Optimization of Die design to abolish surface defect on Telescopic Front Fork (TFF) Tube

2021 ◽  
Vol 01 ◽  
Author(s):  
Asit Kumar Choudhary ◽  
Braj Bihari Prasad
Keyword(s):  
Outer Surface ◽  
Transverse Crack ◽  
Axial Stress ◽  
Substantial Reduction ◽  
Cold Drawing ◽  
Wire Drawing ◽  
Die Design ◽  
Drawing Process ◽  
Die Geometry ◽  
Area Reduction

Background: The telescopic fork is mainly used for suspension purposes in the different devices to absorb the vibration and disturbances from the road or mechanical devices. Factors such as die angle, drawing velocity, lubrication, and area reduction per pass significantly affect the drawing loads and residual stresses formed in the drawn tube during the tube marking process. Objective: Instantaneous transverse crack was found on the pipe's outer surface during the drawing process in the current work, and the key challenges were to reduce the percentage of pipe rejection. Methodology: In this work, optimum drawing die designs were proposed by using the finite element method (FEM). A FEM solving tool called Abaqus has been used for simulating and solving the cold-rolled process. The FEM model of the cold drawing process is generated in Abaqus with the same boundary condition (Axial load and constrain) as using on the actual wire drawing machine. Result: There was a substantial reduction in the area; axial stress (Tensile) along the die side is 672 MPa which is 23 % lower than the current die axial stress value of 877 MPa. A 48 % plastic strain was found along the purposed die side, which was 17 % lower than the existing strain of 64%. Finally, reduced the area by changing the die geometry from ~52% to 35 to 40 %. Conclusion: It was possible to abolish transverse crack on the pipe's outer surface to reduce the area reduction (35 to 40 %) in the output tube and strain (17 %). As part of the optimization of the FEM work process, this work gives us encouraging results. Further research will be considered for future positions.

Influence of Thermomechanical Processing on the Martensitic Transformation Temperatures of NiTi SMA Wire

2010 ◽  
Vol 643 ◽  
pp. 43-48 ◽  
Author(s):  
Leonardo Kyo Kabayama ◽  
Odair Doná Rigo ◽  
Jorge Otubo
Keyword(s):  
Martensitic Transformation ◽  
Thermomechanical Processing ◽  
Cold Drawing ◽  
Wire Drawing ◽  
Mechanical Processing ◽  
Drawing Process ◽  
Intermediate Annealing ◽  
Transformation Temperatures ◽  
Area Reduction ◽  
Niti Sma

Most of the applications of NiTi SMA are as a wire form. In this sense it is important to know the effects of thermo-mechanical processing such as reduction per pass and intermediate annealing on the wire drawing process. For this work they were produced wire by cold drawing using 15 % area reduction per pass with and without intermediate annealing. The starting ingot was produced by VIM process. The influence of thermo-mechanical processing will be related to the martensitic transformation temperatures.

scholarly journals Influences of Different Die Bearing Geometries on the Wire-Drawing Process

Metals ◽  
2019 ◽  
Vol 9 (10) ◽  
pp. 1089 ◽  
Author(s):  
Gustavo Aristides Santana Martinez ◽  
Eduardo Ferro dos Santos ◽  
Leonardo Kyo Kabayama ◽  
Erick Siqueira Guidi ◽  
Fernando de Azevedo Silva
Keyword(s):  
Friction Coefficient ◽  
Radial Stress ◽  
Copper Wire ◽  
Wire Drawing ◽  
Vital Role ◽  
Die Design ◽  
Drawing Process ◽  
Comprehensive Understanding ◽  
Die Geometry ◽  
The Wire

Metalworking is an essential process for the manufacture of machinery and equipment components. The design of the die geometry is an essential aspect of metalworking, and directly affects the resultant product’s quality and cost. As a matter of fact, a comprehensive understanding of the die bearing geometry plays a vital role in the die design process. For the specific case of wire drawing, however, few efforts have been dedicated to the study of the geometry of the bearing zone. In this regard, the present paper involves an attempt to investigate the effects of different geometries of the die bearing. For different forms of reduction as well as bearing zones, measurements are carried out for the wire-drawing process. Subsequently, by extracting the friction coefficients from the electrolytic tough pitch copper wire in cold-drawn essays, the numerical simulations are also implemented. We present the results on both the superficial and center radial tensions obtained by finite element methods. It is observed that the reduction of the friction coefficient leads to an increase in radial stress, while for a given friction coefficient, the substitution of the C-type die by the R-type one results in a decrease in the superficial radial stress of up to 93.27%, but an increase at the center of the material. Moreover, the die angle is found to play a less significant role in the resultant center radial stress, but it significantly affects the superficial radial stress. Lastly, R-type dies result in smaller superficial radial stress, with a change of up to 34.48%, but a slightly larger center radial stress up to 6.55% for different die angles. The implications of the present findings are discussed.

