{"id":17259,"date":"2026-09-18T16:24:56","date_gmt":"2026-09-18T08:24:56","guid":{"rendered":"https:\/\/hkcablemachine.com\/?p=17259"},"modified":"2026-09-18T16:24:56","modified_gmt":"2026-09-18T08:24:56","slug":"cable-extrusion-crosshead-guide","status":"publish","type":"post","link":"https:\/\/hkcablemachine.com\/bn\/cable-extrusion-crosshead-guide\/","title":{"rendered":"\u0995\u09c7\u09ac\u09b2 \u098f\u0995\u09cd\u09b8\u099f\u09cd\u09b0\u09c1\u09b6\u09a8 \u0995\u09cd\u09b0\u09b8\u09b9\u09c7\u09a1: \u099f\u09c1\u09b2\u09bf\u0982, \u09b8\u09c7\u09a8\u09cd\u099f\u09be\u09b0\u09bf\u0982 \u098f\u09ac\u0982 \u09aa\u09b0\u09c0\u0995\u09cd\u09b7\u09be"},"content":{"rendered":"<p>A cable production manager may need new tooling after changing a cable size, adding a layer or finding uneven insulation. Before ordering a new crosshead, separate the cable requirement from the condition of the installed tooling and the way the line is running.<\/p>\n<p><strong>A new cable size does not always require a new crosshead. Check the incoming core structure, the required outside shape and size, and the head&#8217;s confirmed range. Then check line alignment, wall thickness and heating: changing tools or adjusting the head cannot correct every cause of an uneven wall.<\/strong><\/p>\n<p>This guide concerns the information and evidence needed for insulation and jacket extrusion. It is not a universal die-sizing recipe, a centering procedure for a particular machine or a substitute for its operating manual.<\/p>\n<h2>Start with the Layer Being Applied<\/h2>\n<p>Begin with a drawing of the product entering the crosshead and the product leaving it. A solid conductor, a stranded conductor and an assembled cable core should not be treated as interchangeable inputs simply because their nominal diameters are similar.<\/p>\n<p>Record the incoming construction, its size range and the layer being applied. For a finished cable, identify whether the purchase concerns conductor insulation, an inner sheath or the outer jacket. Where several materials or layers are involved, identify them separately rather than requesting a generic \u201cmultilayer head.\u201d<\/p>\n<p>Prepare a short product record containing:<\/p>\n<ul>\n<li>The incoming conductor or core drawing and representative samples.<\/li>\n<li>The compound manufacturer, exact grade and processing guidance.<\/li>\n<li>The finished outside dimension, required wall thickness and applicable acceptance limits.<\/li>\n<li>The number and order of layers, including any stripe or other separate material feed.<\/li>\n<li>Relevant requirements for stripping, adhesion or layer separation, if the cable specification includes them.<\/li>\n<li>The current extruder, crosshead identity, line layout and proposed operating range.<\/li>\n<\/ul>\n<h3>Choose the extrusion method and layer arrangement separately<\/h3>\n<p>Pressure tooling and tubing tooling describe different extrusion approaches. Single-layer and coextrusion describe the layer arrangement. These are separate decisions, not four competing names for the same choice. Tooling manufacturers offer different pressure\/tubing, layer and centering configurations.<sup id=\"fnref1:1\"><a href=\"#fn:1\" class=\"footnote-ref\">1<\/a><\/sup><\/p>\n<p>Start with the product and required wall thickness when choosing the extrusion approach. In the HONGKAI applications discussed for this guide, the optical-fiber tube operation uses tubing tooling, while the sheath operation uses pressure tooling. These are application examples, not a rule that every optical cable tube or jacket uses the same method.<\/p>\n<p>Next, specify whether the product needs one layer, two layers in separate operations, or two layers extruded together. If both layers must be applied in one pass, the proposed head and material feeds must support that coextrusion arrangement. Identify a color stripe separately; a stripe is not automatically another complete sheath layer.<\/p>\n<p><img decoding=\"async\" src=\"https:\/\/hkcablemachine.com\/wp-content\/uploads\/2026\/09\/hongkai-dual-layer-stripe-crosshead-reference-v1.webp\" alt=\"HONGKAI 3D exterior reference for a dual-layer coextrusion crosshead with a color-stripe arrangement\" title=\"Dual-layer crosshead\" \/><\/p>\n<p><em>HONGKAI 3D exterior reference for a dual-layer coextrusion crosshead with a color-stripe arrangement. This is not a dimensioned drawing or a universal design for other crossheads.