1,Identify the types of raw materials used in our cable factory.

Ans. Aluminium

Copper

PVC(poly vinyl chloride)

XLPE(Cross-linked Polyethylene)

2,identify the categories of our product.

Wire production

cable production

3, sketch the process flow chart for each for each of the identified product category.
4, identify the organizational structure of manufacturing division.

Metal section.

Extrusion section.

Assembly section.

5, identify the man power allocation on each machine.

Drawing:

A, large drawing =6

B, medium drawing = 3

C, fine drawing =2

Stranding:

a, Cage =2

b, Frame =2

c, Tublar =2

Extrusion:

Extrusion 65 =2

Extrusion 90 =2
Extrusion 150 =2

6, identify the machine types and their manufacturing capacity.

Metal section : In this section there are two types of operator machines which are "drawing and

stranding".

1,Drawing: To draw depend on wire diameter, there are three drawing machines

1.1, Large drawing, which draws 8mm for copper (Cu) and 9mm for aluminium(Al)

1.2, medium drawing, it can draw from 3mm to 1.04mm.

1.3,fine drawing, this machine can draw from 1.22mm to 0.20 mm.

2, stranding machines: also, In this section there are three operation machines.

2.1, frame: this machine can strand from diameter 50mm_300mm and the maximum capacity

of caring spool is 37.

2.2,Cage : this stranding machine can strand 50mm to 120 mm and it can carry 19 spools.

2.3, Tublar: this stranding machine can strand from diameter 6mm to 35mm also the capacity

to carry the spool is 7 which the caried is mostly single.

Extrusion section :

In this section there are three machines which depend on size.

These are:

1, extrusion 65: this machine can insulate from wire section area 0.75 mm square to 6mm

square.these wires can be either strand or single.

2, extrusion 90: this machine can insulate from wire section area 6 mm square to 300mm

square.

3, extrusion150:this machine can insulate from wire section area 120 mm square to 300mm

square. This machine most of the time used for bedding and sheathing.

Assembly section:

In this section there are two machines those are:

Assembly 1250: this can be assemble from 5X10 to 5x70mm square

Assembly 1600: this machine can assemble from 5x120t to 5x300mm square

Compare your theoretical knowledge with the real world on system mechanism, total quality
management, operations management and others.

7, compare your theoretical knowledge with Real world on system , mechanism, total quality
management, operations management and others

√ In belayab cable factory we have seen several technique and mechanism of manufacturing.
But as a materials science and engineering students who have learned courses theoretically the
course named "fundamental of polymer and metallurgy " we have been focused on materials
characters and properties. And under this investigation we have some problems encountered.
Among these problems,

# why copper wire is repeatedly snapped at drawing?

# Why PVC and XLPE consumption while insulation is different?

Honestly we have been stragling to find the problems and it's solutions.but finally we are here
with solutions.

@# Here is the answer for copper:

Copper, like many other ductile metals, can experience snapping or fracturing during the
drawing process due to various factors:

1. Work Hardening: Copper, when subjected to mechanical deformation during drawing,

undergoes work hardening. Work hardening is a process where the metal becomes more
resistant to deformation as it is stretched and deformed. This increased resistance can lead to
the metal snapping or fracturing if it becomes too hard to deform further.

2. Brittleness at Low Temperatures: Copper can become brittle at low temperatures. When the
drawing process involves cold working or if the copper is at a low temperature, it becomes more
prone to snapping due to reduced ductility.

3. Defects in the Material: If the copper material being drawn contains impurities, defects, or
inclusions, these can act as stress concentrators. Stress concentrations can lead to localized
failure and snapping during drawing.
4. Inadequate Lubrication: Proper lubrication is essential during the drawing process to reduce
friction and heat. Inadequate lubrication can increase friction and heat generation, which can
weaken the copper and make it more prone to snapping.