Deformation Law of Cold Drawing Process of High Strength Bridge Cable Steel

2021 ◽  
Vol 1035 ◽  
pp. 801-807
Author(s):  
Xiao Lei Yin ◽  
Jian Cheng ◽  
Gang Zhao
Keyword(s):  
Strain Path ◽  
High Strength ◽  
Cold Drawing ◽  
Wire Drawing ◽  
Radial Deformation ◽  
Steel Bridge ◽  
Drawing Process ◽  
Single Pass ◽  
Potential Relationship ◽  
The Wire

High-strength cable-steel bridge is the “lifeline” of steel structure bridges, which requires high comprehensive mechanical properties, and cold-drawing is the most important process to produce high-strength cable-steel bridge. Therefore, through the ABAQUS platform, a bridge wire drawing model was established, and the simulation analysis on the process of stress strain law and strain path trends for high-strength bridge steel wire from Φ 12.65 mm by seven cold-drawing to Φ 6.90 mm was conducted. The simulation results show that the wire drawing the heart of the main axial deformation, surface and sub-surface of the main axial and radial deformation occurred, with the increase in the number of drawing the road, the overall deformation of the wire was also more obvious non-uniformity. In the single-pass drawing process, the change in the potential relationship of each layer of material was small, and multiple inflection points appeared in the strain path diagram; the change in the seven-pass potential relationship was more drastic, which can basically be regarded as a simple superposition of multiple single-pass pulls.

scholarly journals Influence of a modified drawing process on the resulting residual stress state of cold drawn wire

2018 ◽  
Vol 190 ◽  
pp. 04004
Author(s):  
Markus Baumann ◽  
Alexander Graf ◽  
René Selbmann ◽  
Katrin Brömmelhoff ◽  
Verena Kräusel ◽  
...  
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Wire Drawing ◽  
Industrial Applications ◽  
Drawing Process ◽  
Die Geometry ◽  
Residual Stress State ◽  
Drawing Die ◽  
Process Modification ◽  
The Wire

Torsion bars are used in automotive engineering as well as in other industrial applications. Such elements are produced by bending cold drawn wires. In conventional drawing processes tensile residual stresses occur near the surface of the wire. Small bending radii, which are required in limited assembly spaces, result in component failure due to reduced formability. Additional operations such as heat treatment or shot peening are necessary to influence the residual stress of the wire and to improve the dynamic stability of the torsion bar. The aim of the research is to reduce tensile residual stresses near the surface of the wire in order to eliminate process steps and to enhance formability. Therefore, a forming technology is developed by using a modified drawing die geometry on the basis of gradation extrusion. Finite element simulation is used to investigate the influences of element geometry, number of elements and process modification on the resulting residual stresses after wire drawing of a steel alloy. The results are evaluated and compared with the conventional wire drawing process. Furthermore, the requirements for the design of an experimental test device will be outlined as well as the measurement of the residual stresses by using X-ray diffraction.

scholarly journals Effect of Process Parameters in Copper-Wire Drawing

Metals ◽  
2020 ◽  
Vol 10 (1) ◽  
pp. 105 ◽  
Author(s):  
Gustavo Aristides Santana Martinez ◽  
Wei-Liang Qian ◽  
Leonardo Kyo Kabayama ◽  
Umberto Prisco
Keyword(s):  
Hydrodynamic Lubrication ◽  
Copper Wire ◽  
Wire Drawing ◽  
Drawing Process ◽  
Stress Distributions ◽  
Operational Parameters ◽  
Die Geometry ◽  
Drawing Speed ◽  
Industrial Productivity ◽  
The Wire

