WIRE DRAWING

A cold working operation

Drawing is an operation in which the cross section of a bar, rod, or
wire is reduced by pulling it through a die opening.
The general features are similar to extrusion. The difference -----the
work is pulled through the die in drawing, whereas it is pushed
through the die in extrusion.
Stress type – Mainly tensile, compressive stress also present

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Hot drawn rods, bars, pipe etc. are again cold drawn for
 Better strength
 Better dimensional accuracy
 Better surface finish
PRODUCTS:
# Frequently used to produce round cross sections, but squares
and other shapes are also drawn.
# Electrical wire and cable; wire stock for fences, coat hangers,
and shopping carts; and rod stock to produce nails, screws,
rivets, springs, and other hardware items.
# Bar drawing is used to produce metal bars for machining,
forging, and other processes.

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The basic difference between bar drawing and wire drawing is

the stock size that is processed.
Bar drawing is the term used for large diameter bar and rod
stock, while wire drawing applies to small diameter stock.
Wire sizes down to 0.03 mm are possible in wire drawing.
Though the mechanics of the process are the same for the two
cases, the methods, equipment, and even the terminology are
somewhat different.
Bar drawing is generally accomplished as a single-draft
operation—the stock is pulled through one die opening. The
beginning stock has a large diameter, it is in the form of a straight
cylindrical piece rather than coiled.
Wire is drawn from coils consisting of several hundred (or even
several thousand) feet of wire and is passed through a series of draw
dies.

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The change in size of the work is given by the area reduction (r),
defined as follows:

In bar drawing, rod drawing, and in drawing of large diameter wire for
upsetting and heading operations, the term draft is used. The draft (d)
is defined as:

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ANALYSIS OF DRAWING

If no friction or redundant work occurred in drawing, true strain is

determined as

For homogeneous frictionless wire drawing, the work done (W) by

drawing force F1 in moving the full length of l1 of the drawn wire is
given by

The work done per unit volume (W/V) in homogeneous deformation

(principal stresses are uniform) is equal to the area under — curve
between appropriate strain values

Eqn. 1

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Why is more than one step required to achieve the desired reduction
in wire drawing? Why is it not possible to achieve the reduction in a
single pass through one die, as in extrusion?

From the earlier equation ---- as the reduction increases draw stress
increases. If the reduction is large enough, draw stress will exceed
the yield strength of the exiting metal. When that happens, the drawn
wire will simply elongate instead of new material being squeezed
through the die opening.

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Because friction is present in drawing and the work metal

experiences inhomogeneous deformation, the actual stress is larger
than provided by Eq. (1).
In addition to the ratio Ao/Af, other variables that influence draw
stress are die angle and coefficient of friction at the work–die
interface.
The draw stress suggested by Schey,

 is the die-work coefficient of friction;  is the die angle and  is a

factor that accounts for inhomogeneous deformation.
 Is given by:

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Where, D is the average diameter of work during drawing, and Lc is

the contact length of the work with the draw die.

The draw force is then given by

The power required in a drawing operation is the draw force multiplied

by exit velocity of the work

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Maximum Reduction per Pass

Let us assume a perfectly plastic metal (n=0), no friction, and no
redundant work.
In this ideal case, the maximum possible draw stress is equal to the
yield strength () of the work material.
The draw stress under conditions of ideal deformation, is given by

And setting as n=0

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Maximum reduction possible

The above value is the theoretical maximum reduction possible in a single

draw. It ignores
1) the effects of friction and redundant work, which would reduce the
maximum possible value, and
2) strain hardening, which would increase the maximum possible reduction
because the exit wire would be stronger than the starting metal

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In practice, draw reductions per pass are quite below the theoretical
limit.
Reductions of 0.50 for single-draft bar drawing and 0.30 for multiple-
draft wire drawing are used as the upper limits in industrial
operations.
Drawing Equipment (bar drawing)

Draw Bench

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Wire Drawing

Wire drawing is done on continuous drawing machines that consist of

multiple draw dies, separated by accumulating drums called a capstan. Each
capstan is motor driven to provide the proper pull force to draw the wire
stock through the upstream die. It also maintains a back tension on the wire
as it proceeds to the next draw die in the series.

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Draw Dies

Four regions in the die

1. Entry
2. Approach angle
3. Bearing surface (land)
4. Back relief

Preparation of the Work

(1) Annealing,
(2) Cleaning, and
(3) Pointing.

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TUBE DRAWING

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Ex: Wire is drawn through a draw die with entrance angle=15.

Starting diameter is 2.5mm and final diameter = 2.0 mm. The
coefficient of friction at the work–die interface = 0.07. The metal has a
strength coefficient K = 205 MPa and a strain-hardening exponent n =
0.20. Determine the draw stress and draw force in this operation

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