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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
= 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
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
= 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 )
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
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
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
Types of Tools
Tube tooling
Die
Dg
Guid
e
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
-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
-1
.
-: THERMAL PROPERTIES SUCH AS
-2
-3
-a
-b
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
= 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
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
= 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
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