Wire Baskets
Wire baskets are made from a series of wires that are woven together or welded to form a shape of a basket. They can also be defined as containers that are made by use of an openwork pattern of metal...
The content of this article contains everything you will need to know about wire handles and bucket handles.
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A wire handle is attached to a bucket, pail, or other type of container to make it easy to lift the container and transport it. They are made of durable and sturdy metals capable of lifting several pounds easily. As with other lifting devices attached to a bucket or container designed that concentrate on the bulk weight of a container, wire handles are added to make movement and transport of containers easy, convenient, and effortless.
The materials for wire handles are carefully chosen for strength, durability, and longevity. They are used to lift pots where there are environmental concerns, tools, wire mesh baskets that contain parts and components, and in the canning industry, for lifting large cans for painting and coating. The designs of wire handles vary in accordance with the type of materials used as handles or grippers, which can vary between wood, metal, plastic, rubber, and unique forms.
The process for manufacturing wire handles falls into the category of wire forming, which involves the use of different machines and compressive force including the programming of computer numeric controlled (CNC) machines. It is a process that has been used for centuries to create a wide assortment of tools and decorative items. The basic aspects of wire forming have not changed much and requires drawing wire to the necessary length and bending and shaping it to the desired form.
Aside from the many alloys used for wire forming, traditional metals such as stainless steel, steel, aluminum, copper, and nickel are used in accordance with the requirements of the handle to be formed. The characteristics of the different metals influence the forming process and the properties of the created handle.
Each of these metals are capable of enduring the stress of the bending, shaping, and forming associated with wire forming. How they are chosen depends on the type of handle, the type of bucket or container, and the weight to be carried. Another factor, which applies to a few applications, metals may be chosen for their appearance.
As with many manufacturing processes, wire forming is not isolated into a single process but is completed using different methods. The key to all processes is bending where the wire is bent at various angles. For complex handles or intricate shapes, the wire may have to withstand several shaping operations to achieve the desired form.
Regardless of the method, wire forming involves applying force to the wire by deforming the wire by compressing it in the axial direction, which is in line with the wire’s length. Each wire forming method applies force in the axial direction, perpendicular to the axial direction, and at other required angles, depending on the design of the handle.
Before wire is shaped and formed into handles, it is drawn by being pushed through a die and pulled out of the die. The purpose of the process is to adjust the thickness of the wire to the desired diameter for forming. Drawing makes it possible to create a wide variety of diameters without the need of having an inventory of wires with different diameters.
The die for drawing is in the form of a drawplate that is secured to an apparatus. The drawplate has the desired diameter of its opening. Since the diameter of the wire is already larger than the opening in the drawplate, the end of the wire has to be tapered such that it can fit into the drawplate. Tapering is a simple process that can be completed by hammering or using a rolling mill.
To make wire more ductile, it is annealed and pickled to remove any oxidation. This prevents the wire from breaking during the drawing process. Friction on the wire is reduced with the application of beeswax, paraffin, or bur lube. Once these preparations are completed, the wire is ready to be pulled through the drawplate.
The wire is inserted into the backside of the drawplate through a hole that is slightly smaller than the diameter of the taper. As the wire moves through the drawplate, a tool is connected to the tapered end that pulls the wire at an even constant rate. The pulling process must occur at a uniform speed to ensure the consistency of the wire’s diameter.
The purpose of wire straightening is to remove disfigurements, flaws, and deformities that are the result of the drawing process. A wire straightening machine is a specialized piece of equipment that consists of a series of rollers that straighten the wire. The rollers of a wire straightening machine are adjustable to match the diameter of the wire. The straightening process makes it easier to form and shape wire into handles and removes any kinks.
Wire that has been stored for an extensive period of time becomes deformed and stressed, which necessitates straightening of the wire. Straighteners flex the wire in different directions to relieve residual stress from the curvature of the wire.
The shaping and forming process involves the applying of force to the prepared wire. The purpose of the force is to change the contour of the wire to achieve the desired shape of the wire handle and an array of configurations and shapes. Although handles can be shaped using manual force, it is more common for the shaping to be completed using dies and cutting equipment.
The type of force is determined by the requirements of the handle and involves twisting, stamping, bending, swaging, extrusion, and upsetting. Of the various processes, upsetting involves compressing the wire towards its axial direction for improving the wire’s shape.
Although bending is the most common process used to form wire handles, there are other methods that are necessary to achieve the desired strength and shape of a wire handle. During shaping, wire endures a series of operations and applications in order to produce the required design, shape, configuration, and properties of the final wire handle.
