Coating thickness of magnet wire

I am totally new to magnet wire production field. I am interested to know how we can calculate enamel consumption based on coating thickness and solid content for round enameled wire?

This is kind of tricky but a rule of thumb is to measure the weight a fixed length of coated wire. a 100 foot or 1000 foot length piece is good. Then measure the weight of the same length of bare wire from the same reel. this should insure that the cross section is identical, the diameter varying only by the die wear.

Compare the weight of the two pieces. Then calculate the number of feet to = 100 pounds of coated wire. if the same length of bare wire is then only 95 pounds then you know that the dried enamel is 5% by weight or 5 pounds.

Next you look at what a gallon of enamel weights. Assume it weights 7.5 pounds liquid and is 40% solids. That means that there is 3 pounds of resin, filler, solids, etc. However not all 100% of the solids gets applied to the wire. Some actually goes up the exhaust stack. This is purely an estimate but lets say 10% goes up the stack. that leaves 2.7 pounds of solids.

Divide the 2.7 into the original 5 pounds and you will get 1.85. That is how many gallons of liquid enamel it take to coat the original 100 pounds of finished wire.

NOTE: This is a good rule of thumb that I know works, however the %solids and the weight of a gallon of enamel varies with different materials and suppliers.

Of course another way is to actually monitor the amount of enamel consumed during a production run and keep an accurate record of the amount of wire produced. When we used to do method 25 EPA tests we had to very accurately measure the amount of enamel consumed during 3 trials, each 1 hour long as well as the actual production during those 3 trials.

Hope this helps.
Spectre

Thanks a lot for your reply. Definitely this gives an idea about how we can calculate enamel consumption.