Drawing Dies calculation

D =D

1+ E%

= 1.2
= 2.5 X 1.02
= 2.738 mm

E = Elongation = 20 %

Elongation = ( D 1 1 ) x 100 %

D2
Considering the above formula calculate die arrangments , elongation % 33 last dia
is 2.9 mm

D 11 = D 2

1+E%

= 2.9

1 + 0.33

= 3 . 34 MM
D 12 = 3 . 34

1 . 33

1 . 33

D 14 = 4 . 44

1 . 33

D 15 = 5 . 12

1 . 33

D 16 = 5 . 9

1 . 33

= 3 . 85
D 13 = 3 . 85
= 4 . 44

D 17 = 6 . 81

1 . 33

D 18 = 7 . 85

1 . 33

7.85 6.81 5.12 4.44 3.85 3.34 2.9

Production Rate : The Weight
Where : L
A
D
V
T
W

= 0.785

= A .L.D
= Velocity x Time = V X T
= Cross Section Area ( mm 2 )
= Density
( Gm / Cm3 )
= Velocaty
(m/s)
( m / min )
= Time
( s ) or
( min )
d2

60

x 60 ( kg )/hr

- 7

19

37 61 91 127 169

* The number of strands in cables are 7 , 19 , 37 , 61 , 91 , 127 or

169
* The arrangment of 7 strands cables 1+ 6
Six strands spiralled around a central strand .
(1+6+12+18+24 )61 & (6+12+18 +1 ) 37 &(1+6+12 ) 19
the other construction add 6 wire for each excesive layer

11

No of wires

19

37

61

91

D c = u Dw
13
15
127

169

A = TT Dw2 n
4
Dw = 1.128 A
n
Dw = 1.128* sqrt (( A* F)/ N )
( F=1.1 COP = 1.06 AL )
Consider 4 mm2 in stranded ( 7 wire ) , solid and flexible
**

A Dw

= 1.128

4
7

= 0.84 mm
D Dw

= 1 . 128

4
1

= 2.25 mm
C Dw

= 1 .128

4
56
= 0 . 3 mm

Direction of stranding
7

S
Z
S
Z

19
37
61

* The alternate layers have right and left spirals .

The arrangent of 7 strands conducter six strands spiralled around
a central strand .

*The direction of spiralling of this layer ( 12 strands ) is in the

oppisite to the previous layer
Lay Length
Lay Length

= Lay factor x Dc
= L F . Dc
No Of wires
7
19
37
61
91

L . L AT 7 wires
L . L at 19 wires
L . L at 37 wires
L . L at 61 wires

LF Range
18 : 16
16 : 14
14 : 12
12 : 10
11 : 9

= 3 x 2 . 25 x 18 = 121
= 3 x 2 . 25 x 16 = 108
=
( 108 : 121 )
= 5 x 2 . 25 x 14 = 157 .5
=
( 121 : 127.5 )
= 7 x 2 . 25 x 12 = 189
=
( 157.5 : 189 )
= 9 x 2 .25 x 10 = 202.5
=
( 189 : 202.5 )

Weight per Km/Kg

Net weight = Lc . Ac .D ----kg
Where : Lc = Conductor Length- km
Ac = Cross section area-mm2
D
= Speccific gravity ( g / Cm3 ) 2.7 AL & 8.9 COPPER

Resistance
Stranded Conductor For Single Core
& Multi Core I . E. C 228
Nominal Corss
Copper
Sectional Area
Conductors
MM2
OHM/KM
0.5
36
0 . 75
24 . 5
1
18 . 1
1.5
12 . 1
2.5
7 . 41
4
4 . 61
6
3 . 08
10
1 . 83
16
1 . 15
25
0 . 727
35
0 . 524
50
0 . 387
70
0 . 268
95
0 . 193
120
0 . 153
150
0 . 124
185
0 . 0991
240
0 . 0754
300
0 . 0601
400
0 . 0470
500
0 . 0366
630
0 . 0283
800
0 . 0221
1000
0 . 0176
1200
0 . 0151
1400
0 .0129
1600
0 . 0113
1800
0 . 0101
2000
0 . 0090

Note : Maximum resisteance of conductor at 20 c .

