Drawing

ME 6222: Manufacturing Processes and Systems
Prof. J.S. Colton GIT 2009

1
Deformation Processing -
Drawing
ver. 1
2
Overview
Description
Characteristics
Mechanical Analysis
Thermal Analysis
Tube drawing
3
Geometry
D
a

D
b

F
a
, o
xa

F
b
, o
xb

o
4
5
Equipment
6
Cold Drawing
7
A. Durer - Wire Drawing Mill (1489)
(copper wire)
8
Self portrait at 28
(1500)
The four horsemen of the apocalypse
(1498)
9
Characteristics
Product sizes:
0.0002 (5m) to several inches (100-150
mm)
Mostly cold (T < 0.4 T
melting
)
below recrystallization point
Small diameter (wire):
uses a capstan
Diameter > 1 inch (25 mm) (rod):
bull blocks on a draw bench
length up to 40 feet (12 m)
10
Characteristics
Fine wire done through several
dies
Speeds
large diameter: 30 feet per minute
(9 m/min)
small diameter: 300 feet per minute
(90 m/min)
fine wires: 5,000 feet per minute
(60 mph 100 km/h)
11
Die Materials
Large diameter
high carbon steel
high speed steel
Moderate diameter
tungsten carbide (WC)
Small diameter
diamond inserts
12
Characteristics
Lubrication
Coatings
Oil
Die angle (o)
typically small: 4-6
o

13
Mechanical analysis (round wire / rod)
Reduction in area (RA)
2
2
2 2
1
|
|
.
|
\
|
=
=
b
a
b
a b
D
D
D
D D
RA
|
|
.
|
\
|
=
|
.
|
\
|
=
a
b
t
D
D
RA
ln 2
1
1
ln c
D
a
D
b

F
a
, o
xa
F
b
, o
xb

o
14
Slab analysis
Assume p, o
x
are
uniform
OK for small o,
o
x
+ do
x

o
x

p
p
p
p
D
D + dD
dx
15
Equilibrium
( ) ( )
0 cos
cos
sin
cos
4 4
2 2
=
+
+ +
o
o
t
o
o
t
t
o
t
o o
dx D
p
dx D
p
D dD D d
x x x
Expanding
( ) ( )
0 cos
cos
sin
cos
4
2
4
2 2 2
=
+
+ + +
o
o
t
o
o
t
t
o
t
o o
dx D
p
dx D
p
D dD DdD D d
x x x
16
Equilibrium
( ) ( ) | |
0 cos
cos
sin
cos 4
2 2
4
2
2 2 2 2
=
+
+ + + + +
o
o
t
o
o
t t
o
o o o o o o
t
dx D
p
dx D
p D
dD d DdD d D d dD DdD D
x
x x x x x x
small small small
Eliminating higher order terms, dividing by D & t, multiplying by
4 and canceling
0 cos
cos
4 sin
cos
4 2 = + + + o
o
o
o
o o
dx
p
dx
p D d dD
x x
17
Equilibrium
dx
dD
2
tan = o
o tan 2
dD
dx =
Noting
dx
D
dD/2
o
0
tan 2 cos
cos
4
tan 2 cos
sin
4 2 = + + +
o o
o
o o
o
o o
dD
p
dD
p D d dD
x x
or
0
tan
2 2 2 = + + +
o
o o
dD
p pdD D d dD
x x
18
Equilibrium
0
tan
1 2 2 =
|
.
|
\
|
+ + + dD p d D dD
x x
o
o o
Finally
19
Maximum shear stress (Tresca) criterion
flow flow x
p o t o = = + 2
B
o
tan
p o
x

t
flow

20
Differential form
pB
dp
D
dD
flow
2 4 +
=
t
( ) B B
d
D
dD
flow x
x
+
=
1 4 2 t o
o
21
Integrating

( )
} }
+
=
xb
xa
b
a
B B
d
D
dD
flow x
x
D
D
o
o
t o
o
1 4 2
22
Drawing stress
where:
o
xb
= back stress (tension)
o
xa
= pulling stress (tension)
B
b
a
flow
xb
B
b
a
flow
xa
D
D
D
D
B
B
2 2
2
1
1
2
|
|
.
|
\
|
+
(
(
|
|
.
|
\
|
+
=
t
o
t
o
D
a
D
b

o
xa

o
xb

o
23
1
2
+
= = =
n
K
Y
n
flow flow
c
o t
Strain hardening
(cold below recrystallization point)
For round parts - Tresca
average flow stress:
due to shape of element
24
Strain rate effect
(hot above recrystallization point)
For a round part (derived for extrusion)

average strain rate due to shape of element
v
b
= velocity of b side
A = area
m
flow flow
C Y c o t

