International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056

Volume: 03 Issue: 08 | Aug-2016 www.irjet.net p-ISSN: 2395-0072

Calculation of Breaking Load of EC Grade Aluminium wire as per

International Standard
Pranab Mukherjee1, Darpan Mukhopadhyay2
1Technical Consultant, Cabcon India Pvt. Ltd, West Bengal, India.
2Student, Heritage Institute of Technology, West Bengal, India.

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Abstract – Breaking Load of E C Grade Aluminium Wire difficult to find mathematically, because there is a lot of
is very difficult to find out mathematically because there is a factors behind to develop the breaking load of Wire such
as 1) Drawing process , 2)Percentage of reduction,
lots of factors behind to develop the breaking load of wire
3)Tension in drawing process, 4)Friction between the
(eg. Stress, Percentage of Die reduction, Columb’s Effect work piece i.e. Coulomb’s effect, 5) Lubrication 6)
etc.). Considering all the factors and practical observation chemical composition 7)Stress etc. Non uniform Die angle
this formula/Equation made to calculate the breaking load may not follow the coulomb constant. Die angle lies
of E C Grade Aluminium wire. Which may fulfill the general between 150 - 250 and may be more than that . Die Angle
requirement of the breaking load of E C Grade Aluminium depend on Wire Drawing Machine System .
wire as per International Standard i.e. IEEE, IEC, ASTM, BS,
DIN, JIS, BIS etc.
2. DERIVATION
Key Words: UTS of E C Grade aluminium wire, Breaking
load of E C Grade Aluminium Wire, E C Grade Aluminium Minimum Breaking Load of EC Grade Aluminium Wire=
[{UTS of Wire(in Kgf/mm2) x Cress-Sectional Area(in
wire for overhead transmission, AAC Bare Conductor for
mm2)}/102] KN
Overhead Transmission Line, ACSR Conductor for
Overhead Transmission Line. Tensile Strength of Wire develop due to stress apply on
drawn wire during Wire drawing stages and secondly
tensile strength develop by the angular pressure of die.
1.INTRODUCTION Stress could not measure directly, only we can calculate it
from different formula. When wire passes through the
E C Grade Aluminium Wire & Conductor is the distinctive multiple dies the flexible stress applied on the wire
because uniform die reduction could not maintained due to
features of our modern civilization. A wide range of uses of the various type of wire drawing machine. Standard
‘E C Grade Aluminium Wire & Conductor’ both in reduction consider in respect to all wire drawing machine
domestically & industrially. E C Grade Aluminium is 20%-25% which may not constant.
Conductor made by Stranding processes of multiple wires Tensile strength increase due to stress maximum upto 80%
as per National or International Standard. of tensile strength of EC Grade Aluminium Wire Rod.
Tensile Strength of wire = Tensile Strength of Rod +
Breaking Load of E.C. Grade Aluminium Wire for
80% of the Tensile Strength of Rod = [85 + (85 x 80%)]
Overhead Transmission is one of the most important MPa = 153MPa = 15.606 Kgf/mm2…………………… eq. (i)
factor in Specification to screening out the Technical
[where, Minium Tensile Strength of Aluminium Wire Rod =
Parameters. As per the purchasers demand, some time we 85 MPa (Range=II as per IS:5484-1997)
have to calculate Breaking Load of Wire (non specified
Secondly, Tensile Strength of wire increase due to another
Wire Diameter in Specification) based on any of the above
factor i.e. die angle pressure, known as Columb effect. For
standard. With the help of “Interpolation” UTS (Kgf/mm 2) EC Grade Aluminum Wire die angle pressure observed
of the wire may calculate to satisfy the Customer. Some practically is differ from the Columb’s factor. For the EC
time the Breaking Load (Kgf/KN) does not tally with the Grade Auminium wire the value of the factor is 0.1293
purchasers Specification or Demand because there is no Kgf/mm2 , which is Pranab’s Constant (Pd) obtain
experimentally.
General Formula Existing in any Specification.
Tensile Strength Increase = [( )/( )]*Pd
I agreed with the opinion Published in Journal of Kgf/mm2 = (11.67/D2) Kgf/mm2.............................. eq. (ii)
“Materials Processing Technology” 162-163|(2005) 551- [Where, d = Aluminium Wire Rod diameter = 9.5 mm (as
557 . Breaking load of EC Grade Aluminium Wire is very per Standard) and, D= Required Wire Diameter in (mm)].
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 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 03 Issue: 08 | Aug-2016 www.irjet.net p-ISSN: 2395-0072