<\/em><\/p>\n<p>For an expansion project, separate the first approved product from future products. Ask the supplier to identify which changes remain within the proposed head and tooling range, and which require a different setup or an application trial. A possible future configuration should not be listed as proven production scope.<\/p>\n<h2>Change the Tools\u2014or the Whole Crosshead?<\/h2>\n<p><strong>Check the tip when the incoming core construction changes, and the die when the required outside shape or dimension changes. If the product is outside the installed head&#8217;s confirmed size range, a tooling change alone is not enough: the head must also change. Staying within that range is only the first compatibility check.<\/strong><\/p>\n<p><img decoding=\"async\" src=\"https:\/\/hkcablemachine.com\/wp-content\/uploads\/2026\/09\/crosshead-tool-change-map-v1.webp\" alt=\"Decision diagram linking core construction to the tip, outer shape and size to the die, and an exceeded head range to a different crosshead\" title=\"Tools or head?\" \/><\/p>\n<p><em>Explanatory decision map based on the application distinctions discussed for this guide. It is not a tooling drawing; fit, material and layer arrangement still require confirmation.<\/em><\/p>\n<p>HONGKAI&#8217;s sizing discussions include U7, U10, U14 and U20 crossheads. In this family, the number indicates the supported maximum line-size range. Confirm the actual limit and which product dimension it refers to against the particular head&#8217;s drawing or specification. These names are not a universal sizing system across manufacturers.<\/p>\n<p>For tooling, separate the incoming construction from the finished shape. A single-core and a two-core product can require different tips. The die must suit the target outer shape and size as well as the agreed material and extrusion method. Do not assume that each product change requires both tools to be replaced, or that a larger die can extend the head beyond its approved range.<\/p>\n<table>\n<thead>\n<tr>\n<th>What changes?<\/th>\n<th>What to review first<\/th>\n<th>What must be confirmed?<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Incoming core construction, such as single-core to two-core<\/td>\n<td>Tip or guide geometry<\/td>\n<td>Passage, guiding arrangement and compatibility with the die<\/td>\n<\/tr>\n<tr>\n<td>Required outside shape or finished dimension<\/td>\n<td>Die geometry and usable range<\/td>\n<td>Target shape and size with the selected material and extrusion method<\/td>\n<\/tr>\n<tr>\n<td>Required product size exceeds the head&#8217;s confirmed limit<\/td>\n<td>A head with a suitable range<\/td>\n<td>The new head, tooling and line interfaces as a complete package<\/td>\n<\/tr>\n<tr>\n<td>Layer arrangement, stripe or material changes<\/td>\n<td>The extrusion arrangement, not just the tool opening<\/td>\n<td>Required feeds, compatible head\/tooling and any application trial<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>For an existing machine, provide its head identification, photographs and tooling drawing. Confirm the mounting dimensions, locating surfaces, holders and adjustment arrangement. Different manufacturers&#8217; tools are not interchangeable merely because the finished cable diameter is the same.<\/p>\n<p>HONGKAI&#8217;s published <a href=\"https:\/\/hkcablemachine.com\/cable-extrusion-line-spare-parts\/\">extrusion spare-parts page<\/a> lists die, tip and adjusting-ring components and asks for photos or drawings before confirming a replacement. That is a starting point for part identification, not evidence that an unknown tool will fit every crosshead.<\/p>\n<p>A worn part can help identify the assembly, but its measured dimensions should not automatically become the dimensions of a new part. Ask the supplier to distinguish the original design from wear, damage or earlier modifications. Record drawing revisions and part numbers so a later order refers to the same approved package.<\/p>\n<p>Have the supplier record the agreed scope: replacement tools, a modified tooling package or a different head. That written boundary is more useful than an unsupported claim that one head can make every future product.