= = = 2
|
|
.
|
\
|
=
a
b
a b
b b
A
A
D D
D v
ln
tan 6
3 3
2
o
c

25
Value for p
p = Y o
or
p = 2t
flow
o

maximum at entrance
p o
x

t
flow

26
Effect of back tension
with back tension
without back tension
drawing stress
entry
exit
die pressure
27
Maximum RA
Solve previous equations with:
o = 6
o
(typical value)
= 0.1
B = 1
o
xb
= 0
For failure: draw stress = material flow {yield} stress

here, say K = 760 MPa, and n = 0.19
1
2
+
= = =
n
K
Y
n
flow flow
c
o t
n
xa
Kc o o = =
28
Maximum RA
Yields RA = 0.6
must be solved for each , o, o
xb

|
|
|
.
|
\
|
|
|
.
|
\
|

|
.
|
\
|
+
=
+
B
b
a
n
n
D
D
B
B
n
K
K
2
1
1
1
c
c
|
|
|
.
|
\
|
|
|
.
|
\
|

|
.
|
\
|
+
=
+
2
1
1
1 1
1
1 19 . 0
b
a
D
D
29
Energy / unit volume (u)
u = F V / A
a
V = o
xa

(with no back stress)
V= volume
30
Drawing - Ex. 1-1
Determine power, and plot o
x
and p
along die length.
Drawing steel rod from | = 13 mm
to | = 12 mm @ 1.5 m/s
K = 760 MPa, n = 0.19
= 0.1, o = 4
o
, o
xb
= 0

31
Drawing - Ex. 1-2
First, we must see if we can do the
process, the limit is

RA = 1 - (D
a
/D
b
)
2
= 0.15 = 15%
c
t
= ln{1/(1-RA)}
= ln {1/(1-0.15)} = 0.16
B = /tano = 0.1 / tan 4
o
= 1.43
n
xa
Kc o o = =
max
32
Drawing - Ex. 1-3
B
b
a
flow
xb
B
b
a
flow
xa
D
D
D
D
B
B
2 2
2
1
1
2
|
|
.
|
\
|
+
(
(
|
|
.
|
\
|
+
=
t
o
t
o
1
2
+
= =
n
K
Y
n
flow
c
t
n
Kc o =
max
33
Drawing - Ex. 1-4
So, equating the equations (with no
back stress) yields
|
|
|
.
|
\
|
|
|
.
|
\
|

|
.
|
\
|
+
+
=
B
b
a
D
D
B
B
n
2
1
1
1
1
1
|
|
.
|
\
|
|
.
|
\
|

|
.
|
\
| +
+
=

43 . 1 2
min
13
1
43 . 1
43 . 1 1
1 19 . 0
1
1
a
D
34
Drawing - Ex. 1-5
Solving gives D
a-min
= 8.53 mm, so we
can do the process and proceed with
the analysis
35
Drawing - Ex. 1-6
35 . 0 0
13
12
1
43 . 1
43 . 1 1
2
43 . 1 2
= +
(
(
|
.
|
\
|
+
=

flow
xa
t
o
( )
MPa
n
K
Y
n
flow
446
1 19 . 0
16 . 0 760
1
2
19 . 0
=
+
=
+
= =
c
t
36
Drawing - Ex. 1-7
o
xa
= 0.35 x 2t
flow

= 0.35 x 446 MPa = 156 MPa
F
draw
= o
xa
x Area = 156 x t(12/2)
2
= 17.6 kN = 3938 lbf
Power = F
draw
x speed
= 17.6 kN x 1.5 m/s = 26.4 kW = 35.4 hp
37
Dimensionless pressures (divided by 2tflow)
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
12 12.2 12.4 12.6 12.8 13
diameter (mm)
sx
p
Drawing - Ex. 1-8
38
Limits on analysis
Larger die angles
more redundant work
o, p, u will be larger than predicted
D
a

D
b

o
39
Redundant work
A = d
m
/L
d
m
= (D
a
+ D
b
) / 2
p = Q
r
o
flow

D
a

D
b

o
L (contact length)
40
Redundant work factor (Backofen)
(frictionless)
Q
r
=
41
Temperature rise
D D
o

