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IS 9861 (1981): Dimensions for wrought copper and copperalloy wires for general engineering purposes [MTD 8: Copperand Copper Alloys]

IS : 9861- 1981

Indian Standard

DIMENSIONS FOR WROUGHT COPPER AND COPPER ALLOY WIRES FOR GENERAL

ENGINEERING PURPOSES

Copper and Copper Alloys Sectional Committee, SMDC 11

Chairman Representing DR L. R. VAIDYANATH Indian Copper Information Centre. Calcutta

Members SH~U DEV KUMAR AGGARWAL Bralco Metal Industries Pvt Ltd, Bombay

SHRI V. R. GADRE ( Alternate ) SHRI S . N. BAFNA Coventary Metals Rajasthan Pvt Ltd, Jodhpur

SHRI N. M. BAFNA ( Alternate ) SHRI B. NAGESH BHA~T Indian Telephone Industries Ltd. Bangalore

SHRI A. DWARKANATH (Alternate ) SHRI V. N. BHIDE Directorate General of Ordnance Factories, Calcutta

SHRI S. K. M~HANTY ( Alternate ) SHRI S. N. CHANDA Bengal Ingot Co Ltd, Calcutta SHRI S. K. DAS Ministry of Defence ( DGI)/DPJ (N)

SHRI S. C. PAUL ( Alternate ) SHRI P. GHOSH Indian Cable Co, Jamshedpur

SHRI TRILOK SINGH ( Alternate ) SHRI A. K. GUHA Directorate General of Supplies & Disposals,

New Delhi SHRI A. V. HARNE Bharat Heavy Electricals Ltd, Secunderabad

SHRI T. MUKHERJEE ( Alternate I > SHRI K. N. WADHWA ( Alterrrate II )

SHR~ D. P. JAIN Saru Smelting Pvt Ltd, Meerut SHRI D. N. CHAKRABORTY ( Alternate )

SHRI S. L. JAIN Alcobex Metals ( P ) Ltd, Meerut SHRI S . RAMAKRISHNAN ( Alternate )

SHR~ F. A. A. JASDANWALLA Indian Standard Metal Co Ltd. Bombay SHRI C. CHA-ITERJEE ( Alternate >

SHRI S. K. KHANDEKAR Vanaz Engineers (P ) Ltd. Pune SHRI A. S. SURYANA~AIN ( Alternate )

( Continued on page 2 )

@ Copyright 1981 INDIAN STANDARDS INSTITUTION

This publication is protected under the Indian Copyright Act (XIV of 1957 ) and

reproduction in whole or in part by any means except with written permission of the

publisher shall be deemed to be an infringement of copyright under the said Act.

IS:9861-1981

( Continued from page 1)

Members Representing SHRI J. MARWAHA Ministry of Steel & Mines, New Delhi and Hindustan

DR S. K. BISWAS (Alternate) Copper Ltd. Ghatsila

SHRI LAXAMAN MISHRA Directorate General of Technical Development, New Delhi

SHRI T. R. MOHAN RAO ( Alternate) SHRI B. M. MISTRY SHRI A. K. MITRA

Ministry of Finance

SHRI S. V. NADKARM National Pipes & Tubes Co Ltd, Calcutta Advani Oerlikon Ltd, Bombay

SHIU S. K. SENGUPTA ( Alternate ) .SHRI A. T. PAL

SHRI I. N. BHAT~A ( Alternate) Ministry of Defence (R & D )

:SHRI H. S. PARCHI Kamani Metals and Alloys Ltd, Bombay SHRI A. H. SABHACHANDANI ( AIternate)

SHRI P. S. RWWAMY Bhandary Metallurgical Corporation Pvt Ltd,

SHRI M. K. RAO Bombay

Indian Non-Ferrous Metals Manufacturers Asso- ciation, Calcutta; and The Binani Metal Works Ltd, Calcutta

Sr-nu B. NAGCHAUDWURI ( Alternate ) REPRESENTATIVE Institution of Engineers (India), Calcutta; and

SHRI S. K. ROY Kbetri Copper Complex, Jodhpur

Ministry of Defence (DGL) SHIU P. K. L. P. NIMANKAIX ( Alternate )

SHRI D. K SEHGAL Leader Engineering Works, Jullundur SHFU V. K. CHOUDHURY ( AIternate )