<\/p>\n<h2>Check the Wire Path Before Blaming the Head<\/h2>\n<p>An uneven wall is a reason to investigate, not an automatic instruction to replace the crosshead. Preserve the sample and operating record before changing the setup. Record whether the issue appeared after a tool change, a material change, a restart or a change in line operation.<\/p>\n<h3>Establish the centering arrangement before production<\/h3>\n<p>Identify whether the particular head uses manual adjustment, assisted adjustment or a fixed\/self-centering arrangement. Follow the setup method for that design before formal production. A head described as requiring no routine centering adjustment still needs correct installation, matched tooling and a check of the finished wall.<\/p>\n<h3>Check installation and traction as well as the head<\/h3>\n<p>HONGKAI&#8217;s commissioning checks for the applications discussed here include equipment leveling, alignment between the crosshead&#8217;s cable path and the haul-off centerline, and abnormal haul-off vibration or jerking. Establish these conditions during installation rather than trying to compensate for them with the head&#8217;s centering adjustment later.<\/p>\n<p>An uneven floor matters if the equipment has not been correctly supported and leveled. The floor does not have to serve as the alignment reference by itself. Ask the installer to verify the machine positions and cable path against the approved layout. A misaligned haul-off or unstable pull is a separate issue to correct; adjusting the head alone does not resolve it.<\/p>\n<p><img decoding=\"async\" src=\"https:\/\/hkcablemachine.com\/wp-content\/uploads\/2026\/09\/crosshead-line-alignment-v1.webp\" alt=\"Simplified cable-path diagram showing a common centerline through the crosshead, cooling section and haul-off with leveling and traction checks\" title=\"Cable-path alignment\" \/><\/p>\n<p><em>Simplified alignment concept, not an installation drawing or a complete production line. Equipment positions, supports and tolerances must follow the actual layout.<\/em><\/p>\n<p>Keep these investigation questions separate:<\/p>\n<ul>\n<li><strong>Part identity:<\/strong> Are the installed tip, die and holders the approved combination?<\/li>\n<li><strong>Assembly condition:<\/strong> Does inspection show damage, contamination or another condition needing correction?<\/li>\n<li><strong>Line behavior:<\/strong> Does the core run consistently through the intended path, or does its position or tension change?<\/li>\n<li><strong>Heating behavior:<\/strong> Do the head&#8217;s measured temperatures and control behavior match the approved recipe, rather than only displaying the intended setpoints?<\/li>\n<li><strong>Extrusion behavior:<\/strong> Are material preparation and output stable under the approved recipe?<\/li>\n<li><strong>Measurement:<\/strong> Is the reported fault an outside-diameter change, uneven wall thickness, ovality or a combination?<\/li>\n<\/ul>\n<p>These questions organize evidence; none establishes the cause on its own. The <a href=\"https:\/\/hkcablemachine.com\/cable-extrusion-defects-troubleshooting\/\">material and process defect investigation guide<\/a> covers the broader checks when bubbles, roughness or unstable extrusion appear as well as dimensional problems.<\/p>\n<p>If several settings are changed together, record all of them. A better sample after multiple changes cannot show which change solved the problem. Where a controlled comparison is practical, agree on the change and its evaluation before running the trial.<\/p>\n<p>Note: Intrusive inspection, cleaning and tool changes require qualified personnel following the machine&#8217;s isolation, pressure-release and temperature-control instructions. This article does not authorize adjusting, opening or reaching into running or pressurized equipment.<\/p>\n<h2>Measure Wall Thickness, Not Only Outside Diameter<\/h2>\n<p><strong>A stable outside diameter does not prove that the conductor or core is centered. Accept the layer using the wall-thickness and dimensional evidence required by the cable specification, not only the diameter display.<\/strong><\/p>\n<p>SIKORA explains that comparing diameters before and after extrusion can provide a thickness value, but that laser-diameter comparison alone does not measure eccentricity. A system intended to measure eccentricity needs the relevant additional measurement capability.