5. Excessive Tension: If excessive tension is applied during the drawing process, it can cause
the copper to reach its breaking point and snap. Proper control of tension is crucial to prevent
this.

6. Inadequate Annealing: Copper wires or rods are often annealed at specific stages during the
drawing process to restore ductility. If annealing is not done correctly or at the right intervals,
the copper may become too brittle and snap.

7. Tooling and Die Design: The design and condition of the drawing dies and tools can also
influence whether copper snaps during drawing. If the dies are not properly designed or
maintained, they can create stress concentrations or damage the copper, leading to snapping.

8. Material Properties: The specific alloy and properties of the copper being used can impact its
behavior during drawing. Different copper alloys have varying levels of ductility and strength,
which can affect how they respond to the drawing process.

To prevent snapping during the drawing process, manufacturers must carefully control various
parameters, including temperature, tension, lubrication, and annealing. Additionally, using high-
quality copper with fewer impurities can also help reduce the likelihood of snapping. Proper die
design and maintenance are also essential to ensure a smooth drawing process without
unexpected failures.

@# And the other cases maybe 🤔

Recycled copper can pose certain challenges when compared to virgin (or newly mined) copper,
primarily due to differences in the quality and composition of the material. These challenges
arise from the impurities, contaminants, and physical properties of recycled copper, which can
affect its suitability for various applications. Here are some reasons why recycled copper can be
challenging and ways to address these challenges:

1. Impurities and Contaminants: Recycled copper often contains impurities and contaminants
that accumulate during its previous use, such as paints, coatings, and other non-metallic
materials. These impurities can affect the conductivity and other properties of the copper.

*Solution*: To address this issue, the recycled copper can go through a refining process to
remove impurities. Techniques like electrolysis or smelting can be employed to purify the
copper and bring it closer to the quality of virgin copper.

2. Alloying Elements: Copper alloys, such as brass and bronze, can be challenging to recycle
because they contain additional metals like zinc, tin, or aluminum. The presence of these
alloying elements can affect the properties of the recycled copper.

*Solution*: Separation and sorting processes are crucial to isolate copper from its alloys
during recycling. This can involve using heat, chemical processes, or mechanical methods to
separate copper from other metals.

3. Physical Properties: Recycled copper might have differences in grain size, crystal structure,
and mechanical properties compared to virgin copper, affecting its suitability for certain
applications.

*Solution*: Depending on the specific application, the recycled copper may need to undergo
heat treatment or other processes to adjust its physical properties and bring them in line with
the requirements of the application.

4. Inconsistent Quality: The quality of recycled copper can vary significantly depending on its
source and the recycling process used. Inconsistent quality can make it challenging to predict
how recycled copper will perform in different applications.

*Solution*: Implementing strict quality control measures during the recycling process and
establishing standards for recycled copper can help ensure a more consistent and reliable
product.

5. Environmental Concerns: While recycling copper is environmentally beneficial, the presence

of contaminants or hazardous materials in recycled copper can pose environmental risks if not
handled properly.

*Solution*: Implementing environmentally responsible recycling practices, including proper

disposal of contaminants and adherence to environmental regulations, can mitigate these
concerns.

6. Economic Considerations: The cost of recycling copper can sometimes be higher than using
virgin copper, especially when dealing with complex or contaminated sources.

*Solution*: Governments and industries can incentivize copper recycling through policies,
subsidies, or tax incentives. Improving recycling technologies and efficiency can also help
reduce the economic challenges associated with recycling.

In summary, while recycled copper is a valuable resource with environmental benefits, it can
present challenges due to impurities, alloying elements, and varying qualities. These challenges
can be addressed through proper recycling processes, quality control, separation techniques,
and environmental responsibility. With the right approach, recycled copper can be a sustainable
and cost-effective alternative to virgin copper in many applications.