.SENIOR CHEMIST & METALLURGIST, Ministry of Railways CENTRAL RAILWAY, BOMBAY

DEPUTY DIRECTOR ( MET)-II, RDSO, LUCKNOW ( Alternate )

SHRI S. C. SNARAMAKRISHNAN National Metallurgical Jamshedpur

Laboratory ( CSIR ),

SHRI N. S. SURANA Multimetals Ltd. Calcutta SHR~ S. S. VMDYANA~AN J. B. Metal Industries Pvt Ltd, Bombay .SHRI C. R. RAMA RAO,

Director ( Strut & Met ) Director General, IS1 ( Ex-officio Member)

Secretary SHRI 0. N. DASGUPTA

Deputy Director ( Met ), IS1

IS : 9861- 1981

Indian Standard DIMENSIONS FOR WROUGHT COPPER AND

COPPER ALLOY WIRES FOR GENERAL ENGINEERING PURPOSES

0. FOREWORD

0.1 This Indian Standard was adopted by the Indian Standards Institution on 20 August 1981, after the draft finalized by the Copper and Copper Alloys Sectional Committee had been approved by the Structural and Metals Division Council.

0.2 The consumption of copper and copper alloy wires used in various fields is increasing as the country’s engineering industry is fast developing. So far, there was no separate specification for dimensions and tolerances for these wires. Need was, therefore, felt to formulate an Indian Standard on this subject.

0.3 While preparing this standard, assistance has been derived from the following publications:

Annual book of ASTM standards 1976 - Part VI - Copper and copper alloys (including electrical conductors ). American Society for Testing and Materials.

Standard handbook - Wrought mill product tolerances. Copper Development Association Inc.

BS : 2873 : 1969 Specification for copper and copper alloy wires. British Standards Institution.

BS : 384 : 1963 Specification for phosphor bronze wire. British Standards Institution

BS : 2786 : 1963 Specification for brass wire for springs. British Standards Institution.

ISO/DIS 3492.2 Dimension and tolerance - Wrought copper and copper alloys - Drawn round wire. International Organiza- tion for Standardization.

0.4 For the purpose of deciding whether a particular requirement of this standard is complied with, the final value, observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance with

3

IS : 9861- 1981

IS : 2-1960”. The number of significant places retained in the rounded off value should be the same as that of the specified value in this standard.

1. SCOPE

1.1 This standard specifies dimensions and tolerances for wrought copper and copper alloy wires.

2. TERMINOLOGY

2.0 For the purpose of this standard, the following definitions as given in IS : 3288 ( Part I )-1981t shall apply.

2.1 Wire - Rolled, extruded or drawn product of solid section of uniform cross-section along its whole length and the distance between two parallel faces not exceeding 6 mm; may be supplied in straight length or in coils or on spools.

2.2 Flat Wire - Wire with rounded edges made by flattening round wire.

3. DIMENSIONS AND TOLERANCES

3.1 The diameter of round wire, determined by means of a suitable micro- meter and by taking the mean of the two measurements at right angle made at the same cross-section of a sample taken from any part of a coil, reel, spool or drum, shall be as ordered within the tolerances specified in Table 1.

3.2 The distance between two parallel faces of hexagonal and octagonal wire shall be as ordered within the tolerances specified in Table 1.

3.3 For square and rectangular wire, thickness tolerances shall be as specified in Table 2.

3.4 For wire other than round, hexagonal, octagonal, rectangular and square like half-oval and half-round shape wires, the tolerance shall be agreed between the purchaser and the supplier and shall be stated on the enquiry and the order.

3.5 Unless otherwise specified, the material shall be finished with com- mercially square corners. The maximum permissible radius to which commercially square corners may be rounded are given in Table 3.

*Rules for rounding off numerical values ( revised). $Glossary of terms for copper and copper alloys: Part I Cast form and wrought

form ( MainTypes ) ( second rewsion ).