Four slide wire handle forming is an alternative to power presses that operate in one direction. The process can produce intricate and multiple shapes by forming the wire from four directions. Four slide wire forming is ideal for the production of wire handles due to its ability to produce wire handles at high volume. Essentially, it is a wire bending process that can quickly and efficiently produce any type of wire handle.
The mechanism for a four-slide wire handle forming machine consists of four fixed position slides that are formed in a square around a forming mandrel or center tool. Additional slides may be added for cutting, feeding, and more specific operations. The movement of the slides is driven by four shafts on the outside of the machine that are driven by four bevel gears. The shape of a wire handle is determined by a shaping tool that is attached to the slide, which cuts the wire and forms it into the required handle shape.
In most cases, the types of metals used to produce wire handles are sufficiently resilient to withstand the use that a wire handle endures during its use. In certain cases, depending on how the handle will be used, various finishing coatings are added to wire handles to increase their durability. The coatings are used for handles that come in contact with acidic or caustic substances or for industrial environments. The type of finishing process can be dipping or spraying depending on the manufacturing process. Certain types of wire handle metals are more accepting of coating materials and are selected for that characteristic.
Grips are not used with all wire handles and are applied in several ways with the most common way being during the bending process when as the wire comes off a reel, is straightened, and pushed to the die. At the top of the die, the handle or gripper is positioned for the wire to be thrusted through its center. The solid grips are affixed to the wire handle as the wire handle machine applies force to the wire and bends it to its designed shape.
The materials used to manufacture wire handle grips vary from very light plastic for less stressful bucket use to more sturdy grips for construction, manufacturing, and industrial applications. All grips take the same shape, which is that of a short cylinder with a hole through its center such that it can be attached to the wire handle. Wood, plastic, and rubber are the most common materials used to produce wire grips.
Wire handles are attached to buckets or pails for easy transport of the bucket or pail and its contents. Depending on the nature of the material being carried in a bucket, its handle has to be able to withstand the weight of the contents. The wire for wire handles is carefully chosen to match the requirements of the load. In industrial and construction operations, handles have to be substantial, strong, and highly durable and made of wire that can endure the conditions.
Of the various wires used to produce wire handles, galvanized steel wire is one of the most popular due to its resistance to rust, durability, strength, and longevity. The galvanizing process, or galvanization, involves applying a coating of zinc to iron or steel. The methods of galvanizing cover a wide spectrum of techniques that are designed for an even application of the zinc coating.
A common form of galvanization is hot dipping where the wire goes through a set of processes in order to apply its zinc coating. The first step in the process is to remove dirt, grease, and other contaminants from the surface of the metal, which is completed by placing the wire in a caustic cleaning solution that is rinsed off prior to the wire being pickled. The process of pickling is the cleaning of the metal using an acidic solution that is also rinsed off. Prior to the metal being placed in a bath of molten zinc, it is fluxed to help the zinc adhere to the wire. In the zinc bath, the wire is immersed until it matches the temperature of the bath.
Galvanized iron wire is like galvanized steel wire but is made from iron. The application of zinc to galvanized iron wire protects it against rust and corrosion and makes it possible to take advantage of the exceptional strength of iron wire. The wide use of galvanized iron wire for the manufacture of wire handles is due to the ease with which the wire can be shaped and formed into wire handles. Regardless of the wire handle manufacturing process, galvanized iron wire can be cut, shaped, bent, and formed to meet the requirements of any type of wire handle application. The main property of galvanized iron wire is its longevity. Once it is securely attached to a bucket or pail, it remains in place without the need for adjustments or replacement.
In most cases, stainless steel handles are used with stainless steel buckets or pails. Of the various choices of metals, stainless steel is one of the most resilient and comes in a wide array of alloys with each alloy capable of being designed to fit specific environments and conditions. Stainless steel handles are bent and shaped using the same methods used to manufacture all other forms of wire handles.
Stainless steel is very smooth and has an attractive appearance. The even surface of stainless steel, and the reason it is used as buckets and handles, makes bucket handles made from stainless steel easy to handle and grip. Depending on the industry using stainless steel handles, the handles may come with or without a grip.
The series of stainless steel that are most commonly used to manufacture stainless steel bucket handles are series 304 and 316L, which are two of the most popular stainless steel grades and the most versatile. Stainless steel series 304, also known as 18/8, is an austenitic stainless steel that can be deeply drawn to form bucket and pail handles. Series 316L is also an austenitic stainless steel that contains a percentage of molybdenum. It has high corrosion resistance, which makes it ideal for harsh environments.