So, Tesile Strength of the wire = eq. (i) + eq. (ii) = [15.606+ 3.00
(11.67/D2)] Kgf/mm2 . 2.50

Breaking Load in KN
Minimum Breaking Load of the Wire = [{UTS of Wire(in 2.00
Kgf/mm2) x Cress-Sectional Area(in mm2)] Kgf = [{15.606+ 1.50
(11.67/D2)} x ] Kgf = [{15.606 + (11.67/D2)} x 1.00

]/102 KN = [0.120166D2 + 0.089859] KN 0.50

0.00

1.35
1.71
2.13
2.59
2.70
2.89
3.27
3.29
3.39
3.63
3.66
3.71
3.85
3.94
3.96
4.09
4.09
4.15
4.18
4.33
4.39
4.43
4.58
Table -1: Comparing Calculated B/L with IEC-61089 Diameter in mm
Specification.
IEC Standard Value Calculated Valu

Chart -1: Comparing Calculated B/L with IEC-61089

B/L from specification Calculated B/L Value Deviation
Specification.
Dia in (MM) in (KN) in(KN) (KN)
Table -2: Comparing Calculated value with IS:398(Part1
1.35 0.28 0.31 -0.03
&2) 1996.
1.71 0.43 0.44 -0.01
Calculated
Breaking Load in (KN) as per
Dia Of Wire(mm) Breaking Load in
2.13 0.64 0.64 0.01 Specification
(KN)

2.59 0.89 0.90 0.00 1.37 0.32 0.32

2.70 0.97 0.97 0.01 1.50 0.32 0.36

2.89 1.12 1.09 0.02 1.96 0.54 0.55

3.27 1.39 1.37 0.01 2.11 0.63 0.62

3.29 1.40 1.39 0.01 2.21 0.68 0.68

3.39 1.48 1.47 0.01 2.59 0.89 0.90

3.63 1.65 1.67 -0.02 3.00 1.17 1.17

3.66 1.68 1.70 -0.02 3.10 1.24 1.24

3.71 1.73 1.74 -0.01 3.18 1.29 1.31

3.85 1.86 1.87 -0.01 3.35 1.43 1.44

3.94 1.95 1.96 -0.01 3.50 1.55 1.56

3.96 1.97 1.97 -0.01 3.53 1.57 1.59

4.09 2.11 2.10 0.01 3.80 1.80 1.83

4.09 2.10 2.10 0.00 3.99 1.98 2.00

4.15 2.16 2.16 0.00 4.09 2.08 2.10

4.18 2.20 2.19 0.01 4.13 2.13 2.14

4.33 2.36 2.34 0.02 4.39 2.40 2.41

4.39 2.41 2.41 0.00 4.65 2.70 2.69

4.43 2.46 2.45 0.01 4.72 2.78 2.77

4.58 2.64 2.61 0.03

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 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 03 Issue: 08 | Aug-2016 www.irjet.net p-ISSN: 2395-0072

3.00
3

2.50
2.5

2.00
Breaking Load in KN

Breaking Load in KN
2

1.50
1.5

1 1.00

0.5 0.50

0 0.00

2.06
2.36
2.59
2.79
3.00
3.10
3.18
3.25
3.35
3.40
3.78
3.86
4.22
4.39
4.65
4.72
1.37
1.50
1.96
2.11
2.21
2.59
3.00
3.10
3.18
3.35
3.50
3.53
3.80
3.99
4.09
4.13
4.39
4.65
Diameter in mm 4.72 Diameter in mm
Breaking Load in (KN) Calculated value
Breaking Load in (KN) Calculated Breaking Load in (KN)

Chart -2: Comparing Calculated value with IS:398(Part1

Chart -3: Comparing Calculated Breaking load with
&2) 1996.
BS:215(Part 1 & 2)1970.
Table -3: Comparing Calculated Breaking load with Table -4: Comparing Calculated Breaking Load with DIN-
BS:215(Part 1 & 2)1970. EN50182-2001-12.