@# The answer for PVC and XLPE consumption while insulation:

The difference in PVC (Polyvinyl Chloride) product quality when using recycled PVC material
versus virgin PVC material for insulating wires and cables can be attributed to several factors:

1. Contamination and Impurities: Recycled PVC may contain impurities, contaminants, or other
materials that were present in the original PVC products. These impurities can affect the
performance and quality of the PVC when used for insulation. Manufacturers need to carefully
process and clean recycled PVC to minimize these issues.
2. Polymer Degradation: PVC can degrade over time due to exposure to heat, UV radiation, and
other environmental factors. Recycled PVC may have experienced more degradation compared
to virgin PVC, which can result in reduced mechanical properties and durability.

3. Variability in Properties: Recycled PVC material can come from a variety of sources, including
different types of PVC products. This can lead to variability in the properties of the recycled PVC,
making it challenging to consistently produce high-quality insulation materials.

4. Processing Challenges: Recycling PVC involves melting and reprocessing the material. During
this process, the PVC may experience thermal degradation, which can negatively impact its
properties. It can be challenging to maintain the desired properties of the PVC during recycling.

5. Quality Control: Manufacturers of wires and cables need to maintain strict quality control
measures to ensure the insulation materials meet safety and performance standards. Using
recycled PVC can introduce additional variability and quality control challenges.

6. Regulatory Compliance: In many regions, there are strict regulations and standards governing
the use of PVC in electrical insulation due to safety and environmental concerns. Manufacturers
may need to meet specific requirements when using recycled PVC to ensure compliance.

Overall, while recycling PVC is an important step towards sustainability and reducing waste, the
quality of the final product can vary depending on the recycling process and the source of the
recycled PVC. To achieve consistent and high-quality results, manufacturers must carefully
manage the recycling process and ensure that the recycled PVC meets the necessary standards
for electrical insulation applications.

@# the another case also maybe 🤔

PVC (polyvinyl chloride) is commonly used as an insulating material for wires and cables in
electrical and electronic applications. The consumption of PVC in insulating wires and cables
can differ for several reasons:

1. Wire and Cable Size: The size and gauge of the wire or cable play a significant role in
determining the amount of PVC consumed. Thicker wires or cables require more PVC insulation
to provide adequate electrical insulation and protection.

2. Voltage Rating: Wires and cables can have different voltage ratings, and higher voltage
ratings often require thicker insulation to withstand the electrical stresses. This can result in
variations in PVC consumption.

3. Application Requirements: The specific application and environmental conditions in which the
wires or cables will be used can influence the choice of PVC insulation. Harsher environments
may require thicker or more robust insulation, affecting the PVC consumption.

4. Regulatory Standards: Different regions and industries may have specific regulatory
standards and requirements for wire and cable insulation thickness. Compliance with these
standards can lead to variations in PVC consumption.

5. Cable Types: Various types of cables exist, such as power cables, control cables,
communication cables, and more. Each type may have different insulation requirements, leading
to differences in PVC consumption.

6. Insulation Techniques: The method used for applying PVC insulation, such as extrusion or
wrapping, can impact the thickness and uniformity of the insulation layer, affecting PVC
consumption.

7. Customization: In some cases, wires and cables may be customized to meet specific project
or application requirements. Customization can result in variations in PVC consumption based
on the desired properties.

8. Market Preferences: Market preferences and manufacturer choices can also influence PVC
consumption. Some manufacturers may use different materials or insulation thicknesses based
on customer demand and cost considerations.
It's important to note that while PVC is a common insulating material, there are other insulation
materials available, such as XLPE (cross-linked polyethylene), EPR (ethylene propylene rubber),
and more. The choice of insulation material can also affect consumption, as different materials
have varying properties and requirements.

In summary, PVC consumption for insulating wires and cables can differ due to a combination
of factors, including the specific application, electrical requirements, industry standards, and
manufacturer preferences. These factors collectively determine the thickness and amount of
PVC insulation needed for a particular wire or cable.

Prepared by:

Estifanos Lulie

Hayelom ashenafi