The list of wire handles is as long as the list of buckets and pails and covers a wide range of shapes, sizes, and designs. Although wire handles are a relatively simple part of a bucket or pail, they have to be configured to fit the capacity of the bucket or pail since they bear the weight of the load. The various shapes of wire handles are engineered to provide the necessary resistance to withstand heavy and cumbersome materials.
The different types of wire handles are determined by the type of bucket or pail to which they are attached. Plastic buckets tend to be less resilient than metal buckets and normally have a lighter weight wire handle designed to handle lighter loads. Metal buckets, due to the nature of their use, have wire handles of varying diameters and materials since metal buckets or pails are designed for heavier work and heavier loads.
A bail wire handle is attached to a bucket with a loop in the ends of the handle or an inward bent angle that is pushed through the material of the bucket or pail. The looped and bent designs allow the handle to rotate to one side or the other of a bucket or pail such that the contents can be poured out or materials can be poured in. Bail wire handles are seen on cookware and paint buckets since they move out of the way when working with the contents of the container.
As with the majority of wire handles, bail wire handles are made of exceptionally sturdy metals such as galvanized steel or galvanized iron due to the weight of the materials they carry. The varieties of bail wire handles include ones for decorative buckets or pails for carrying flowers or other decorations.
Fixed wire handles can be fixed in place or be movable depending on their use. They can be attached to a wide variety of buckets or pails but are generally connected to various types of metal containers that require a great deal of strength and durability in their handles.
Although the term fixed is used to describe fixed wire handles, not all fixed wire handles are solidly attached. In certain cases, they can be attached using screws, loops, or hooks, all which have to be very sturdy to endure the work of a fixed wire handle. The term fixed wire handle refers to a metal container that has its wire handle welded to it or secured using some other means. As with all forms of fixed wire handles, the welded types are used for industrial applications for the movement of parts after various types of treatments.
A unique form of fixed wire handle has two wires that are held together with a grip or handle and are connected on each side of the container with an attachment for each wire. In most cases, those types of wire handles are for decorative purposes.
Folding wire handles take several forms and are widely used with grocery baskets. The form of folding wire handles is similar to that of two wire fixed wire handles in that they consist of two wires that are connected on both sides of the container. When the handles are not in use, they fold down and rest on the ends of the container.
A common use for folding handles is in industrial settings where space is limited and containers are used to transport parts. Folding handles make it possible to easily organize containers, usually part baskets, when the baskets are not in use. Additionally, the stacked containers can be placed conveniently for immediate access for efficiency.
The frequent use of folding handles requires that they be made of highly durable materials to ensure their functionality and longevity. This particular aspect is especially important in industrial settings where the failure of a wire handle can be damaging and harmful.
Wire loop handles are smaller wire handles that can be connected to tools. They are a single wire that has both ends attached to a tool. When used with buckets, pails, or containers, there are usually two wire loops that are permanently attached on either side of a container. Attachment methods for wire loop handles vary from welding to crimped brackets.
The use of wire loop handles is due to their strength and secure attachment to a container. In many cases, such as plastic buckets, the handles are molded into the walls of a bucket or pail.
The name wire loop handle can give the impression that all wire loop handles are shaped like a loop, which is not the case. They can have rectangular, square, round, and looped shapes depending on their use. When wire loop handles are used with tools, they are usually in the shape of a loop. There are several different styles of wire loop handles, which vary according to their use and the weight of the loads they have to support.
Wire frame bucket handles are a unique form of bucket handle in that they are made of various types of wire but are built into the container, bucket, or pail. They serve as the structural frame for the container and its handles, which are on opposite sides of a container. There are several types of wire frame bucket handles that vary between ones for office wastebaskets to ones that are extremely sturdy and are used to carry parts and components.
Regardless of the different types of wire frame bucket handles, the frames of each type are very sturdy and solid with the main variation being the type of wire used to form the frame. Industrial wire frame bucket handles usually form the frame for a basket or solid container.
As with wire frame bucket handles, V wire bucket handles are an unusual form of bucket handle in that they have a bend in the top of the handle in the shape of an upside-down V, which makes it possible to hang the bucket on a nail, clip, or hook. Depending on the use of a V wire bucket handle, they can also have a grip attached that allows the V to protrude out of the grip.