The efforts to increase the operating speed of the wire drawing process play a crucial role regarding the industrial productivity. The problem is closely related to various features such as heat generation, material plastic deformation, as well as the friction at the wire/die interface. For instance, the introduction of specific lubricants at the interface between the die and the wire may efficiently reduce the friction or in another context, induce a difference in friction among different regimes, as for the case of hydrodynamic lubrication. The present study systematically explores various aspects concerning the drawing process of an electrolytic tough pitch copper wire. To be specific, the drawing speed, drawing force, die temperature, lubricant temperature, and stress distributions are analysed by using experimental as well as numerical approaches. The obtained results demonstrate how the drawing stress and temperature are affected by the variation of the friction coefficient, die geometry, and drawing speed. It is argued that such a study might help in optimizing the operational parameters of the wire drawing process, which further leads to the improvement of the lubrication conditions and product quality while minimizing the energy consumption during the process.

Influence of Die Geometry on Drawing Force in Cold Drawing of Steel Tubes Using Numerical Simulation

2016 ◽  
Vol 716 ◽  
pp. 708-712 ◽  
Author(s):  
Peter Bella ◽  
Pavol Buček ◽  
Martin Ridzoň ◽  
Milan Mojžiš ◽  
Ľudovít Parilák
Keyword(s):  
Numerical Simulation ◽  
Cold Drawing ◽  
Point Of View ◽  
Tool Geometry ◽  
Drawing Process ◽  
Drawing Force ◽  
Steel Tubes ◽  
Physical Point ◽  
Cold Forming ◽  
Die Geometry

In Železiarne Podbrezová, cold drawing process is the final process in production of precision seamless steel tubes. This particular technology utilizes multiple drawing sequences and intermediate annealing. From the physical point of view, it is nothing just the optimal use of plastic deformation during cold forming that grants the final tube dimensions. The drawing process itself is significantly affected by physical and metallurgical properties of the tube, the tool geometry, the lubrication, and the sequence of operations. This paper deals with the relationship between the tool geometry and the drawing force. The FEM-based numerical model of the process was prepared in DEFORM 3D in order to optimize the geometry of the die; eight die geometries were investigated in total. The numerical simulation itself considered a hot rolled hollow at Ø32 mm × 4 mm, cold drawn into Ø25 mm × 4 mm using die drawing (sinking) sequences only. Calculated drawing force showed that the change of the run-in angle of the die led to a decrease of the drawing force.

Wear Conditions of Al2O3-TiC/Al2O3-TiC-CaF2 Laminated Ceramic Drawing Die Used for 45#Steel Drawing Process

2013 ◽  
Vol 873 ◽  
pp. 223-227
Author(s):  
Pei Long Song ◽  
Xue Feng Yang ◽  
Shou Ren Wang ◽  
Li Ying Yang
Keyword(s):  
Simulation Analysis ◽  
Axial Stress ◽  
Fem Simulation ◽  
Wire Drawing ◽  
Simulation Software ◽  
Finite Element Models ◽  
Drawing Process ◽  
Drawing Force ◽  
Pressing Method ◽  
Drawing Die

Al2O3-TiC/Al2O3-TiC-CaF2laminated ceramic drawing die used for drawing experiment was prepared by vacuum hot pressing method. The finite element models of 45#-steel and wire drawing die were built by SolidWorks and simulation analysis of drawing process were done by FEM simulation software. The axial stress, strain distribution and drawing force during deformation were got. The microstructure of the worn drawing die was observed by scanning electron microscopy (SEM) and the composition was investigated by energy dispersive X-Ray spectroscopy (EDS). Results show that the wear conditions of Al2O3-TiC-CaF2material layers were serious than Al2O3-TiC. And because of the dragging effect, solid lubricating films formed in Al2O3-TiC-CaF2material layers covered on Al2O3-TiC material layers. The drawing die owes self-lubricating performance. Without considering friction effective on invariable zone of the drawing die, the simulation result of drawing force was smaller than the measurement value.

