite is negligible at ambient conditions. Diamond is renowned as a material with superlative or a ruby A ruby is a pink to blood-red gemstone, a variety of the mineral corundum . The red color is caused mainly by the presence of the element chromium. Its name comes from ruber, Latin for red. Other varieties of gem-quality corundum are called sapphires. The ruby is considered one of the four precious stones, together with the sapphire, the emerald,. The object of utilising precious stones is to enable the dies to be used for a considerable period without losing their size, and so producing wire of incorrect diameter. Diamond dies must be rebored when they have lost their original diameter of hole, but the metal dies are brought down to size again by hammering up the hole and then drifting it out to correct diameter with a punch.
Uses
Wire has many uses. It forms the raw material of many important manufacturers Manufacturing is the use of machines, tools and labor to make things for use or sale. Also it can be used for selling things. The term may refer to a range of human activity, from handicraft to high tech, but is most commonly applied to industrial production, in which raw materials are transformed into finished goods on a large scale. Such, such as the wire-net industry, wire-cloth making and wire-rope A rope is a length of fibres, twisted or braided together to improve strength for pulling and connecting. It has tensile strength but is too flexible to provide compressive strength . Rope is thicker and stronger than similarly constructed cord, line, string, and twine spinning, in which it occupies a place analogous to a textile A textile is a flexible material consisting of a network of natural or artificial fibres often referred to as thread or yarn. Yarn is produced by spinning raw wool fibres, linen, cotton, or other material on a spinning wheel to produce long strands. Textiles are formed by weaving, knitting, crocheting, knotting, or pressing fibres together fiber Fiber, also spelled fibre, is a class of materials that are continuous filaments or are in discrete elongated pieces, similar to lengths of thread. They are very important in the biology of both plants and animals, for holding tissues together. Human uses for fibers are diverse. They can be spun into filaments, string or rope, used as a component. Wire-cloth A textile is a flexible material consisting of a network of natural or artificial fibres often referred to as thread or yarn. Yarn is produced by spinning raw wool fibres, linen, cotton, or other material on a spinning wheel to produce long strands. Textiles are formed by weaving, knitting, crocheting, knotting, or pressing fibres together of all degrees of strength and fineness of mesh is used for sifting and screening machinery, for draining paper pulp, for window screens, and for many other purposes. Vast quantities of aluminium Aluminium (UK: /ˌæljʉˈmɪniəm/ AL-yew-MIN-ee-əm) or aluminum (US: /əˈluːmɨnəm/ ( listen) ə-LOO-mi-nəm) is a silvery white member of the boron group of chemical elements. It has the symbol Al and its atomic number is 13. It is not soluble in water under normal circumstances. Aluminium is the most abundant metal in the Earth's crust,, copper Copper is a chemical element with the symbol Cu (Latin: cuprum) and atomic number 29. It is a ductile metal with very high thermal and electrical conductivity. Pure copper is rather soft and malleable, and a freshly exposed surface has a pinkish or peachy color. It is used as a thermal conductor, an electrical conductor, a building material, and a, nickel Nickel is a chemical element, with the chemical symbol Ni and atomic number 28. It is a silvery-white lustrous metal with a slight golden tinge. It is one of the four ferromagnetic elements that exist around room temperature, the other three being iron, cobalt and gadolinium and steel Steel is an alloy that consists mostly of iron and has a carbon content between 0.2% and 2.1% by weight, depending on the grade. Carbon is the most common alloying material for iron, but various other alloying elements are used, such as manganese, chromium, vanadium, and tungsten. Carbon and other elements act as a hardening agent, preventing wire are employed for telephone and data wires and cables, and as conductors in electric power transmission Electric power transmission or "high voltage electric transmission" is the bulk transfer of electrical energy, from generating plants to substations located near to population centers. This is distinct from the local wiring between high voltage substations and customers, which is typically referred to as electricity distribution, and heating. It is in no less demand for fencing, and much is consumed in the construction of suspension bridges, and cages, etc. In the manufacture of stringed musical instruments and scientific instruments wire is again largely used. Among its other sources of consumption it is sufficient to mention pin and hair-pin making, the needle and fish-hook industries, nail, peg and rivet making, and carding machinery; indeed there are few industries into which it does not enter.
