Professional Documents
Culture Documents
Dr. Supratik Mukhopadhyay
(smukh@iitk.ac.in)
Overview
Process and types
Mechanical Analysis
Worked examples
Drawing defects
Drawing Process
In this process, the cross‐section of a wire or bar or tube is
reduced by pulling the workpiece through a conical orifice or die.
When high reduction is required, the process is carried out in several passes.
Workpiece Die
Pull
https://www.youtube.com/watch?v=VVewNWWBVjs
Draw Die
Four main regions of a draw die can be identified
Entry: The entry is usually bell‐shaped mouth that does not contact the work. Its
purpose is to funnel the lubricant into the die and prevent scratching of work and
die surfaces.
Approach: The approach is where the drawing process occurs. It is a cone
shaped with half angle 𝛼 ranging between 6° 20°
Bearing surface (land): Flat surface that decides the final size of the drawn stock.
Back relief: This is the exit zone.
Entry
Approach Back relief
Bearing surface (land)
Approach angle 𝛼
Die materials
Usually High‐carbon steels and carbides.
Diamond dies are used for fine wire.
Mandrels for tube drawing are usually made of High‐carbon steels or of carbides.
Lubrication
Wet drawing: dies and rod are completely immersed in the lubricant (oils and
emulsions containing fatty or chlorinated additives)
Dry drawing: surface of rod is coated with a lubricant (dry soap powder)
Coating: rod or wire is coated with a soft metal that acts as a solid lubricant.
Copper or tin for example can be chemically deposited on the surface of the metal.
Drawing Equipment
Wire drawing is accomplished on a machine known as draw‐bench, consisting of
an entry table, die stand carriage and exit rack.
The carriage is used to pull the stock through the draw die and is powered
hydraulically or by motor‐driven chains.
Very long wires (more than a km) and wires with smaller cross‐section are drawn
by rotating drum (called bull‐block or capstan). The tension in this setup provides
the necessary drawing force through multiple dies (tandem drawing).
Kalpakjian and Schmidt
(a) (b)
(c) (d)
Tube drawing (a) no mandrel (b) fixed (c) floating and (d) moving mandrel. A
variety of diameters could be produced from the same tube stock (which has been
made by other processes).
https://www.youtube.com/watch?v=QKAg1yMZIpY
Mechanical Analysis
Objective:
To determine the drawing force and power in wire drawing.
To determine the maximum possible cross‐ sectional reduction.
Assumptions:
The coefficient of friction 𝜇 and the half‐cone angle 𝛼 are small.
The yield stress in tension 𝜎 is constant and given by the average of initial and
final values at the beginning and end of the operation.
𝜎 and 𝑝 are the principal stresses.
𝜎 does not vary in the radial direction.
𝑟
𝑑
𝑑 𝛼
𝐹 𝑥 𝐹
𝑑𝑥 𝑥
The degree of drawing 𝐷 is expressed in terms of reduction in cross‐sectional area:
𝐴 𝐴 𝑑 𝑑 𝑑 𝑙 𝐴 1
𝐷 1 𝜀 ln ln ln
𝐴 𝑑 𝑑 𝑙 𝐴 1 𝐷
𝜀 = True strain