Aluminium
Conductors
OHM/KM

7 . 41
4 . 61
3 . 08
1 . 91
1 . 20
0 . 868
0 . 641
0 . 443
0 . 320
0 . 253
0 . 206
0 . 164
0 . 125
0 . 100
0 . 0778
0 . 0605
0 . 0469
0 . 0367
0 . 0291
0 . 0247
0 . 212
0 . 0186
0 . 0165
0 . 0149

Low voltage section

Cross sections Areas used in Low Voltage Section
&
Nominal Insulation Thickness
Nominal Cross
Section areas

PVC Insulation
Thickness

XLPE Insulation
Thickness

630
500
400
300
240
185
150
120
95
70
50
35
25
16
10

3
2.8
2.6
2.4
2.2
2
1.8
1.6
1.6
1.4
1.4
1.2
1.2
1
1

2.4
2.2
2
1.8
1.7
1.6
1.4
1.2
1.1
1.1
1
0.9
0.9
0.7
0.7

Maximum Rated Temperature at Normal Operation

& short ckt
Insulation
Max. temp at S.C. temp for 5
Material
Normal
sec.
Operation
PVC
70 c
160 c
PE
70 c
130 c
XLPE
90 c
250 c
ER
90 c
250 c

Tolerance of insulation thickness:

T min = 0.9 Tn - 0.1
T max = Tn + 0.2

Types of Tools
Tube tooling

Die

Dg

Guid
e

D guide = 1.1 x D cable (before)

D die = D guide (out) + (3 - 5) T insulation
3 at Bedding
4 at sheathing and insulation
5 at sheathing of wired and copper screen
single core cables
Example
185 S = 22 mm
PVC = 2 mm

D die

Dg = 1.1 x 22 = 24.2 mm
Dgout = 24 + 4 insulation thick X2 = 28
Ddie = 28 + 4 x 2 = 36 mm
Pressure Tooling

Dg

Dgide = Dcable before + 0.2

Ddie = Dcable after process
Example
For wire 1 X35 mm2
Insulation thickness 1.2 mm
Core diam 7.5
Dgide = 7.5 + 0.2 = 7.7
Ddie = 7.5 + 2 x 1.2 = 9.9

The Insulation Materials used in Low Voltage section

-1

Dd

PVC consist of
Resin K70
Plasticeser
Stablizer
Lubricant
Filler
Additives
The selection of insulating materials to surround the conductors
Selection factors of insulation electrical factors

a. High dielectric resistance

b- low insulation power factor .
c- high insulation resistance .
d- charging current .
e- arc resistance .
f- ozone resistance .
g- tracking susceptibility

-: MECHANICAL PROPERTIES SUCH AS

-1

a. Toughness and flexiblity

b- tensile , compressive and impact strengths .
c- resistance to abrasion , crushing , moisture .
d- brittleness

.
-: THERMAL PROPERTIES SUCH AS

-2

a.softening and flow temprature

b- expansion and contraction .
c- compatibility with ambient , operating , and short circuit .

: CHCMI CAL PROPER TIES SUCHAS

. stability of materials an exposure to oils , flame and ozone
. moisture absorption

-3
-a
-b

Ratio of insulating matrials

1.resin of p.v.c .
63%
2-plasticizer .
28.75 %
3-stabilizer .
5.75 %
4-lubricant .
1.50 %
5-filler .
1%

Round Cable
Dass = 2 . 16 X Dins

( For 3 Core ) .
Phase

Dass = 2 . 42 X Dins

( For 4 Core ) .
Phase
Assembly Lay Length

= ( 18 : 20) Dass

= 3 A + Clearance

( For 3 Core ) .

( For 3 Core ) .

Dass = 1 . 33 (sqrt A) + 5 t
Assembly Lay Length
( For AL )
( For Ca )

= ( 28 : 32 ) Dass
= ( 30 : 34 ) Dass

Note That : Performing Lay Length

Weigth Of Filling
D

= Assembly Lay Length

= (D2 -3d2 ) **F /4

= Diameter after assembly
d

= Diameter of phase
= Dass + 2 t
= density of filler gr/cm3 0.93
F = Factor of compression =0.5
t ( Bed ) = 0 . 0 2 X D . ( ass ) + 0 . 6 ( mm )
D . Assembly
From ( mm )
To ( mm )
25
25
35
35
45
45
60
60
80
80
-

t . bed ( mm )
1
1.2
1.4
1.6
1.8
2.0

D ( bed ) = Dass + 2 t ( bed

Diameter After Bedding

Thickness of
armouring tabe
From ( mm )
To ( mm )
30
0.2
30
70
0.5
70
0.8
Armour Wire : AL Or AL Alloy Wire Arm
Diameter After Bed .
Diam. Of
Arm . Wire
From ( mm )
To ( mm )
15
0.8
15
25
1.6
25
35
2
35
60
2.5
60
3 . 15
D . ( arm ) = D . ( bed ) + 4 X ( Thick . of arm . tabe ) mm

Note : The gap between adjacent turns of each tape shall not exceed
50 % of the widddth of the tape .
Cos
Lay

Wst *
40 %
( Dbed + tst )
= Wst

40 %
Cos

Net weight of steel tape .