Not all metals and metallic alloys An alloy is a partial or complete solid solution of one or more elements in a metallic matrix. Complete solid solution alloys give single solid phase microstructure, while partial solutions give two or more phases that may be homogeneous in distribution depending on thermal history. Alloys usually have different properties from those of the possess the physical properties necessary to make useful wire. The metals must in the first place be ductile Ductility is a mechanical property that describes the extent in which solid materials can be plastically deformed without fracture and strong in tension, the quality on which the utility of wire principally depends. The metals suitable for wire, possessing almost equal ductility, are platinum Platinum is a chemical element with the chemical symbol Pt and an atomic number of 78. Its name is derived from the Spanish term platina del Pinto, which is literally translated into "little silver of the Pinto River." It is in Group 10 of the periodic table of elements. A dense, malleable, ductile, precious, gray-white transition metal,, silver Silver is a metallic chemical element with the chemical symbol Ag and atomic number 47. A soft, white, lustrous transition metal, it has the highest electrical conductivity of any element and the highest thermal conductivity of any metal. The metal occurs naturally in its pure, free form (native silver), as an alloy with gold and other metals, and, iron Iron is the most common element in the earth as a whole, and the fourth most common in the Earth's crust. It is produced as a result of stellar fusion in high-mass stars, and it is the heaviest stable element produced by stellar fusion because the fusion of iron is the last nuclear fusion reaction that is exothermic. Iron is the most widely used, copper Copper is a chemical element with the symbol Cu (Latin: cuprum) and atomic number 29. It is a ductile metal with very high thermal and electrical conductivity. Pure copper is rather soft and malleable, and a freshly exposed surface has a pinkish or peachy color. It is used as a thermal conductor, an electrical conductor, a building material, and a, aluminium and gold Gold is a chemical element with the symbol Au (from Latin: aurum, "shining dawn", hence adjective, aureate) and an atomic number of 79. It has been a highly sought-after precious metal for coinage, jewelry, and other arts since the beginning of recorded history. The metal occurs as nuggets or grains in rocks, in veins and in alluvial; and it is only from these and certain of their alloys with other metals, principally brass and bronze, that wire is prepared. By careful treatment extremely thin wire can be produced. Special purpose wire is however made from other metals (e.g. tungsten wire for light bulb and vacuum tube filaments, because of its high melting temperature). Copper wires could be plated with other metals, such as tin, nickel, and silver to handle different temperatures.
Production
Wire mill, 1913. Main article: Wire drawingWire is often reduced to the desired diameter and properties by repeated drawing through progressively smaller dies, or traditionally holes in draw plates. After a number of passes the wire may be annealed to facilitate more drawing or, if it is a finished product, to maximise ductility and conductivity.
Finishing, jacketing, and insulating
Electrical wires are usually covered with insulating materials, such as plastic, rubber-like polymers, or varnish. Insulating and jacketing of wires and cables is nowadays done by passing them through an extruder. Formerly, materials used for insulation included treated cloth or paper, and various oil-based products. Since the mid-1960s, plastic and polymers exhibiting properties similar to rubber have predominated.
Two or more wires may be wrapped concentrically, separated by insulation, to form coaxial cable. The wire or cable may be further protected with substances like paraffin, some kind of preservative compound, bitumen, lead, or aluminium sheathing, or steel taping. Stranding or covering machines wind material onto wire which passes through quickly. Some of the smallest machines for cotton covering have a large drum, which grips the wire and moves it through toothed gears; the wire passes through the centre of disks mounted above a long bed, and the disks carry each a number of bobbins varying from six to twelve or more in different machines. A supply of covering material is wound on each bobbin, and the end is led on to the wire, which occupies a central position relatively to the bobbins; the latter being revolved at a suitable speed bodily with their disks, the cotton is consequently served on to the wire, winding in spiral fashion so as to overlap. If a large number of strands are required the disks are duplicated, so that as many as sixty spools may be carried, the second set of strands being laid over the first.
Coaxial Cable, one example of a jacketed and insulated wire.For heavier cables, used for electric light and power, and submarine cables, the machines are somewhat different in construction. The wire is still carried through a hollow shaft, but the bobbins or spools of covering material are set with their spindles at right angles to the axis of the wire, and they lie in a circular cage which rotates on rollers below. The various strands coming from the spools at various parts of the circumference of the cage all lead to a disk at the end of the hollow shaft. This disk has perforations through which each of the strands pass, thence being immediately wrapped on the cable, which slides through a bearing at this point. Toothed gears having certain definite ratios are used to cause the winding drum for the cable and the cage for the spools to rotate at suitable relative speeds which do not vary. The cages are multiplied for stranding with a large number of tapes or strands, so that a machine may have six bobbins on one cage and twelve on the other.