Calculated Breaking Load in Calculated Breaking Load Calculated Breaking

Dia(mm)Of Wire Breaking Load in (KN) Diameter in (mm)
(KN) (KN)As Per Spec. Load (KN)

2.06 0.60 0.60 1.70 0.43 0.44

2.36 0.77 0.76 1.80 0.47 0.48

2.59 0.90 0.90 2.10 0.63 0.62

2.79 1.03 1.03 2.25 0.72 0.70

3.00 1.19 1.17 2.50 0.87 0.84

3.10 1.25 1.24 2.80 1.04 1.03

3.18 1.31 1.31 2.89 1.11 1.09

3.25 1.37 1.36 2.96 1.16 1.14

3.35 1.45 1.44 3.00 1.19 1.17

3.40 1.49 1.48 3.23 1.36 1.34

3.78 1.80 1.81 3.35 1.45 1.44

3.86 1.87 1.88 3.74 1.78 1.77

4.22 2.24 2.23

4.39 2.41 2.41

Chart -4: Comparing Calculated Breaking Load with DIN-
4.65 2.70 2.69
EN50182-2001-12.
4.72 2.78 2.77

© 2016, IRJET | Impact Factor value: 4.45 | ISO 9001:2008 Certified Journal | Page 1421
 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 03 Issue: 08 | Aug-2016 www.irjet.net p-ISSN: 2395-0072

2.00
1.80
1.60 BIOGRAPHIES
1.40
Pranab Mukherjee passed B.Sc,
Breaking Load in KN

1.20
1.00 D.M.L.T & having 35 years of
0.80 industrial experience in Wire &
0.60 Conductor Manufacturing Unit.
0.40 He has works for many
0.20 companies including GROUPS OF
0.00 USHA MARTIN , INDO AMERICAN
1.70 1.80 2.10 2.25 2.50 2.80 2.89 2.96 3.00 3.23 3.35 3.74 ELECTRICAL LTD. and many
Diameter in mm other companies as a Quality
Calculated Breaking Load (KN)As Per Spec. Control Engineer. Now he is
working for M/s. CABCON IND.
Calculated Breaking Load as per formula in (KN)
PVT. LTD. As Technical
Consultant. His field of interest is
Standing and Wire Drawing.
3. CONCLUSIONS
This Formula covers the requirement of Breaking Load Darpan Mukhopadhyay received
of E.C Grade Aluminium (AAC & ACSR , ACAR) used for the B.Tech (Mechanical
overhead power transmission . This formula may help to Engineering) degree from
calculate the Breaking Load of EC Grade Aluminium Wire Heritage Institute of Technology,
Kolkata affiliated to Maulana Abul
from 5.50mm to 1.25mm. UTS of wire will be increase or
Kalam Azad University of
decrease in proper manner. In this process the breaking
Technology (Formerly known as
Load will maintain in order. West Bengal University of
Technology) in 2016. His field of
As we can see from the above chart and graph, that interests in Strength Of Materials,
calculated value of Breaking Load by using the derived Heat Transfer, Thermodynamics
formula giving the results very close to the Standard and Fluid Mechanics.
Values. The Small deviation found between the calculated
value and the specified value because:-

1. Chemical Compositions of EC Grade

Aluminium Rod.
2. Error in Experimental Setup.
3. Lubricant Temperature & types of lubricant.
4. Type of Drawing Machine (Slip type, Non-Slip
Type).
5. RPM of Machine.
6. Area reduction of dies.
7. Angle of the die.

REFERENCES

[1] IEC : 61089.

[2] IS : 398 (Part-1&2) 1996.
[3] BS : 215 (Part-1&2) 1970.
[4] DIN - EN50182-2001-12 (part-5).
[5] ASTM : B231 &B232.
[6] JIS C 3109.
[7] IS : 5484 1997.

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