Аutomatisation of Calculation Method of Technological Parameters of Wiredrawing with Account of Speed Factor and Material Properties

2020 ◽  
Vol 299 ◽  
pp. 552-558
Author(s):  
Irina Nikolaevna Khaimovich ◽  
Alexander I. Khaimovich ◽  
E.A. Kovalkova
Keyword(s):  
Finite Element ◽  
Wire Drawing ◽  
Radius Of Curvature ◽  
Work Piece ◽  
Technological Parameters ◽  
Die Geometry ◽  
Speed Factor ◽  
Draw Force ◽  
The Wire ◽  
Linear Sections

The article presents the mathematical model worked out for calculating the operating force of the wire drawing. The solution of the problem was achieved by dividing the wire work piece material in the deformation zone into an infinitely small finite elements ij; and, by parting the working area of the die geometry, consisting of crimping cone, drawing cylinder and the radius of curvature between them into infinitely small linear sections. The authors described the conditions for continuity at the finite element line, the dependencies required to determine the geometric grid sizes. To determine the total modified draw force, the authors obtained formulas to describe the stress condition at each point of the finite element, based on the motion equations, equations of velocity fields, the incompressibility condition, the deformation rate intensity, taking into account the speed factor and viscoplastic properties of the work material. The article presents the adequacy of the proposed model.

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 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.

Studies of Influence of Process Parameters on the Strain Rate at High-Speed Wire Drawing

2019 ◽  
Vol 946 ◽  
pp. 832-838
Author(s):  
Ludmila V. Radionova ◽  
Viacheslav V. Shirokov ◽  
Sergei R. Faizov ◽  
Maxim A. Zhludov
Keyword(s):  
Strain Rate ◽  
Process Parameters ◽  
High Speed ◽  
Wire Drawing ◽  
Wire Diameter ◽  
Technological Parameters ◽  
Single Strain ◽  
Half Angle ◽  
The Wire ◽  
Drawing Dies

This article presents the results of the effect of drawing speed on the strain rate and resistance to plastic deformation. The wire drawing on modern high speed wire drawing machines significantly increases the required amount of drawing dies. The influence of the technological parameters: speed drawing, half-angle of the die, wire diameter and a single strain on the rate of deformation of the metal. The influence of the technological parameters: speed drawing, half-angle of the die, wire diameter and a single strain on the rate of deformation of the metal. It is found that increasing the resistance to drawing dies and achieve passport velocities drawing, when selecting process parameters drawing guided by the principle of uniform strain over the cross section of the wire by matching the single strain with half-angle dies and friction coefficient on the formula given in the article.

Prediction of Hardness in Drawn Copper Wire by Effective Strain from Finite Element Simulation

2019 ◽  
Vol 947 ◽  
pp. 103-108
Author(s):  
Chao Cheng Chang ◽  
Yen Ta Hsieh ◽  
Chun Hsuan Kao ◽  
Shun Yu Shao ◽  
Chia Hao Hsu
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Copper Wire ◽  
Wire Drawing ◽  
Reference Curve ◽  
Element Simulation ◽  
The Wire ◽  
The Difference ◽  
Drawing Dies ◽  
Hardness Values

The study developed a hardness-strain reference curve to be used with the finite element simulation for the prediction of the hardness in the drawn copper wire. The hardness values of the deformed copper specimens from tensile tests were analyzed to construct a relationship between hardness and strain. By using an industrial wire drawing machine, a copper wire was drawn by 5 passes to reduce its diameter from 8 to 4.64 mm. All drawing dies used the same configurations which include an area reduction ratio of 20 percent, an approach angle of 7°, and a bearing length of 0.5 times the feeding wire diameter. The finite element simulations of the wire drawing processes were also performed to predict the effective strains in the drawn copper wires. With the use of the developed hardness-strain curve, the hardness of the drawn wires can be estimated. The results show that the difference between the predicted and measured hardness values is about 10 percent lower in the early stage of the wire drawing process, and the difference increases with the number of passes to about 30 percent higher in the later stage of the process.

scholarly journals The experience of modernization of mills of wet wire drawing for the metal wire cord

2019 ◽  
pp. 97-102
Author(s):  
A. V. Demidov ◽  
I. A. Muraveiko
Keyword(s):  
Small Diameter ◽  
Wire Drawing ◽  
Metal Wire ◽  
Technological Parameters ◽  
Plastic Properties ◽  
Metal Cord ◽  
Different Types ◽  
The Wire ◽  
Metal Wires ◽  
Positive Effect

There is a tendency in recent years to use by the world’s leading manufacturers of tires metal wires of small diameter (0,175– 0,20 mm) with higher strength, which requires the use of increased total number of extracts on wet drawing. The possibility of increasing the compression can be limited not only by the ductility of the processed metal, but also by the design of the existing drawing mills, in particular, by the insufficient total passport kinematic drawing and, as a consequence, to the excessive sliding of the wire relative to the drawing washers. Results of modernization of mills of different types including increase in number of transitions of drawing to 28 with decrease in private and increase in total passport extracts at the expense of installation of additional drawing washers of small diameter and additional reducing dies are considered. The results show that the positive effect of the improvement of some technological parameters can be offset by the deterioration of other factors. It is shown that the mills with three pairs of drawing cones have more opportunities for this modernization than similar mills, but with two pairs of cones. The criterion of estimation of influence of sizes of drawing washers on plastic properties of a wire for a metal cord based on experience of operation of mills with different construction of kinematics is offered.

Modeling Analysis of the Wire-Drawing Operation Using the Weighted-Residual Finite Element Method

2011 ◽  
Vol 367 ◽  
pp. 677-684
Author(s):  
M.H. Oladeinde ◽  
John A. Akpobi
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Finite Element Model ◽  
Condensed System ◽  
Element Model ◽  
Wire Drawing ◽  
Stiffness Matrices ◽  
The Wire ◽  
The Finite Element Model ◽  
Element Method

Numerical analysis of a wire drawing operation to compute the stress distribution along the blank cross-section is presented. The governing equation describing the wire drawing equation is weakened using the Bubnov-Galerkin finite element method to obtain the finite element model. The blank is descritized into a mesh of C0 quadratic isoparametric and C0 cubic finite elements. Stiffness matrices for all elements are obtained using the finite element model which were subsequently assembled by enforcing continuity of the nodal stress. Boundary conditions are applied and the resulting condensed system of equation solved for unknown nodal stresses using Gauss Seidel method. The relative performance of the C0 quadratic and C0 cubic elements are assessed. Parametric analysis is carried out to show the influence of drawing parameters on the stresses generated and drawing load. The analysis was carried out using a Visual Basic.Net program developed by the authors.The results are presented in both graphical and tabular forms.

Multi-grain finite element model for studying the wire drawing process

2007 ◽  
Vol 39 (1) ◽  
pp. 23-28 ◽  
Author(s):  
J. Očenášek ◽  
M. Rodriguez Ripoll ◽  
S.M. Weygand ◽  
H. Riedel
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Element Model ◽  
Wire Drawing ◽  
Drawing Process ◽  
The Wire
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