W

= 2 Darm. T

100
100 + gap

C.S.A

= Darm. T

100
100 + gap
Where :
: density =7.8 gm/cm3
Darm. : diameter after armouring
Gap : gap (mm)
T
: Thichness of tape (mm)

t ( sh ) = 0 . 0 35 x D ( arm. ) + 1 =
mm
D ( sh ) = D ( arm. ) + 2 x t. ( sh ) = mm
t ( m ) = 0 . 8 t. ( n ) X 0 . 2 = mm
Where : -

t. ( n )

t. ( sh )
= Thickness of sheathing .
D. ( arm ) = Diameter of cable after armouring .
D. ( sh ) = Diameter of cable after sheathing .
t. ( m )
= Minium thickness of sheathing .
= Nominal thinckness of sheathing

3x240+70
Dass

Tb

NAYBY

= 1 . 31sqrt( A) + 5 t
= 1 . 31|*sqrt ( 3 X 120+70) + 5 X 1 . 6
= 35 . 16 mm.
= 0 . 02 Dass + 0 . 6
= 0 . 02 X 35 . 16 + 0 . 6
=1.3
mm

Db

= Dass + 2 Tb
= 35 . 16 + 2 X 1 . 3
= 37 . 77 mm

Tst
Darm

=0.5
= Db + 4 Tst
= 37 . 77 + 4 X 0 . 5
= 39 . 77 mm

Tsh

= 0 . 035 Darm + 1
= 0 . 035 X 39 . 77 + 1
= 2 . 39 mm
Dsh

= Darm + 2 Tsh

=
39 . 77 + 2 X 2 . 39
= 44 . 55 mm

Weight of Bedding
=

( Db

Dass ) 2

= 0 . 785 X 1 . 35 ( 37 . 77 35 . 16 )2
= 20 kg
Weight of Sheathing
=
( Dsh

Darm ) 2
= 0 . 785 X 1 . 53 ( 44 . 55 39 . 77 )2
= 480 kg

CIRCULAR COPPER CONDUCTORS

Conductor C.S.A.

Construction

Diameter of wire

Diameter

Resistance

Weight

Notes.

1.5
2
2.5
3
4
6

7
7
7
7
7
7

0.52
0.6
0.67
0.73
0.84
1.04

1.56
1.8
2.01
2.19
2.52
3.12

12.1
9.15
7.41
6.1
4.61
3.08

13
17.5
21.5
26
34.5
51.5

Round

10
16
25
35
50

7
7
7
7
19

1.43
1.75
2.18
2.65
1.86

3.7
4.7
5.8
6.9
8.2

1.83
1.15
0.727
0.524
0.387

86.5
137
217
298
410

Round

Filler

Round
Round
Round
Round
Round
Round
Round
Round
Round

S/N

CABLE SIZE
MM2

OUTSIDE
FILLER

INSIDE
FILLER

1
2
3

4X2.5
5X2.5
3X4

4X4

5
6

5X4
2X6

3X6

4X6

5X6

10
11
12
13

2X10
3X10
4X10
5X10

14

2X16

15
16
17

3X16
4X16
5X16

18

2X25

19
20

3X25
4X25

21

5X25

22

2X35

23

3X35

24

4X35

25

5X35

26

2X50

27

3X50

28

4X50

29
30
31
32
33

5X50
3X70
4X70
3X95
4X95

34

3X120

35
36
37

4X120
3x150
4x150

5X24000
5X24000
3X36000
4X36000+1X24
000
5X36000
4X36000
3X36000+3X24
000
4X85000+5X24
000
5X36000+5X24
000
4X36000
3X85000
5X85000
5X85000
4x36000+2x24
000
6x36000
5X85000
5X85000
4x36000+2x24
000
6x36000
4x85000
5x85000+2X36
00
4x36000
3x85000+1x36
000
4x85000+2x36
000
6x85000
2x85000+1x36
000
3x85000+2x36
000
4x85000+1x36
000
6x85000
4x85000
5x85000
5x85000
5x85000
4X85000+3X36
000
9x85000
4x85000
9x85000

2.2

3.2

3.7
3.6

4.7
4.3

38

3x185

39

4x185

40

3X240

41

4X240

42

3X300

43

4X300

44

3X25+16

45

3X35+16

46

3X50+35

47

3x50+25

48

3X70+35

49
50

3X120+70
3X95+50

51

3X240+120

52

3x300+150

53

3x150+70

4X85000+3X36
000
4x85000+1x25
0000
3x85000+2x36
000
4x85000+1x25
0000
4x36000
4x85000+1x25
0000
5X85000+4X36
00
9X85000
3x85000+2x36
000
3x85000+2x36
000
4X85000+3X36
000
5x85000
5x85000
9X85000+2X36
000
9X85000+2X36
000
5x85000