Influence of the Die Bearing Length on the Hydrogen Embrittlement of Cold Drawn Wires

2013 ◽  
Vol 577-578 ◽  
pp. 553-556 ◽  
Author(s):  
Jesús Toribio ◽  
Miguel Lorenzo ◽  
L. Aguado ◽  
Diego Vergara ◽  
Viktor Kharin
Keyword(s):  
Hydrogen Embrittlement ◽  
Hydrogen Diffusion ◽  
Cold Drawing ◽  
Wire Drawing ◽  
Wire Radius ◽  
Drawing Process ◽  
Strain Fields ◽  
Characteristic Value ◽  
The Wire ◽  
Definition Of

Prestressing steels, obtained by cold drawing, are highly susceptible to hydrogen embrittlement (HE) phenomena. Stress and strain fields produced by cold drawing play an essential role in this process since they affect hydrogen diffusion. Therefore, variations of such fields due to changes in drawing conditions could modify life in-service of these structural components. In this work the effect on HE of a parameter of the wire drawing process, thebearing length, is analyzed by means of diverse numerical simulations by the finite element method (FEM). The results of this work allow the definition of acharacteristic valueof the die bearing length equal to the wire radius, and demonstrate that the effects of stress-strain fields produced by wire drawing on HE are reduced when the bearing length exceeds such a characteristic value, so that the optimum cold drawing process is that with a bearing length higher than the wire radius.

Investigation of Residual Stresses in Drawn Wire by the Finite Element Method

1990 ◽  
Vol 112 (2) ◽  
pp. 231-235 ◽  
Author(s):  
K. Sawamiphakdi ◽  
P. K. Kropp ◽  
G. D. Lahoti
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
Parametric Study ◽  
Wire Drawing ◽  
Reduction Factor ◽  
Initial Stresses ◽  
Die Geometry ◽  
Area Reduction ◽  
The Wire ◽  
Inlet Angle

Based on a finite element modeling of the wire drawing process, a parametric study was conducted to investigate the effects of die geometry and area reduction factor on the magnitude and distribution of residual stresses through the wire cross section at the die exit. Two major variables of die geometry were considered in the study: the die radius and the die inlet angle. Three different die inlet angles of 12.5, 16.0 and 22.0 degrees were used in the analyses while the die radius was fixed at 25.4 mm. The die inlet angle was then set at 16.0 degrees and the die radius was varied from 12.7 mm through 38.1 mm in 12.7 mm increments. For each of the above cases, the area reduction factor was considered for 16.0 and 20.0 percents. In addition, the effect of initial stresses in wire was also investigated. The calculated results were compared to the analytical results published in the literature and an excellent agreement was obtained. The parametric study indicated that the die inlet angle has significant effect on the residual stresses at the surface of drawn wire. Specifically, smaller die inlet angle causes less tensile stresses at the surface and more compressive stresses at the center. The larger die radius reduces the level of residual stresses, but this reduction is only marginal. No significant change in either magnitude or distribution on patterns of residual stresses due to the initial stresses were found.

scholarly journals Thermomechanical Analysis of an Electrically Assisted Wire Drawing Process

2017 ◽  
Vol 139 (11) ◽  
Author(s):  
Antonio J. Sánchez Egea ◽  
Hernán A. González Rojas ◽  
Diego J. Celentano ◽  
Jordi Jorba Perió ◽  
Jian Cao
Keyword(s):  
Mechanical Response ◽  
Cold Drawing ◽  
Wire Drawing ◽  
Thermomechanical Analysis ◽  
Drawing Process ◽  
Thermomechanical Model ◽  
Electron Backscattered Diffraction ◽  
Hardening Law ◽  
Electrically Assisted ◽  
Material Tests

Electrically assisted (EA) wire drawing process is a hybrid manufacturing process characterized by enhancement of the formability, ductility, and elongation of the wire drawn specimen. A thermomechanical model to describe the change of the mechanical response due to the thermal contribution is proposed in this work. Additionally, a numerical simulation was conducted to study the potential and limitations of this hybrid process by using two different hardening laws: a phenomenological and a dislocation-based hardening laws. The results show how the flow stress, the effective plastic strain, and residual stresses behave under the electroplusing effect. In addition, electron backscattered diffraction was used to study the electropulsing treatments on the microstructure during cold drawing. It is observed a decrease of the high- and low-angle grain boundaries (LAGB) for samples deformed with electropulsing. This detwinning process has a strong influence on the strain hardening by improving the material formability. It was shown that the two proposed hardening laws adequately describe the EA wire drawing process showing a similar mechanical behavior. Nevertheless, the dislocation-based hardening law has the potential to be generalized to many other material and process configurations without extensive number of material tests as the phenomenological hardening law would require.

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