The wire handles of V wire bucket handles are bail type, which allows the handle to rotate across the top of the bucket for easy placement. Their wires are exceptionally sturdy in order to handle the loads they carry. V bucket handles are commonly used with livestock feeding and to carry water or feed.
Grips for wire bucket handles, regardless of the material from which they are made, tend to have a very similar structure, which is a cylinder-like tube with a hole through the center of the cylinder enabling them to be attached to the wire handle. The difference between the various groups is the material from which they are made and whether they have rigs or are smooth.
The purpose of grips is to make lifting the weight of a bucket or pail easier, comfortable, and secure. Grips can be solidly attached to the wire handle such that they are immovable or be loose and movable. They are made of various types of plastics such as silicone and polyethylene and wood, which are chosen for their strength and durability. Some versions of wire bucket grips are finger molded to enhance the gripping ability of the user. They have indentations or slots for fingers to fit into.
Wire handle bucket grips are a necessity for carrying hot materials since the heat from the material moves up the wire handle. Also, they are especially important for lifting extremely heavy loads by providing a more secure grip on a bucket or pail and the load.
Due to the nature of wire handles, wire handle grips come in a wide variety of sizes capable of fitting any type of wire handle. They can fit wire gauges of 0.091 up to 0.187 and are able to easily hold five gallon (19 liters) loads.
There are a set of considerations that have to be examined when choosing a wire handle for a bucket or pail. The first factor is the metal wire, which has to be sturdy enough to carry a load and support the bucket. Other factors include type of grip, load capacity, and how the handle will be attached. Although there are generic handles that can fit any type of bucket or pail, it is essential to choose a handle that fits the specific needs of the application for which it is used.
It is easy to get confused regarding the types of materials that are used to produce bucket and pail handles since there are so many varieties. Galvanized steel and galvanized iron are the most common forms of metal wire used to manufacture wire bucket handles due to their strength and durability. The important factor regarding the metal for a wire handle is its ability to to endure regardless of the conditions, which is the reason that wire handles are made of materials that do not rust or corrode.
Wire handles normally have a smooth surface that is easy to grip and hold. The problem with gripping a wire handle is the thickness or diameter of the wire since smaller diameters can cut into the hand. In those cases, plastic, rubber, or wood grips or handles are added for hand protection. When carrying metal buckets, it is common to have a handle attached to a wire handle in case the contents of a bucket has hot material.
The load capacity of a bucket is a crucial factor regarding the type of handle that will be attached to a bucket or pail. A complex formula used to calculate the volume of a container is used to develop the standard capacity for a bucket. The durability of the wire handle of a bucket has to match the weight capacity of the container, which can vary from a few pounds or liters to several pounds or liters depending on the size of a bucket or pail. This aspect of wire handle selection is important in regard to handles that may fail when used to lift loads beyond their capacity, a factor that can be crucial in certain instances.
There are an endless number of ways that a wire handle can be attached to a bucket, which vary from being molded into a bucket or pail to being attached using rivets, screws, or welding. The molded method is one of the more secure methods of attaching wire handles and is used with plastic buckets during bucket manufacturing. Molded attached wire handles are permanent and are seldom changed. Screws or rivets provide more flexibility and allow for changing the type of bucket handle while welded bucket handles are attached for the life of a bucket or container.
In many ways, the choice of bucket handle determines the usage life of a bucket. Properly chosen bucket handles increase the longevity of a bucket and ensure safe and efficient use. When a bucket handle is firmly attached and secure, it ensures that a bucket is able to withstand constant use without risk of failure or breakage.
A factor that all manufacturers want their customers to realize is that not all standard bucket handles can be used for all applications. In many cases, a customized bucket needs to be designed to match special needs and conditions. In such cases, engineers and designers work with customers to develop a wire bucket handle capable of meeting conditions that are outside the realm of standard bucket use.
Some of these conditions can pertain to extreme and hostile environments where buckets have to carry loads in harsh stressful conditions. In scientific laboratory conditions, special buckets may be required to carry unusual fluids and substances that are being tested. Clean rooms are especially susceptible to requiring buckets that are hygienically clean and durable.
It is interesting to note that the simple bucket handle, which is taken for granted in most instances, can be a crucial and integral part of an industrial operation and scientific research. In most cases, wire bucket handles are overlooked and ignored, a factor that is contrary to their use. They provide a secure grip on loads, enable easy transport, offer durability, and have designs that specifically meet the conditions of an application.
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