{"id":30301,"date":"2026-06-01T06:08:48","date_gmt":"2026-06-01T06:08:48","guid":{"rendered":"https:\/\/doingcable.com\/?p=30301"},"modified":"2026-06-01T06:08:50","modified_gmt":"2026-06-01T06:08:50","slug":"how-does-a-continuous-extrusion-machine-for-copper-wire-work","status":"publish","type":"post","link":"https:\/\/doingcable.com\/ar\/how-does-a-continuous-extrusion-machine-for-copper-wire-work\/","title":{"rendered":"\u0643\u064a\u0641 \u062a\u0639\u0645\u0644 \u0622\u0644\u0629 \u0627\u0644\u0628\u062b\u0642 \u0627\u0644\u0645\u0633\u062a\u0645\u0631 \u0644\u0623\u0633\u0644\u0627\u0643 \u0627\u0644\u0646\u062d\u0627\u0633\u061f"},"content":{"rendered":"

In modern cable and conductor manufacturing, continuous extrusion technology<\/strong> (also known as the Conform\u2122 process<\/strong> \u0623\u0648 Continuous Rotary Extrusion \u2013 CRE<\/strong>) has revolutionized the production of copper flat wire, round wire, small busbars, and specialized profiles.<\/p>\n\n\n\n

Unlike conventional batch extrusion that requires pre-heated billets and multiple discontinuous steps, a continuous extrusion machine transforms copper rod feedstock directly into finished products in one seamless, high-speed operation. This results in superior productivity, dramatically lower energy consumption, near-zero scrap, and excellent metallurgical quality.<\/p>\n\n\n\n

This comprehensive guide explains exactly how a continuous extrusion machine for copper wire works<\/strong>, based on the established Conform process used by leading global manufacturers.<\/p>\n\n\n\n

The Core Working Principle: Friction-Driven Continuous Rotary Extrusion<\/h2>\n\n\n\n

The Conform process is a solid-state, friction-based metal forming technology<\/strong>. It relies on the rotating extrusion wheel to generate both the driving force and the necessary heat through friction \u2014 eliminating the need for external billet heating in most copper applications.<\/p>\n\n\n\n

\"continuous<\/figure>\n\n\n\n

Detailed Step-by-Step Process<\/h3>\n\n\n\n
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  1. Feedstock Preparation and Entry<\/strong> Oxygen-free copper rod (typically \u00d812.5 mm for TLJ300H models) is paid off from a large coil and fed into a precision coining roll<\/strong> that forces it into the circumferential groove of the rotating extrusion wheel.<\/li>\n\n\n\n
  2. Gripping and Frictional Drive<\/strong> The large contact area between the copper rod and the grooved wheel creates powerful frictional grip. As the wheel rotates (controlled by a high-power AC motor, e.g., 110 kW on TLJ300H), the rod is continuously drawn forward along the groove.<\/li>\n\n\n\n
  3. Frictional Heating and Plasticization<\/strong> Intense friction between the moving rod, the wheel groove, and the stationary shoe generates significant heat. For copper, temperatures can reach 400\u2013500\u00b0C or higher<\/strong> without any external heaters. This brings the material into a highly plastic state suitable for extrusion.<\/li>\n\n\n\n
  4. Upsetting at the Abutment<\/strong> The groove is enclosed by a stationary shoe assembly<\/strong>. At the end of the arc, a fixed abutment<\/strong> (block) protrudes into the groove and stops the forward movement of the material. This creates high pressure and forces the plasticized copper to \u201cupset\u201d (pile up) in front of the abutment.<\/li>\n\n\n\n
  5. Radial Extrusion Through the Die<\/strong> The accumulated material is forced radially outward into the die chamber<\/strong> located in the shoe. Under extreme pressure, it flows through a precisely engineered die orifice, forming the desired continuous profile (flat wire, round wire, or busbar).<\/li>\n\n\n\n
  6. Product Exit, Cooling, and Take-up<\/strong> The extruded copper product exits continuously, is cooled in a water or air bath to prevent oxidation, dried, measured, and wound onto reels or cut to length.<\/li>\n<\/ol>\n\n\n\n

    The entire cycle is continuous \u2014 the machine runs 24\/7 as long as feedstock is supplied, producing theoretically unlimited product lengths.<\/p>\n\n\n\n

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    Process Diagram (Conform Wheel, Shoe, Abutment & Die Chamber)<\/h4>\n\n\n\n
    \"\"<\/figure>\n\n\n\n

    Complete Continuous Extrusion Line Layout<\/p>\n\n\n\n

    Key Components of a Continuous Extrusion Machine<\/h2>\n\n\n\n