DESC:TECHNICAL FIELD
The present disclosure relates to a field of material sciences. Particularly, the disclosure relates to an apparatus for carrying out simultaneous scrapping and straightening of calcium wire to obtain uniform diameter throughout the length of the wire. The disclosure also relates to a method of carrying out simultaneous scrapping and straightening.

BACKGROUND OF THE DISCLOSURE
Cored wire is a continuous steel tube filled with calcium bearing material. This continuous steel tube is wound in the form of a coil which is called Metallurgical Cored wire coils. The process includes de-coiling of pure calcium wire. The wire is subsequently fed into a U-shaped steel strip and is further encapsulated to form a closed tube, called metallurgical cored wire. Such tubes are closed by folding both the edges of the steel strip and lock one side into another. The consistency and strength of the lock is very important for successful use of the cored wire during its injection into the steel ladle.
The pure calcium wire is supposed to be of uniform diameter as per specification and reasonably straight throughout the length of the coil. However, due to variation in process parameters during production of pure calcium wire, there is variation in diameter of the wire beyond the specified limit and as well as bends/kinks are observed in the wire.
It is noted that when the diameter of the calcium wire is higher than the specified limit, it creates imperfection during encapsulation and closing of the tube. This results in improper locking of the steel over the pure calcium wire and hence the cored wire becomes unusable and does not pass the quality test. Similar imperfection is noted when the pure calcium wire is not straight

Thus, there is a need to arrive at an apparatus and method in order to avoid imperfections, due to variation in diameter and straightness of the pure calcium wire

STATEMENT OF THE DISCLOSURE
Accordingly, the present disclosure provides an apparatus which is capable of simultaneously carrying out scrapping and straightening of calcium wire. The apparatus is simple and cost effective in obtaining straightened calcium wire having desired diameter and uniform diameter throughout the length of the wire.

The present disclosure further provides a method of scrapping and straightening of calcium wire employing the apparatus described above to obtain the calcium wire having desired diameter and uniform diameter throughout the length of the wire. The method of scrapping and straightening of the calcium wire is simple, economical and environmentally friendly.

BRIEF DESCRIPTION OF THE ACCOMPANYING FIGURE
In order that the disclosure may be readily understood and put into practical effect, reference will now be made to exemplary embodiments as illustrated with reference to the accompanying figures. The figures incorporated herein form part of the specification, and serve to further illustrate the embodiments and explain various principles and advantages, in accordance with the present disclosure:

FIGURE 1: provides a simple representation of the cylindrical hollow tubes of the apparatus and its diameters.

FIGURE 2: provides a photographic image of the apparatus of the present disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE
Unless otherwise defined, all terms used in the disclosure, including technical and scientific terms, have meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. By means of further guidance, term definitions are included for better understanding of the present disclosure.

As used herein, the singular forms ‘a’, ‘an’ and ‘the’ include both singular and plural referents unless the context clearly dictates otherwise.

The term ‘comprising’, ‘comprises’ or ‘comprised of’ as used herein are synonymous with ‘including’, ‘includes’, ‘containing’ or ‘contains’ and are inclusive or open-ended and do not exclude additional, non-recited members, elements or method steps.

The recitation of numerical ranges by endpoints includes all numbers and fractions subsumed within the respective ranges, as well as the recited endpoints.

The term ‘about’ as used herein when referring to a measurable value such as a parameter, an amount, a temporal duration, and the like, is meant to encompass variations of ±10% or less, preferably ±5% or less, more preferably ±1% or less and still more preferably ±0.1% or less of and from the specified value, insofar such variations are appropriate to perform the present disclosure. It is to be understood that the value to which the modifier ‘about’ refers is itself also specifically, and preferably disclosed.

The present disclosure provides an apparatus capable of carrying out scrapping and straightening of calcium wire simultaneously to obtain calcium wire having desired diameter and uniform diameter throughout the length of the wire.

In some embodiments of the present disclosure, the apparatus comprises at least three cylindrical hallow tubes connected to each other and capable of passage of calcium wire sequentially.

In some embodiments of the present disclosure, the apparatus comprises three cylindrical hollow tubes (tube 1, tube 2 and tube 3) connected to each other sequentially and capable of passage of the calcium wire for scrapping and straightening simultaneously.

In some embodiments of the present disclosure, the tube 1 has inner diameter of [X+D1] mm, wherein the X is the maximum diameter of the calcium wire ranging from about 8.2 mm to 9 mm and the D1 is ranging from about -0.2 mm to +1.0 mm, including all the values in the range, for instance, -0.21 mm, -0.22 mm, -0.23 mm, -0.24 mm and so on and so forth, depending on mill requirement.

In some embodiments of the present disclosure, the tube 2 has inner diameter of [X+D2] mm, wherein the X is the maximum diameter of the calcium wire ranging from about 8.2 mm to 9 mm and the D2 is ranging from about -0.2 mm to +1.0 mm, including all the values in the range, for instance, -0.21 mm, -0.22 mm, -0.23 mm, -0.24 mm and so on and so forth, depending on mill requirement.

