Testing of Wires

The testing of wires is used to analyse their mechanical properties and ensure their quality. Important test methods include the tensile test, the torsion test and the bending test.

In the tensile test, the wire is subjected to an axial tensile force to determine its tensile strength and ductility. This method helps to analyse the load limits and the breaking behaviour of the wire.

The bending fatigue test tests the flexibility and fatigue strength of the wire by repeatedly bending it. This test provides information about the fatigue strength and the ability of the wire to withstand repeated bending cycles.

The torsion test checks the torsional strength by twisting the wire until it breaks. This test is particularly important to evaluate the torsional strength and behaviour under torsional load.

Hegewald & Peschke offers various testing machines, including testing software, for wire testing. The testing technology can be used to ensure that wires fulfil the required standards for various industrial applications (e.g. in the electronics or construction industry).

Universal Testing Machines for Tensile Tests on Wires

Test Applications:

Tensile test on metallic materials according to EN ISO 6892-1
Determination of elongation at break and tensile strength according to EN 60851-3 (IEC 60851-3)

Depending on the diameter, material and the tendency of the wires to break at the clamps, the use of special clamping tools is required for reliable clamping.

Wedge Type Grips with Extended Clamping Jaws

Due to the long design of the clamping jaws, the clamping force is introduced softly into the specimen, thereby reducing the notch effect at the end of the clamping surface. Particularly with specimens that do not have a cross-section reduction between the clamping area and the test cross-section, the fracture position is otherwise much more frequently located directly at the clamping jaw.

Pneumatic or Mechanical Rope Grips

The load reduction curve relieves the load on the specimen and does not require such high clamping forces, significantly reducing the risk of clamp breakage.

Hydraulic Grips for Wires and Stranded Wires up to 600 kN

Hydraulic clamping tools enable the wires to be clamped quickly and without slipping. Special clamping jaws are available for gentle clamping of (braided) wire ropes.

Further information about tensile testing machines for tensile tests on wire ropes

Further information about specimen grips for universal testing machines

Video Extensometer for Long Wires and Steel Strands

Perfect for static tensile tests on tensile strands according to ISO 15630-3 /ASTM A416 / ASTM A1061
2-camera video extensometer system for determining the modulus of elasticity and elongation at break
Measurement of yield strength according to ASTM A1061
Specimen break always within the strain measurement range
No artificial specimen marking required
Also suitable for twisted tensioning wires
Digital image correlation enables:
- Determination of local strains (location and direction resolved)
- Creation of colour-coded area maps for visualisation of strain distribution

Testing room of a testing machine with two video extensometers

Further information about the video extensometer ONE

Bending Fatigue Testing Maschine 180° for Wire Specimens according to DIN 51211 and ISO 7801

The wire samples are of a defined length. They are bent with a 90° angle to the left and to the right. The angle deviates by max. ± 3°. The lower end of the wire is clamped into a screw terminal and guided through a pair of bending rolls. The bending rolls are made of special hardened material to allow the testing of wires up to 2,000MPa. The rolls ensure defined bending depending on the wire diameter. The bending rolls can be exchanged. The upper end of the wire is clamped into a movable, servomotor-driven bending arm. The testing facility is adjustable according to the standard indicated above. The test station allows the simultaneous testing of upt to 3 specimen depending on the wire diameter. Accordingly the test time can be reduced dramatically.

Further information on the reverse bend testing machine

Torsion Testing Devices

Torsion Testing Devices with Controller

Field of application:

Torsional load on specimens made of different materials at static tests, e. g. torsion tests on wires according to DIN ISO 7800 and ASTM A938 as well as alternating torsion tests on wires according to DIN EN 2002-13

Advantages:

high torsional stiffness and high angular resolution
electrical overload protection
variable testing speed
maintenance-free AC servo drive with a planetary gear set free of play
operation with customary PC and material testing software LabMaster
protection of the operating staff by a coverage of the workroom with an electromagnetic locking

Various models of torsion tester are available with a maximum torque of between 200 Nm and 5000 Nm.

Overview of various torsion testing machines

Torsion Testing Device TW-500H for Tests according to DIN ISO 7800

Field of application:

Simple torsion test on metallic materials according to DIN ISO 7800

Advantages:

Compact complete system
- Fixed work table with integrated control unit
- Robust industrial control
  → Automatic breakage detection by the control system
  → Indirect torque measurement via motor power
User-friendly operation via touch panel
- Simple test configuration
- Interactive user guidance based on the standard-based test sequence
- Fast test execution based on templates
- Export of test results as CSV
Industrial safety standard
- Safety door electrically closed and interlocked (PLd)
- Safe stop (STO) with open safety door
- Pneumatic pressure release (PLc)
Easy clamping of the wire specimens with optimized specimen holders
Simple adjustment of the clamping length via scaling in the machine bed

Further information on torsion testing device TW-500H for tests according to DIN ISO 7800

The Ideal Testing Software for Component Testing of Wires

Our test systems are equipped with the LabMaster test software, which enables user-friendly setup and procession of the test procedures for customised tests. It guarantees fast and reliable determination of results and offers a high degree of flexibility when integrating external measuring devices. Data import and export for customised software such as QDAS or SAP is also possible.

Further information on the testing software LabMaster