Solid versus stranded
Stranded copper wireSolid wire, also called solid-core or single-strand wire, consists of one piece of metal wire. Stranded wire is composed of a bundle of small-gauge wires to make a larger conductor.
Stranded wire is more flexible than solid wire of the same total cross-sectional area. Solid wire is cheaper to manufacture than stranded wire and is used where there is little need for flexibility in the wire. Solid wire also provides mechanical ruggedness; and, because it has relatively less surface area which is exposed to attack by corrosives, protection against the environment. Stranded wire is used whenever ease of bending or repeated bending are required. Such situations include connections between circuit boards in multi-printed-circuit-board devices, where the rigidity of solid wire would produce too much stress as a result of movement during assembly or servicing; A.C. line cords for appliances; musical instrument cables; computer mouse cables; welding electrode cables; control cables connecting moving machine parts; mining machine cables; trailing machine cables; and numerous others.
At high frequencies, current travels near the surface of the wire because of the skin effect, resulting in increased power loss in the wire. Stranded wire might seem to reduce this effect, since the total surface area of the strands is greater than the surface area of the equivalent solid wire, but in fact a simple stranded wire will not improve skin effect since all the strands are short-circuited together and still behave as a single conductor. A stranded wire will have higher resistance than a solid wire of the same diameter because the cross-section of the stranded wire is not all copper, there are unavoidable gaps between the strands (this is the circle packing problem for circles within a circle). A stranded wire with the same cross-section of conductor as a solid wire is said to have the same equivalent gauge and is always a larger diameter.
However, for many high-frequency applications, proximity effect is more severe than skin effect, and in some limited cases, simple stranded wire can reduce proximity effect. For better performance at high frequencies, litz wire, which has the individual strands insulated and twisted in special patterns, may be used.
Number of strands
The more individual wire strands in a wire bundle the more flexible, kink resistant, break resistant, and stronger the wire is. But more strands cost more.
The lowest number of strands is 7. One in the middle, and 6 surrounding it.
The next level up is 19, which is another layer of 12 strands on top of the 7. After that the number varies, but 37 and 49 are common, then in the 70 to 100 range (the number is no longer exact). Even larger numbers than that are typically found only in very large wires.
For application where the wire moves 19 is the lowest that should be used (7 should only be used in applications where the wire is placed and then doesn't move), and 49 is much better. For applications with constant repeated movement, such as assembly robots, and headphone wires, 70 to 100 is mandatory.
Varieties
- Hook-up wire is small-to-medium gauge, solid or stranded, insulated wire, used for making internal connections inside electrical or electronic devices. It is often tin-plated to facilitate soldering.
- Magnet wire is solid wire, usually copper, which, to allow closer winding when making electromagnetic coils, is insulated only with varnish, rather than the thicker plastic or other insulation commonly used on electrical wire. It is used for the winding of electric motors, transformers, inductors, generators, speaker coils, etc.
- Resistance wire is wire with higher than normal resistivity, often used for heating elements or for making wire-wound resistors. Nichrome wire is the most common type.
See also
| Look up wire in Wiktionary, the free dictionary. |
- Barbed wire
- Cable
- Chicken wire
- Electrical wiring
- Litz wire
- Razor wire
- Tape wire
- THHN
- Wire gauge
- Wire netting
- Wire rope
- Welding wire
- Wollaston wire
References
- ^ Jack Ogden, ‘Classical Gold wire: Some Aspects of its Manufacture and Use’, Jewellery Studies, 5, 1991, pp. 95–105.
- ^ Jack Ogden, ‘Connections between Islam, Europe, and the Far East in the Medieval Period: The Evidence of the Jewelry Technology’. Eds P. Jett, J Douglas, B. McCarthy, J Winter. Scientific Research in the Field of Asian Art. Fiftieth-Anniversary Symposium Proceedings. Archetype Publications, London in association with the Freer Gallery of Art, Smithsonian Institution, 2003.
- ^ H. R. Schubert, 'The wiredrawers of Bristol' Journal Iron & Steel Institute 159 (1948), 16-22.
- ^ M. B. Donald, Elizabethan Monopolies: Company of Mineral and Battery Works (Olver & Boyd, Edinburgh 1961), 95-141.
- ^ D. G. Tucker, 'The seventeenth century wireworks at Whitebrook, Monmouthshire' Bull. Hist. Metall. Gp 7(1) (1973), 28-35.
- "Wire". Encyclopædia Britannica (11th ed.). 1911.
External links
- Wire Gauge to Diameter—Diameter to Wire Gauge Converter - Online calculator converts gauge to diameter or diameter to gauge for any wire size.
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