4

IS : 9861- 1981

TABLE 1 TOLERANCE FOR DIAMETERS/DISTANCE BETWEEN PARALLEL FACES

( C’[auses 3.1 and 3.2 )

DIAMETER OR DISTANCE ROUND HEXAGONAL,~CTAGONAL BETWEEN PARALLEL FACES INPLUSAND IN PLUS AND MINUS

MINUS mm mm mm

up to 0’10 0’002 5 -

Over 0.10 up to @25 0’005 0 -

Over 0.25 up to 0.50 0.007 6 -

Over @50 up to @75 0.010 0 -

Over W75 up to 1.00 0.013 0 0.050

Over 1.00 up to 1.25 0.015 0 0.076

Over 1’25 up to 1.50 0.020 0 0.076,

Over 1.50 up to 2.00 0.025 0 0.100

Over 200 up to 4’00 0.030 0 0’100

Over 4.00 up to 6.00 @0400 0.120

TABLE 2 THICKNESS TOLERANCE FOR SQUARE, RECTANGULAR AND FLAT WIRES

( CIouses 3.3 and 3.7 )

THICKNE~.Y THICKNESS TOLERANCE IN PLUS AND MINUSFOR WIDTH

----7 mm mm mm

Up to and including 0.50 Up to 12.7 Over 12.7 up to 32 0.025 0.038

Over 0’50 up to 1.25 PO38 0’051

Over 1.25 up to 2.25 0.051 0.076 Over 2.25 up to 3.25 0.076 0.100 Over 3.25 up to 590 0.100 0.110

NOTE - Restricted tolerances, within the specified limit may be made subject to mutual agreement between the purchaser and the manufacturer.

5

IS:9861-1981

3.6 When specified, the material may be finished with corners rounded to a quarter circle of a radius ( see Fig. 1 ) as given in Table 4. The tolerance on the radius shall be plus and minus 25 percent.

3.7 Width tolerance for flat wires is given in Table 5 and thickness tolerance shall be in accordance with Table 2.

TABLE 3 TOLERANCE ON RADIUS OF CORNERS

( Cluuse 3.5 )

SPECIFIED THICKNESS MAXIMUM RADIUS OF CORNERS ALLOWAB~~~;~?

mm mm

Up to 1’60 0.25

Over 1.60 up to 5.00 0.40

FIG. 1 ROUNDED CORNER

NOTE - The arc of the rounded corner shall not necessarily be tangent at points ‘A’, but the product shall be commercially free from sharp, rough, or projecting edges.

TABLE 4 NOMINAL RADIUS OF ROUNDED CORNERS

( Clause 3.6 )

SPECIFIED THICKNESS

mm

Up to and including 1.80

Over 1.80 to 3.20 up

Over 3.20 up to 5.00

NOMINAL RADIUS OF CORNERS

mm

0,30

0.40

0.80

6

IS:9861-1981

TABLE5 WIDTHTOLERANCE FORFLATWIRES

( Clause 3.7 )

WIDTH TOLERANCE WITH PLUS AND MINUS

mm mm

Up to and including l-25 0038

Over 1.25 to 2-25 up 0.051

Over 225 to 3.25 up 0.076 Over 3’25 up to 5.00 0.100

Over 590 to 12’70 up 0.130

Over 12.70 up to 38.00 0.180

3.8 Straightness tolerance for flat wires, applicable to any longitudinal edge of material supplied in normally flat straight length and in rolls or on bucks is given in Table 6.

TABLE 6 STRAIGHTNESS TOLERANCE FOR FLAT WIRES

( Clause 3.8 )

MAXIMUM EDGE-WISE CURVATURE ( DEPTH

OF ARC ) IN ANY 2 m LENGTH

For material having a

cross-section area of O-064 5 cm’ and over and a

thickness of 0.25 mm and

over, furnished in straight

length or in rolls or on bucks

13 mm

INTERNATIONAL SYSTEM OF UNITS ( SI UNITS)

Base Units

Quantity

Length Mass Time Electric current Thermodynamic

temperature Luminous intensity Amount of substance

Supplementary Units

Quantity Plane angle Solid angle

Derived Units

Quantity

Force Energy Power Flux Flux density Frequency Electric conductance Electromotive force Pressure, stress

Unit

metre kilogram second ampere kelvin

candela mole

Unit radian steradian

Unit

newton joule watt weber tesla hertz siemens volt Pascal

Symbol

ki

i K

cd

Symbol rad sr

Symbol

N

4 Wb

T HZ

s V

Pa

Definltlon

1 N = 1 kg.m/ss 1 J = 1 N.m 1 w = 1 J/s 1 Wb = 1 V.s 1 T = 1 Wb/ms 1 Hz = 1 c/s ( s-r) 1 S = 1 A/V 1 V = 1 W/A 1 Pa = 1 N/m*