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.

scholarly journals The Analysis of the High Speed Wire Drawing Process of High Carbon Steel Wires Under Hydrodynamic Lubrication Conditions

2015 ◽  
Vol 60 (1) ◽  
pp. 403-408 ◽  
Author(s):  
M. Suliga
Keyword(s):  
High Speed ◽  
Hydrodynamic Lubrication ◽  
High Carbon Steel ◽  
Wire Drawing ◽  
Drawing Process ◽  
Wire Surface ◽  
Compressive Stresses ◽  
Steel Wires ◽  
Drawing Speed ◽  
The Wire

Abstract In this work the analysis of the wire drawing process in hydrodynamic dies has been done. The drawing process of φ5.5 mm wire rod to the final wire of φ1.7 mm was conducted in 12 passes, in drawing speed range of 5-25 m/s. For final wires of φ1.7 mm the investigation of topography of wire surface, the amount of lubricant on the wire surface and the pressure of lubricant in hydrodynamic dies were determined. Additionally, in the work selected mechanical properties of the wires have been estimated. It has been shown that in the drawing process under hydrodynamic lubrication by drawing speed of 25 m/s the phenomena of uncontrolled formation of the surface and the diameter of the wire appears, and in the process the compressive stresses eliminating cracks on the wire surface occur, causing further smoothing. The wires drawn hydrodynamically in speed of 25 m/s, besides clearly worse properties compared to the wires drawn hydrodynamically at speeds in the range of 5 to 20 m/s, also exhibit large dimensional variations.

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.

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.

The High Speed Wire Drawing Process of Steel Wires under Fluid Frictions Conditions

2016 ◽  
Vol 716 ◽  
pp. 76-84
Author(s):  
Maciej Suliga
Keyword(s):  
High Speed ◽  
High Carbon Steel ◽  
Wire Drawing ◽  
Drawing Process ◽  
The Finite Element Method ◽  
Wire Surface ◽  
Steel Wires ◽  
Drawing Speed ◽  
The Wire ◽  
Multiparameter Analysis

The essential purpose of the work was to determine the phenomena that occur in multipass wire drawing process of high carbon steel wires with high speed in hydrodynamic dies and to assess their influence on moulding the wire properties after the drawing process. The multiparameter analysis of the issues has involved the theoretical dissection of the phenomena arising in high speed wire drawing process in hydrodynamic dies with the usage of the finite element method supported by the experimental multipass drawing process in industrial conditions. On the basis of numerical analysis the influence of drawing speed on wire temperature was estimated. For final wires the investigation of mechanical properties, topogrhaphy of wire surface, the amount of lubricant on the wire surface, the pressure of lubricant in hydrodynamic dies were determined.

Effect of Drawing Processes on Wire Breaking in Steel Wire Production

2014 ◽  
Vol 941-944 ◽  
pp. 1667-1670
Author(s):  
Ying Lei Xu
Keyword(s):  
Compression Ratio ◽  
Steel Wire ◽  
Wire Drawing ◽  
Drawing Process ◽  
Drawing Speed ◽  
Bending Stresses ◽  
The Wire ◽  
The Right ◽  
The Impact ◽  
Main Factor

Wire breaking is a major factor in the impact of wire drawing production, and drawing process is an important factor causing the wire breaking, which cannot be ignored. In this paper, the impact of tension, bending stresses, centrifugal stresses, compression ratio of die arrangement and drawing speed in the process of the wire drawing process on wire breaking were calculated theoretically. Then the corresponding measurements to reduce the rate of wire breaking were proposed. The results show that the the tension of drawing process was the main factor, while choosing the right compression ratio and drawing speed according to the actual situation, the rate of wire breaking could be reduced effectively.

Numerical modelling of defect formation on copper wire surfaces during the wire drawing process

2001 ◽  
Vol 215 (2) ◽  
pp. 237-246 ◽  
Author(s):  
P Phelan ◽  
J Brandon ◽  
M Hillery
Keyword(s):  
Defect Formation ◽  
Copper Wire ◽  
Equivalent Stress ◽  
Theoretical Models ◽  
Wire Drawing ◽  
Drawing Process ◽  
Surface Cracking ◽  
The Wire ◽  
Von Mises Equivalent Stress ◽  
Von Mises

The crowsfoot defect, a characteristic surface cracking defect in wire drawing, usually occurs at fine wire diameters. This paper reports a numerical simulation of the wire drawing process where copper wire is reduced in diameter under varying conditions of friction, die angle and reduction ratios. The results of this analysis show that, contrary to existing theoretical models, the largest drawing stress and von Mises equivalent stress occur at the outer surface of the wire and not along the central axis as previously postulated.

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 Analysis of the Heating of Steel Wires During High Speed Multipass Drawing Process/ Analiza Nagrzewania Się Drutów Stalowych W Procesie Ciągnienia Wielostopniowego Z Dużymi Prędkosciami

2014 ◽  
Vol 59 (4) ◽  
pp. 1475-1480 ◽  
Author(s):  
M. Suliga
Keyword(s):  
Surface Layer ◽  
High Speed ◽  
Heated Surface ◽  
Experimental Studies ◽  
Drawing Process ◽  
Heat Accumulation ◽  
Steel Wires ◽  
Drawing Speed ◽  
The Wire ◽  
Surface Layer Thickness

Abstract The analysis of the heating of the wire including theoretical studies showed that in the multistage drawing process a increase drawing speed causes intense heating of a thin surface layer of the wire to a temperature exceeding 1100°C, which should be explained by the accumulation of heat due to friction at the interface between wire and die. It has been shown that with increasing of drawing speed the heated surface layer thickness measured at the exit of the wire from the dies is reduced significantly and at drawing speed of 25 m/s is equal to about 68 μm. The decrease in the thickness of this layer can be explained by a shorter time of heat transfer to the wire, which causes additional heat accumulation in the surface layer. Thus fivefold increase in drawing speed caused an approximately 110% increase in the temperature in the surface layer of the wire. Experimental studies have shown that the increase of drawing speed of 5 to 25 m/s will increase the temperature of the wire after coiled on the spool more than 400%.

Prediction of die wear in the wire-drawing process

1997 ◽  
Vol 65 (1-3) ◽  
pp. 11-17 ◽  
Author(s):  
T.H. Kim ◽  
B.M. Kim ◽  
J.C. Choi
Keyword(s):  
Wire Drawing ◽  
Drawing Process ◽  
Die Wear ◽  
The Wire
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