<sup id=\"fnref1:2\"><a href=\"#fn:2\" class=\"footnote-ref\">2<\/a><\/sup><\/p>\n<p><img decoding=\"async\" src=\"https:\/\/hkcablemachine.com\/wp-content\/uploads\/2026\/09\/crosshead-wall-eccentricity-v1.webp\" alt=\"Two illustrative cable cross-sections with equal outside diameters but centered and offset cores, showing different wall thickness distributions\" title=\"OD versus centering\" \/><\/p>\n<p><em>Conceptual cross-sections with the same outside diameter. The offset core changes the wall distribution; these are not measured samples or acceptance limits.<\/em><\/p>\n<p>Keep the inspection terms clear in the purchase and trial records:<\/p>\n<table>\n<thead>\n<tr>\n<th>\u09aa\u09cd\u09b0\u09ae\u09be\u09a3<\/th>\n<th>What it helps establish<\/th>\n<th>What it does not establish by itself<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Outside-diameter record<\/td>\n<td>Variation in the measured outer dimension<\/td>\n<td>Position of the conductor or core inside the layer<\/td>\n<\/tr>\n<tr>\n<td>Prepared cross-section<\/td>\n<td>Local wall distribution in that particular sample<\/td>\n<td>Quality of the entire production length<\/td>\n<\/tr>\n<tr>\n<td>Suitable online wall or eccentricity measurement<\/td>\n<td>Behavior of the measured parameter during the recorded run<\/td>\n<td>Suitability for an unverified material, size or construction<\/td>\n<\/tr>\n<tr>\n<td>Surface inspection<\/td>\n<td>Visible appearance at the inspected location<\/td>\n<td>All hidden dimensional or electrical requirements<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>Before the trial, agree on how samples will be prepared and measured. Identify the instrument, the recorded quantities and the acceptance limits. Where a percentage such as \u201cconcentricity\u201d appears in a proposal, require its definition and calculation method; do not assume that different reports use identical terminology.<\/p>\n<p>Link each result to the same material batch, tooling setup and sample position or production time. If an online gauge and an offline sample disagree, first confirm that they refer to the same product and measurement conditions. Do not choose whichever result happens to be more favorable.<\/p>\n<p>The measuring system also needs an application check. Ask which materials, layer arrangements, product dimensions and operating conditions it can evaluate in the proposed setup. This guide does not require a particular instrument brand or claim that one sensing method covers every cable.<\/p>\n<h2>Accept a Reproducible Setup, Not One Good Sample<\/h2>\n<p>Agree on the trial before accepting the proposed crosshead or tooling change. Define the sample product, material grade, setup identity, operating conditions, measurement method and decision limits. The buyer and supplier should know what evidence will settle acceptance before the machine is demonstrated.<\/p>\n<p>For the head itself, HONGKAI&#8217;s priorities in the applications discussed here are the actual product&#8217;s centering and normal heating behavior. Demonstrate both on the agreed product: inspect the wall distribution and retain the corresponding temperature records. These head-focused checks do not replace the other tests required for the finished cable.<\/p>\n<p><img decoding=\"async\" src=\"https:\/\/hkcablemachine.com\/wp-content\/uploads\/2026\/09\/crosshead-acceptance-evidence-v1.webp\" alt=\"Acceptance evidence diagram connecting product centering and heating behavior to the same tooling, material and time or length record\" title=\"Trial evidence\" \/><\/p>\n<p><em>Explanatory record map, not a test report. Link centering samples and temperature records to the same setup; agree the actual limits and other product tests separately.<\/em><\/p>\n<p>A useful trial record links the following items rather than storing them as unrelated photographs:<\/p>\n<ul>\n<li>The approved cable drawing and the compound batch used.<\/li>\n<li>The head identification, tooling part numbers and drawing revisions.<\/li>\n<li>The centering arrangement, verified line alignment and agreed operating conditions.<\/li>\n<li>The specified temperature settings and the corresponding measured temperature records.<\/li>\n<li>The retained samples with their time or length references.