Transformation and Upgrading of A Lead Compacting Machine into A Lead-Wire Production Line

Abstract

A large amount of scrap/waste lead accumulated in the Elshugara Ammunition factory through years of production. The optimal utilization of all resources available for manufacturing is a basic function of manufacturing engineers. So, the question is how to make useful of this scrap? The answer is to establish a production line of lead wire. After the studying of the existing machines and equipment, which was a lead scrap compacting machine, the properties of raw materials, and the specifications of the product, it was found that the extrusion process is the best method, among the family of forming metal process, to be applied for this purpose. The existing machine was redesigned to extrude lead billets of cylindrical shape (dia. = 70 mm) casted in a line designed and implemented by the author into a lead-wire (dia. = 6.2 mm). The design and modifications done on the machines and equipment facilitated that its original function may be retained i.e. to work with a dual function. The layout of the equipment was designed. The modifications of equip-ment were studied, designed and implemented. A new machine (wire distribution machine) was designed and produced by the author. The project is completed and the line was put into production, it was found that, technically and economically the project is properly earning.