High-Efficiency 11-Block Straight-Line Wire Drawing Machine Supplied to Russia for High-Carbon Mattress Spring Wire Production

Client Background & High-Carbon Spring Wire Challenge in Russia

The furniture and bedding manufacturing industry in Russia and Eastern Europe demands exceptional quality for high-tensile steel spring wire. Innerspring mattresses, Bonnell springs, and pocket spring units require precise wire dimensions, superior fatigue resistance, and high tensile strength to withstand long-term mechanical stress without deformation.

A prominent steel wire processing facility located in Russia approached JIAKE Machinery seeking an advanced wire drawing plant solution. Their primary raw material comprised 6.8mm high-carbon steel wire rods (C68D / C72D grade), which needed to be processed into fine 2.0mm high-tensile mattress spring wire.

Drawing high-carbon steel presents severe technical hurdles: high deformation resistance, rapid work hardening, elevated drawing friction, and intense temperature buildup across drawing dies. Traditional pulley-type machines often cause wire twisting, surface scratching, and internal thermal stress, rendering the wire brittle. To achieve continuous, high-speed drawing with uncompromised steel ductility, JIAKE senior engineers designed a fully automated 11-Block Straight-Line Wire Drawing Line.

Technical Solution: Why JIAKE Recommended an 11-Block Straight-Line Machine

Unlike conventional pulley machines where wire wraps and twists around capstans, a Straight-Line Wire Drawing Machine passes wire straight from block to block without axial twisting. Combined with AC frequency conversion and sensor-driven tension arm synchronization, this setup ensures smooth reduction ratio distribution across 11 continuous drawing passes.

Key Engineering Advantages of JIAKE Straight-Line Wire Drawing Line

1. Torsion-Free Drawing & Superior Steel Properties

Zero Wire Twisting: Because the steel wire travels straight through capstans without bending or twisting on the block surface, the physical structure and cross-sectional grain alignment of high-carbon steel remain intact. This delivers maximum spring resilience and prevents wire breakage during subsequent coiling into Bonnell springs.

2. Dual High-Efficiency Cooling System (Water + Air)

Overheating during multi-pass drawing degrades lubricant powder and induces brittleness in high-carbon steel. JIAKE integrated an internal narrow-slot water cooling jacket inside each of the 11 capstan blocks, complemented by external high-pressure blower air cooling around the die boxes. This keeps working temperatures low, extending die lifespan and maintaining consistent 2.0mm dimensional tolerances (≤±0.01mm).

3. Intelligent Synchronized Frequency Control

Each capstan block is individually driven by a dedicated AC motor with dynamic sensor tuning arms between blocks. The Siemens PLC automatically adjusts the speed of all 11 blocks in real time according to wire elongation rates, achieving operating speeds up to 12-18 m/s while eliminating wire slip and snap risks.

Factory Testing & Immediate Purchase Order

During the factory acceptance test in our Anping manufacturing facility, JIAKE engineers fed 6.8mm high-carbon wire through the 11-block system. The machine smoothly drawn the steel down to 2.0mm spring wire at high speed, achieving smooth surface finish, uniform diameter, and ideal tensile strength.

Extremely satisfied with the high drawing precision, robust build, intelligent PLC interface, and zero-twist performance, the Russian client signed the final purchase contract immediately on-site and placed the order for immediate delivery.

Client Feedback & Shipment to Russia

The 11-block straight-line wire drawing line was carefully anti-rust treated, vacuum wrapped, and loaded into heavy containers for ocean/rail transport to Russia. JIAKE technical support provided complete wiring schematics, foundation drawings, and step-by-step remote commissioning guidance.

“Drawing high-carbon steel wire for mattress springs requires high precision and zero wire damage. JIAKE’s 11-block straight-line wire drawing machine runs flawlessly. The water cooling system keeps capstans cool even at maximum speed, and our 2.0mm spring wire meets exact tensile standards. Choosing JIAKE was a huge win for our production facility in Russia.”

Optimize Your Wire Drawing Plant with JIAKE Machinery

As a leading manufacturer of wire drawing machinery and mesh equipment, JIAKE Machinery delivers complete factory solutions tailored to low, medium, and high-carbon steel wire production. Explore our additional machinery lines including wire drawing machines, wire mesh welding machines and expanded metal mesh machines.