<\/li>\n<li>The corresponding dimensional results and other applicable product checks.<\/li>\n<li>Any interruption or adjustment, the reason for it and the result afterward.<\/li>\n<\/ul>\n<p>Where frequent product changes are important, include an agreed changeover in the demonstration. The question is not merely whether an experienced operator can produce one acceptable short sample. It is whether the factory can identify the approved tools, follow the documented setup and verify the result again under the agreed conditions.<\/p>\n<p>Do not invent a universal test speed, duration or sample count. Those values must match the product, contract and factory&#8217;s acceptance method. Startup material and output made during an unapproved adjustment should remain identifiable under the factory&#8217;s quality procedure.<\/p>\n<p>At handover, retain the accepted tool drawings or identifiers, setup instructions, maintenance guidance and sample records. List future materials and product sizes separately if they have not been demonstrated. A clear scope prevents the accepted setup for one cable from becoming an unsupported promise about every cable the factory may make later.<\/p>\n<p>The strongest result is a matched tooling package with traceable samples and a repeatable setup. That gives production staff a basis for the next changeover and gives the buyer evidence for accepting the equipment.<\/p>\n<div class=\"footnotes\">\n<hr \/>\n<ol>\n<li id=\"fn:1\">\n<p>Guill Tool &amp; Engineering, <a href=\"https:\/\/guill.com\/series\/\" rel=\"nofollow noopener\" target=\"_blank\">Series and configuration options<\/a>. Used only to substantiate the existence of distinct pressure\/tubing and fixed\/adjustable configurations, not as a HONGKAI product specification, supplier endorsement or universal selection rule.&#160;<a href=\"#fnref1:1\" rev=\"footnote\" class=\"footnote-backref\">\u21a9<\/a><\/p>\n<\/li>\n<li id=\"fn:2\">\n<p>SIKORA, <a href=\"https:\/\/sikora.net\/en\/thickness-measurement\/\" rel=\"nofollow noopener\" target=\"_blank\">Thickness measurement<\/a>, particularly the laser-measurement discussion. Supports the distinction between diameter-derived thickness and eccentricity measurement; no vendor-specific accuracy or performance claim is adopted.&#160;<a href=\"#fnref1:2\" rev=\"footnote\" class=\"footnote-backref\">\u21a9<\/a><\/p>\n<\/li>\n<\/ol>\n<\/div>","protected":false},"excerpt":{"rendered":"<p>\u0995\u09c7\u09ac\u09b2 \u0989\u09ce\u09aa\u09be\u09a6\u09a8 \u09ae\u09cd\u09af\u09be\u09a8\u09c7\u099c\u09be\u09b0\u09a6\u09c7\u09b0 \u099c\u09a8\u09cd\u09af \u098f\u0995\u099f\u09bf \u09ac\u09cd\u09af\u09ac\u09b9\u09be\u09b0\u09bf\u0995 \u0997\u09be\u0987\u09a1 \u09af\u09be \u099f\u09bf\u09aa\u09b8 \u098f\u09ac\u0982 \u09a1\u09be\u0987 \u09ae\u09bf\u09b2\u09be\u09a8\u09cb, \u0985\u09b8\u09ae \u09aa\u09cd\u09b0\u09be\u099a\u09c0\u09b0\u0997\u09c1\u09b2\u09bf \u09a4\u09a6\u09a8\u09cd\u09a4 \u0995\u09b0\u09be \u098f\u09ac\u0982 \u09a8\u09a4\u09c1\u09a8 \u0995\u09cd\u09b0\u09b8\u09b9\u09c7\u09a1 \u09b8\u09c7\u099f\u0986\u09aa \u0997\u09cd\u09b0\u09b9\u09a3\u09c7\u09b0 \u0986\u0997\u09c7 \u09aa\u09cd\u09b0\u09ae\u09be\u09a3\u09c7 \u098f\u0995\u09ae\u09a4 \u09b9\u0993\u09af\u09bc\u09be\u09b0 \u09ac\u09bf\u09b7\u09af\u09bc\u0997\u09c1\u09b2\u09bf \u09a8\u09bf\u09b0\u09cd\u09a6\u09c7\u09b6 \u0995\u09b0\u09c7\u0964.<\/p>","protected":false},"author":1,"featured_media":17270,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"_angie_page":false,"site-sidebar-layout":"default","site-content-layout":"","ast-site-content-layout":"default","site-content-style":"default","site-sidebar-style":"default","ast-global-header-display":"","ast-banner-title-visibility":"","ast-main-header-display":"","ast-hfb-above-header-display":"","ast-hfb-below-header-display":"","ast-hfb-mobile-header-display":"","site-post-title":"","ast-breadcrumbs-content":"","ast-featured-img":"","footer-sml-layout":"","ast-disable-related-posts":"","theme-transparent-header-meta":"default","adv-header-id-meta":"","stick-header-meta":"","header-above-stick-meta":"","header-main-stick-meta":"","header-below-stick-meta":"","astra-migrate-meta-layouts":"set","ast-page-background-enabled":"default","ast-page-background-meta":{"desktop":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center 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