D
o
/D ~ 6
k
D

(1-r)Q
DIE
v
k
w
,
w
, c
w

rQ
WIRE
l
42
Temperatures
u = u
o
+ u
s
+ u
f

u
o
= ambient (room) temperature

u
s
= temperature rise in the wire
due to plastic shear energy, u
s
u
f
= interface temperature rise due
to frictional energy, u
f

43
Specific energies
u = u
s
+ u
f

u = o
xa

u
s
= 2t
flow
c

44
Specific energies
From the example above (steel rod):
u = o
xa
= 156 MPa
u
s
= 2t
flow
c = 446 * 0.16
= 71.4 MPa
u
f
= u - u
s
= 156 71.4
= 84.6 MPa

45
Shear temperature (u
s
)
Since the shear strain is uniform
in the wire
and all the shear energy remains
in the rod as heat
Then, we can obtain the shear
temperature in the wire:
w w
s
s
c
u
u =
46
Material properties
For this material:
k
w
= 60 W/m-K

w
= 7850 kg/m
3
c
w
= 500 J/kg-K
o
w
= 1.53 x 10
-5
m
2
/s
For a WC die:
k
D
= 42 W/m-K
47
Shear temperature (u
s
)
C
c
u
w w
s
s

2 . 18
500 7850
10 71.4
6
=
= =
u
48
Frictional heat (Q
f
)
v = velocity
(1-r)Q
f
goes into the die
4
2
v D
u Q
f
f
t
=
Q represents all heat generated by friction
49
Q
f
calculation
W Q
v D
u Q
f
f
f
14352
4
5 . 1 012 . 0
10 6 . 84
4
2
6
2
=

=
=
t
t
50
Die and wire temperatures (u)
For the die (steady):

For the wire (moving):
( )
D
D
l k
Q r
o
D
f
o
ln
2
1
+ =
t
u u
v
l
Dlk
Q r
w
w
f
s o
2
07 . 1
o
t
u u u
|
|
.
|
\
|
+ + =
ref: Carslaw and Jaeger
51
Dimensions
D = 12 mm
from D
o
/ D ~ 6
D
o
= 72 mm in this example
l = contact length
= reduction in radius / sin o
= 0.5 mm / sin 4
o
= 7.17 mm

dr
l
o
52
Die temperature
( )
D
D
l k
Q r
o
D
f
o
ln
2
1
+ =
t
u u
( )
( ) r
r
+ =

+ =
1 13591 20
12
72
ln
00717 . 0 42 2
14352 1
20
t
u
53
Wire temperature
v
l
Dlk
Q r
w
w
f
s o
2
07 . 1
o
t
u u u
|
|
.
|
\
|
+ + =
r
r
+ =

|
|
.
|
\
|

+ + =
07 . 181 2 . 38
5 . 1 2
00717 . 0 10 53 . 1
60 00717 . 0 012 . 0
14352
07 . 1 2 . 18 20
5
t
u
54
Heat flow ratio and Temperature
Equating the previous equations yields:
r = 0.985
Hence (difference due to round-off error)
u = 223
o
C (die) = 496 K
u = 216
o
C (die) = 489 K
T
melt
= 1500
o
C = 1723 K
So u/T
melt
= 0.33, cold (below
recrystallization point)
55
Temperature in practice
In practice, r ~ 1
all heat goes into wire

l
v D
c
u
c
u
w w w
f
w w
s
o
|
|
.
|
\
|
+ + =
o
u u
2
19 . 0
56
Tube drawing
57
Plane strain / Slab analysis
(
(
|
|
.
|
\
|
+
=
*
1
1
2
*
*
B
i
f
flow
xa
t
t
B
B
t
o
o
tan
*
B
Fixed mandrel
(plane tube
is modeled as a
flat section)
Moving mandrel
(plane and slab)
o
tan
2
*
B
2 *
tan
2
B
Moving mandrel with friction towards exit,
takes into account motion between mandrel
and tube (B may be negative) (plane) o

tan
*
mandrel die
B

Fixed mandrel
(slab circular tube)
58
Summary
Description
Characteristics
Mechanical analysis
Thermal analysis
Tube drawing
59

Drawing

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Drawing

Uploaded by

Copyright:

Available Formats

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2009

ME 6222: Manufacturing Processes and Systems

You might also like