In some embodiments of the present disclosure, the tube 3 has inner diameter of [X+D3] mm, wherein the X is the maximum diameter of the calcium wire ranging from about 8.2 mm to 9 mm and the D3 is ranging from about -0.2 mm to +1.0 mm, including all the values in the range, for instance, -0.21 mm, -0.22 mm, -0.23 mm, -0.24 mm and so on and so forth, depending on mill requirement.

In some embodiments of the present disclosure, the tube 1 provides for straightening of the calcium wire and removes waviness of the calcium wire.

In some embodiments of the present disclosure, the tube 2 scrapes the calcium wire to filter deviations in the calcium wire.

In some embodiments of the present disclosure, the tube 2 scrapes out any variation in the diameter of the calcium wire at the joints.

In some embodiments of the present disclosure, the tube 3 additionally scrapes out any further variation in the diameter of the calcium wire.

In some embodiments of the present disclosure, the tube 1 is an inlet for the calcium wire and the tube 3 is an outlet for the scrapped and straightened calcium wire having uniform diameter throughout the length of the wire.

In some embodiments of the present disclosure, the calcium wire subjected to scrapping and straightening has diameter ranging from about 8.2 mm to 9 mm, including all the values in the range for instance, 8.21 mm, 8.22 mm, 8.23 mm, 8.24 mm and so on and so forth.

In some embodiments of the present disclosure, scrapped and straightened calcium wire has uniform diameter throughout the length of the wire ranging from about 8 mm to 8.1 mm, including all the values in the range for instance, 8.01 mm, 8.02 mm, 8.03 mm, 8.04 mm and so on and so forth.

The inventors in the present disclosure have particularly provided an improved apparatus that is capable of carrying out scrapping and straightening of calcium wire simultaneously when compared to conventional apparatus available in the art. The conventionally available apparatus can carry out only straightening of the calcium wire. However, the conventional apparatus was not capable of removing any variations in the diameter of the calcium wire, particularly at the joints of the calcium wire. In other words, the conventional apparatus was not able to yield calcium wire having uniform diameter throughout the length of the wire.

The apparatus designed by the inventors is simple and economical that can simultaneously carry out scrapping and straightening of the calcium wire to obtain calcium wire having desired diameter ranging from about 8 mm to 8.1 mm, including all the values in the range for instance, 8.01 mm, 8.02 mm, 8.03 mm, 8.04 mm and so on and so forth, throughout the length of the calcium wire.

In some embodiments of the present disclosure, the apparatus provides for scrapped and straightened calcium wire that can be directly employed for cored wire production without any further processing or treatment.

In some embodiments of the present disclosure, the apparatus removes any variation in the diameter of the calcium wire, particularly variations at the joints of the calcium wire are removed so that uniform diameter is obtained throughout the length of the calcium wire.

In some embodiments of the present disclosure, the apparatus additionally comprises a collection unit for collecting scraped calcium wire.

In an embodiment of the present disclosure, the Figure 1 provides simple representation of the cylindrical hollow tubes of the apparatus described above. The step 1 represents tube 1, wherein straightening and waviness removal is carried out; the step 2 represents tube 2, wherein scrapping of the calcium wire is carried out to filter any deviation from the desired diameter of the calcium wire; and step 3 represents tube 3, through which scrapped and straightened calcium wire is obtained having uniform diameter throughout the length of the calcium wire. The tube 3 carries out additional scrapping to remove any further variations in the diameter of the calcium wire.

In an embodiment of the present disclosure, the Figure 2 provides a photographic image of the apparatus described above.

The present disclosure further relates to a method for simultaneous scrapping and straightening of calcium wire.

In some embodiments of the present disclosure, the method comprises passing the calcium wire through the cylindrical tubes of the apparatus described above to obtain uniform diameter ranging from about 8 mm to 8.1 mm, including all the values in the range, for instance, 8.01 mm, 8.02 mm, 8.03 mm, 8.04 mm and so on and so forth, throughout the length of the calcium wire.

In some embodiments of the present disclosure, the method comprises passing the calcium wire through tube 1, tube 2 and tube 3 sequentially to obtain scrapped and straightened calcium wire having uniform diameter throughout the length of the calcium wire.

In some embodiments of the present disclosure, in the method of simultaneous scrapping and straightening of the calcium wire, the wire is passed through the tube 1, tube 2 and tube 3, sequentially at a speed ranging from about 30 meter/minute to 80 meter/minute, including all the values in the range for instance, 31 meter/ minute, 32 meter/ minute, 33 meter/ minute, 34 meter/ minute and so on and so forth.

In some embodiments of the present disclosure, the method removes or scrapes variation in the diameter of the calcium wire at the joints of the calcium wire.

