Complete solutions for wire drawing and cable manufacturing processes
High-performance ceramics significantly increase the service life and efficiency in demanding mechanical engineering applications.
Special surface qualities extend machine runtimes and reduce maintenance costs, sustainably optimising your processes. With our refurbishment service, you receive customized, complete solutions from a single source.
Optimally adapted tools for your requirements
The tools used must be precisely tailored to the requirements of the drawing process in order to prevent permanent damage to the wire surface. The tool surfaces require large contact areas and optimal roughness. By precisely controlling the particle sizes of the ceramic materials used, we ensure excellent surface quality and roughness of the tools.
With our advanced manufacturing methods, we guarantee thermal and hydrothermal stability under demanding operating conditions.
Our customers benefit from tribological excellence through:
- Longer machine service life & reduced costs
- Increased process reliability & fewer downtimes
- Maximum wear resistance
- Extended tool life
- Tailor-made solutions for their specific requirements
Rauschert is continuously advancing in this field through its TechCenters.
Products for wire drawing and cable manufacturing processes
With our reliably high-quality products, you can optimise your processes and avoid unplanned downtime caused by machine wear or failure.
Capstan
for process-safe wire drawing in multi-wire machines
Our capstans (also known as drawing rollers) made of MgO-stabilized zirconia or high-purity alumina are characterised by excellent wear and temperature resistance. The optimised surface structure ensures defined sliding friction and minimizes wire breaks in the continuous drawing process.
Standard dimensions: Diameter from 50 mm to 135 mm, 2-step to 16-step designs
Materials: MgO-stabilized zirconia, yellow or white
Drawing cones
for stable processes in fine wire drawing
Our drawing cones made of wear-resistant zirconia or alumina ensure consistent wire guidance and stable friction conditions, even at high drawing speeds and with the smallest wire diameters. The ceramic materials offer excellent fracture toughness and enable long service life with minimal maintenance requirements.
Drawing cones can be designed as full ceramic or composite constructions.
Drawing rings and eyelets
for precise wire guidance
Our highly wear-resistant drawing rings for coarse wire drawing are available in diameters up to 500 mm.
The eyelets and wire guide elements ensure precise wire guidance, reliably preventing surface damage and wire contamination.
Thanks to finely tuned geometries and smooth, tribologically optimized surfaces, they are ideally suited for use in high-speed processes and with extremely fine wires.
Refurbishment service
for ceramic surfaces
In wire and cable drawing processes, tool surfaces are exposed to extreme stresses, which can lead to wear over time.
Our experts can refurbish ceramic surfaces according to your specific requirements, allowing tools to be reliably re-integrated into your processes.
Material selection
Zirconia – MgO-stabilized
Our zirconia materials are stabilized with magnesium and are characterized by:
- High fracture toughness
- High strength
Due to their similar coefficient of thermal expansion, zirconia components are particularly suitable for use in combination with steel parts. We offer zirconia in the standard colors white and yellow.
Alumina with purity levels up to 99,9 %
Alumina is a very hard high-performance ceramic material that remains stable at high temperatures and in aggressive chemical environments.
Depending on purity level and grain size, we use it for a wide range of demanding technical applications.
We offer alumina in purity grades from 90% to 99.9%.
For drawing extremely fine wires (some customers process down to 0.003 mm), the ring must be made of alumina.
Further information on Rapal® is available here:
Downloads
Catalogs
FAQ
About ceramic wire-drawing tools
Which wire materials are ceramic wire-drawing components suitable for?
Rauschert uses ceramic wire-drawing tools for processing copper, stainless steel, and aluminium wire, among other materials. Other material and process requirements are assessed for the specific application.
When should alumina or MgO-stabilised zirconia be used for wire drawing components?
• MgO-ZrO₂: for high mechanical loads and ceramic assemblies, as its coefficient of thermal expansion is similar to that of steel
• Alumina: for every fine wires (down to wire diameters of 0.003 mm)
When is an all-ceramic drawing cone recommended, and when is a composite design preferable?
Rauschert offers both designs. In composite solutions, ceramic is used specifically in the functional areas exposed to wear and combined with a metal support. This allows the benefits of ceramic to be used where they are needed in the process, while the component design can be adapted flexibly to existing machines and installation conditions. All-ceramic drawing tools are only appropriate where the design does not allow sufficient space for a metal supporting structure.
Which surface finish is suitable for my wire drawing process?
The appropriate surface finish is selected according to the wire type and the requirements of the drawing process. A standard polish provides the necessary slip in most applications. A high-polish finish can be used for very fine wires. Rauschert helps customers select the appropriate surface finish.
What are the advantages of ceramic components when drawing coated or sensitive wires?
Ceramic contact surfaces are resistant to wear and corrosion, and can be tailored to guide the wire gently. This helps reduce scratches, abrasion, and localised damage to the wire surface. This is particularly relevant for enamelled, tin-plated or otherwise coated wires.
When drawing coated wires, it is particularly important to avoid damaging the thin coating through excessive slip or mechanical contact. Even with slight wear, ceramic drawing tools retain consistent frictional properties and do not mechanically damage the wire coating.
When can worn ceramic components be refurbished?
Rauschert assesses the component geometry, wear pattern and process requirements to determine whether refurbishment is technically and economically viable. For suitable drawing capstans, drawing cones, drawing rings and wire guide components, the ceramic functional surfaces are reworked to restore the required surface finish. This allows existing components to be reused.
Ceramic drawing tools can be refurbished to a certain extent. Drawing components can usually be reworked twice before they become too small. For cones, the diameter ratios are adjusted to match the original dimensions. All drawing tools in a machine are reground to the same dimensions.
Can existing wire drawing components be replaced with ceramic solutions?
Rauschert manufactures both all-ceramic components and ceramic-metal composite solutions. This allows ceramic to be used specifically on contact surfaces subject to particularly high loads.
On standard machines, the mounting dimensions of drawing tools are generally the same, allowing either steel or ceramic tools to be fitted. However, only one tool material should be used for drawing within a given machine.
What dimensions and special geometries can Rauschert manufacture?
Rauschert manufactures customised drawing components. Examples include large drawing rings with a diameter of up to 550 mm and standard drawing capstans (also known as drawing rollers) with diameters from 50 to 135 mm. Custom solutions can also be developed for drawings or specific requirements.
Can ceramic wire drawing components reduce process costs?
Yes. The high wear resistance of ceramic wire drawing components enables long tool life and can extend the service life of machine components exposed to high loads. At the same time, optimised ceramic surfaces support smooth rotation and stable wire guidance. This improves process reliability and can reduce unplanned downtime, tool changes and maintenance requirements.
How quickly can Rauschert respond to urgent replacement requirements for wire drawing components?
Rauschert manufactures wire drawing parts in Europe. The European production sites enable
• direct and efficient communication
• a rapid response to requirements
