Wire Tension Chart

Like in a

guitar string, maybe?

See this article regarding transmission lines -- most are aluminum and steel these days.

As far as copper is concerned, tensile strength is given by a number of sources, including copper.org about a variety of alloys and copper.org about pure copper.

Hi,

Thanks for all your response!

But I didn't get the thing, what i'm looking for! It's my fault that my query is not elaborated....

Here the situation,

We are using copper magnetic wire for coil winding, In that we are facing the noticeable failure rate of insulation breakdown after winding... We suspect the tension of wire could have influence the enamel which entails to insulation breakdown,

Note: In process, we're randomly setting the wire tension.

We've already seek the aid of wire manufacturer, Whilst if anybody have the relevant details, let me know...

Hari

It sounds as though you need some sort of tension control in your wire feed. You also may want to consider a winding machine that lays the wires beside each other like a fishing reel. This will prevent wires from crossing each other, which causes mechanical stress to the insulation. Keep rubbing and chafing to an absolute minimum. Also, calculate the voltage gradient between layers. If it is too high for the insulation, get better insulation or inrease the number of layers. Please let us know how you make out.

Try here: http://www.globe-usa.com/globeexactrolewt.htm For 16 - 40 awg copper wire. You will need a tension gauge when winding.

DGCYS is got the tensile load limits on his chart (thanks), but there is no fixed amount of tension for each wire gauge, you have to play with tension from zero to a maximum specified on the chart, the guideline is to achieve a Spec. resistance per coil, the designer has to give you this information:

Number of turns, Caliber, inductance, magnet wire material, dielectric strenght, surge test limits, resistance and physical lay-out of the windings.

You are correct about suspecting the tensioning techniques for causing damage, it is a very, very frequent cause. BUT you should also make sure that your thru guide and wire path, as well as the tensioning device, have ceramic and/or carbide inserts with round edges wherever they touch the wire.

It may happen also to be your wire spools that come damaged, for this you have to run a sparks count test (just Google it) on them.

You have to know also other data like the type of insulation of the wire (material, single or reinforced, duty Etc.) and varnish coating techniques.

I hope this helps

Yahlasit