Theoretical Modeling of Wire Dynamics and Failure Modes During Manufacture on a Double Twist Machine

Abstract

The problem of wire ballooning, or wire breakage, due to force imbalance is common during the production of wire on double twist machines. This paper examines the forces in wire during the bunching or twinning process. The bow shape is simplified to represent the arc of a circle for mathematical simplicity, which also allows the work to be related to any size of double twist machine produced by any manufacturer, with the proviso that a catenary curve forms the basis of the bow shape. Mathematical approximations of the level of force imbalance between the pre-tension and take-up tension during production are made, and the location of wire breakage within the bow is predicted.