The inventors by the described apparatus and the method of the present application have overcome the following disadvantages caused due to conventionally available apparatus and method-
- Opening of steel seam locking due to restricted filler volume;
- Breakages of the wire during wire straightening;
- Stoppages of the mill due to wire overturn at rollers; and
- Opening of the wire lock during use of the cored wire.

The apparatus and the method of the present application provides for many advantages, such as:
- The scrapped and straightened wire obtained has uniform diameter throughout the length of the wire and can be directly employed for cored wire production without need of any further processing or treatment.
- Stoppages at the production of cored wire due to breakage of the wire is negligible.
- The brazing during manufacturing has become almost negligible.
- The apparatus enables smooth passing of the calcium wire without any disturbance or hinderance.
- Productivity has increased by at least 25%.
- Lock opening of the wire is almost negligible.

It is to be understood that the foregoing description is illustrative not a limitation. While considerable emphasis has been placed herein on particular features of this disclosure, it will be appreciated that various modifications can be made, and that many changes can be made in the described embodiments without departing from the principles of the disclosure. Those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein. Similarly, additional embodiments and features of the present disclosure will be apparent to one of ordinary skill in art based upon description provided herein.

Descriptions of well-known/conventional methods/steps and techniques are omitted so as to not unnecessarily obscure the embodiments herein. Further, the disclosure herein provides for example illustrating the above-described embodiments, and in order to illustrate the embodiments of the present disclosure, certain aspects have been employed. The example used herein for such illustration are intended merely to facilitate an understanding of ways in which the embodiments may be practiced and to further enable those of skill in the art to practice the embodiments. Accordingly, following example should not be construed as limiting the scope of the embodiments herein.

EXAMPLE

Example 1: Scrapping and straightening of calcium wire
A calcium wire having diameter greater than or equal to about 8.2 mm was subjected to scrapping and straightening in the apparatus described above and according to the method described above. The said calcium wire was passed through tube 1, wherein waviness of the wire was removed, and the wire was straightened. The straightened wire was passed through tube 2, wherein the calcium wire was scrapped to achieve uniform diameter of about 8.1 mm throughout the length of the calcium wire. Further, the calcium wire was passed through tube 3, wherein the calcium wire undergoes further scrapping to remove any further variation in the diameter of the wire. The output calcium wire from the tube 3 was observed to have diameter in the range of about 8 mm to 8.1 mm throughout the length of the wire without any waviness.
The calcium wire was passed through tube 1, tube 2 and tube 3, respectively at a predetermined speed of about 60 meter/min to obtain scrapped and straightened calcium wire having uniform diameter throughout the length of the wire.
The scrapped calcium wire was collected and stored for further applications.

The foregoing description of the specific embodiments reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments in this disclosure have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.

Throughout this specification, the term ‘combinations thereof’ or ‘any combination thereof’ or ‘any combinations thereof’ are used interchangeably and are intended to have the same meaning, as regularly known in the field of patents disclosures.

Any discussion of documents, acts, materials, devices, articles and the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
,CLAIMS:1. An apparatus for scrapping and straightening of calcium wire, comprising- at least three cylindrical hollow tubes connected to each other and capable of passage of calcium wire, wherein-
- tube 1 has inner diameter of [X+D1] mm;
- tube 2 has inner diameter of [X+D2] mm; and
- tube 3 has inner diameter of [X+D3] mm.
and wherein: ‘X’- denotes specified maximum diameter of the calcium wire;
D1 is ranging from about -0.2 mm to +1.0 mm
D2 is ranging from about -0.2 mm to +1.0 mm; and
D3 is ranging from about -0.2 mm to +1.0 mm.

2. The apparatus as claimed in claim 1, wherein the tube 1 removes waviness of the calcium wire and straightens the calcium wire.

3. The apparatus as claimed in claim 1, wherein the tube 2 scrapes and filters deviation in diameter of the calcium wire.

4. The apparatus as claimed in claim 1, wherein the tube 3 additionally scrapes excess material to remove any additional variation in diameter of the calcium wire.

5. The apparatus as claimed in claim 1, wherein the tube 1 is inlet for the calcium wire and the tube 3 is outlet for the scrapped and straightened calcium wire.

6. The apparatus as claimed in claim 1, wherein diameter of the calcium wire subjected to pass through the tube 1 has diameter ranging from about 8.2 mm to 9 mm.

7. The apparatus as claimed in claim 1, wherein the straightened and scrapped calcium wire obtained from the tube 3 has diameter ranging from about 8 mm to 8.1 mm.

8. A method for scrapping and straightening of calcium wire, said method comprises passing of calcium wire through the cylindrical hallow tubes of the apparatus as claimed in claim 1.

9. The method as claimed in claim 8, wherein the method comprises passing of the calcium wire through the tube 1, tube 2 and tube 3 sequentially to obtain scrapped and straightened calcium wire having uniform diameter ranging from about 8 mm to 8.1 mm.

10. The method as claimed in claim 8, wherein the method removes variation in diameter of the calcium wire at joints of the wire.