Optimization of Parameters of Diamond-Coated Dies for Cu Wire Drawing by FEM Simulations

2010 ◽  
Vol 154-155 ◽  
pp. 588-592 ◽  
Author(s):  
Zi Chao Lin ◽  
Fang Hong Sun ◽  
Zhi Ming Zhang ◽  
He Sheng Shen ◽  
Song Shou Guo
Keyword(s):  
Copper Wire ◽  
Fem Simulation ◽  
High Hardness ◽  
Wire Drawing ◽  
Drawing Process ◽  
Low Friction ◽  
Drawing Die ◽  
Von Mises ◽  
Von Mises Stresses ◽  
Drawing Dies

Diamond-coated drawing dies are considered as ideal drawing dies for their unique characteristics, such as high hardness, wear resistance and low friction. In order to optimize the parameters of diamond coated drawing dies, this study conducts a finite element method (FEM) simulation to calculate the von Mises stresses distribution on the interior-hole surfaces of diamond coated drawing die during the copper wire drawing process, and then refines the diamond coated drawing dies based on the simulation results. Furthermore, the drawing performance of the optimized diamond coated drawing die is examined in a real production of drawing copper wires, and the results show that its working lifetime increase by a factor of 12 comparing with the conventional tungsten carbide drawing die.

FEM Simulation of the Cold Drawing Process for Copper Strip with Diamond-Coated Shaped Die

2013 ◽  
Vol 770 ◽  
pp. 297-302
Author(s):  
Zi Chao Lin ◽  
Fang Hong Sun ◽  
Zhi Ming Zhang ◽  
He Sheng Shen ◽  
Song Shou Guo
Keyword(s):  
Wear Resistance ◽  
Fem Simulation ◽  
High Hardness ◽  
Cold Drawing ◽  
Drawing Process ◽  
Optimal Parameters ◽  
Diamond Coatings ◽  
Low Friction ◽  
Copper Strip ◽  
Drawing Dies

Diamond-coated drawing dies are considered as ideal drawing dies for their unique characteristics, such as high hardness, wear resistance and low friction. To utilize the superior characteristics of diamond coatings, the FEM simulation is used to simulate the copper strip cold drawing process. The stress and the drawing load are predicted. The influence of parameters of drawing process on the drawing load is investigated. The optimal parameters are obtained.

Features of Mechanical Treatment of Zirconia Crystals when Manufacturing Dies

2021 ◽  
Vol 1037 ◽  
pp. 203-208
Author(s):  
Valery V. Alisin ◽  
Michael A. Borik ◽  
Alexei V. Kulebyakin ◽  
Elena E. Lomonova ◽  
Dmitriy M. Gutsev
Keyword(s):  
Mechanical Treatment ◽  
Wire Drawing ◽  
Drawing Process ◽  
Stabilized Zirconia ◽  
Zirconia Ceramics ◽  
Cable Industry ◽  
Drawing Die ◽  
Friction Units ◽  
Drawing Dies ◽  
Highly Loaded

Materials based on partially stabilized zirconia (ceramics and crystals) are distinguished by high values of mechanical strength, crack resistance, hardness, corrosion resistance, low coefficient of friction when operating in tandem with most metals, which makes them promising materials for a wide tribotechnical application in highly loaded friction units. An example of such a unit is the die mechanism, which is an integral part of the drawing die tool in the cable industry. These hard precision tools (drawing dies or wire dies) actually determine the ultimate success in the wire drawing process.

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.

Optimization of Diamond-Coated Drawing Dies for Stainless Steel Tubes Based on the FEM Simulation

2011 ◽  
Vol 418-420 ◽  
pp. 865-869 ◽  
Author(s):  
Zi Chao Lin ◽  
Bin Shen ◽  
Fang Hong Sun ◽  
Zhi Ming Zhang ◽  
Song Shou Guo
Keyword(s):  
Stainless Steel ◽  
Axial Stress ◽  
Fem Simulation ◽  
High Hardness ◽  
Steel Tube ◽  
Stainless Steel Tube ◽  
Diamond Coatings ◽  
Low Friction ◽  
Nonlinear Fem ◽  
Drawing Dies

Diamond-coated drawing dies are considered as ideal drawing dies for their unique characteristics, such as high hardness, wear resistance and low friction. In order to utilize the superior characteristics of diamond coatings towards improving the drawing performance, the nonlinear FEM simulation is used to simulate the whole stainless steel tube hollow sinking process, with 2D axi-symmetric elastic-plastic element. Based on the simulation results, the distributions of the axial stress and radial stress are analyzed, the influence of parameters of drawing dies on the diameter shrinkage is investigated. Optimal die parameters are obtained.

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.

Research on the Wire Drawing Die Pass Parameter Calculation Based on the Least Square Algorithm

2012 ◽  
Vol 591-593 ◽  
pp. 850-853
Author(s):  
Huai Xing Wen ◽  
Yong Tao Yang
Keyword(s):  
Pore Structure ◽  
Least Squares ◽  
Least Squares Method ◽  
Piecewise Linear ◽  
Wire Drawing ◽  
Least Square ◽  
Structure Characteristics ◽  
Drawing Die ◽  
The Wire ◽  
Drawing Dies

Drawing Dies meter A / D acquisition module will be collected from the mold hole contour data to draw a curve in Matlab. According to the mold pore structure characteristics of the curve, the initial cut-off point of each part of contour is determined and iteratived optimization to find the best cut-off point, use the least squares method for fitting piecewise linear and fitting optimization to find the function of the various parts of the curve function, finally calculate the pass parameters of drawing mode. Parameters obtained compare with the standard mold, both of errors are relatively small that prove the correctness of the algorithm. Also a complete algorithm flow of pass parameters is designed, it can fast and accurately measure the wire drawing die hole parameters.

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.

Optimization of Diamond-Coated Drawing Dies for Low Carbon Steel Tubes Based on the FEM Simulation

2012 ◽  
Vol 499 ◽  
pp. 126-131 ◽  
Author(s):  
Zi Chao Lin ◽  
Bin Shen ◽  
Fang Hong Sun ◽  
Z.M. Zhang ◽  
H.S. Shen ◽  
...  
Keyword(s):  
Carbon Steel ◽  
Axial Stress ◽  
Fem Simulation ◽  
Low Carbon Steel ◽  
High Hardness ◽  
Steel Tube ◽  
Low Carbon ◽  
Diamond Coatings ◽  
Nonlinear Fem ◽  
Drawing Dies

Diamond-coated drawing dies are considered as ideal drawing dies for their unique characteristics, such as high hardness, wear resistance and low friction. In order to utilize the superior characteristics of diamond coatings towards improving the drawing performance, the nonlinear FEM simulation is used to simulate the whole low carbon steel tube hollow sinking process, with 2D axi-symmetric elastic-plastic element. Based on the simulation results, the distributions of the axial stress and radial stress are analyzed, the influence of parameters of drawing dies on the diameter shrinkage is investigated. Optimal die parameters are obtained.

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