Wire Drawing 2011

Drawing
1. Introduction
2. Drawing equipments
3. Drawing die
4. Drawing defects
Suez Canal University

Dr. Eng. Sabbah Ataya 1
Faculty of Petroleum and Mining Eng.
Introduction
Drawing is one of the in indirect compression systems of
deformation where an applied tensile stress induces two
mutually perpendicular compressive stresses. This type of
deformation is allowed only by cold working.
In wire drawing operation the diameter of a cylindrical piece of

metal is reduced by pulling it through a tapered hole which is
the internal profile of a drawing die.

Rod and wire drawing equipments
Rod Drawing
Rod Drawing
Swift or capstan to hold the coil of rod ready for drawing,

Die which executes the actual reduction and
Drawing block which supplies the load and energy for reduction;
it also accumulates the drawn wire in a coil form.

Continuous drawing machine continue
A continuous machine, which holds several dies, will also

have several drawing blocks. Since the diameter of the wire
decreases from die 1 to die 5, the velocity and length will
increase proportionally.

Continuity equation and drawing
A1 V1
AV
1 1
= A2V2 =const. A2 V2
A1 V 2
=
A2 V 1
Example:
Ingot diameter Do= 8 mm  L2   A1   1 
ε = ln   = ln A  = ln  
 L1   2 1− r 
Wire diameter d = 2 mm
Velocity of the drawing block = 10 m/sec
Final diameter = 1 mm
Velocity of the end drawing block = 40 m/sec
Achieved total true reduction in area = 4.16

Continuous drawing machine
This results in friction and the evolution of heat which is

dispersed by immersing the whole stepped-cone arrangement in
an oil bath. They are therefore called Immersed or Slip machines
whereas the first type is described as a Non-slip machine.

Wire drawing die
Wire drawing die consists of casing and nib.
Casing: made of steel for large-diameter dies and of brass for
small dies and its main function is to protect the nib.
The nib which is contained inside the casing is made of
extremely hard material (made of tungsten carbide for large
dies and industrial diamond for small) since it is the part where
the actual reduction is carried out. The nib has a hole through
its center which has a definite profile

Wire drawing die continue
The profile of the die consists of:

(a) the bell (entrance)
(b) the approach
(c) the bearing or parallel
(d) the relief (exit).

Wire drawing die continue
For constant µ and reduction values
UT
Ur
UP
The optimum angle: UF

aluminum 24°, copper
12°and steel 6°°.
In a typical 15-die machine (di = 510 µm df = 200 µm), final speed is 70 m/s.
The energy of deformation appears as a temperature rise.
To achieve dissipation the dies and blocks are totally immersed in a bath
of lubricant acting as a coolant.

Drawability limit
Work for actual Drawing efficiency
η = Up / UT
drawing process
Ideal drawing work,

from integration of
flow curve, at µ = 0

Maximum reduction in one pass (ideal condition)
A1 - A2 A2 The drawing pressure (uniform
r= = 1-
A1 A1 deformation energy):
A2
=1- r
A1
- For ideal conditions σxa = σo
- Breakage occurs when:
A1 L 2 σo = σUTS and (r = rmax)
A1 L1 = A2 L2 , =
A2 L1
 L2  A   1  σo  1 
ε = ln  = ln  1  = ln  = 1 = ln 
1 − r max 
 
 L1   A2  1− r  σ UTS
Breaking Load = A2 x σUTS rmax =0.63 or 63%

Wire drawing & Patenting heat treatment
Nonferrous wire and low-carbon steel wire are produced in a

number of tempers ranging from dead soft to full hard.
Depending on the metal and the reduction involved,
intermediate anneals may be required. Steel wire with a
carbon content > 0.25 % is given in special patenting heat
treatment.
This consists of heating above the upper critical temperature

(~970°C) then cooled at a controlled rate or transforming in a
lead bath at a temperature around 315°C to cause the
formation of fine pearlite. Patenting produced the best
combination of strength and ductility for the successful
drawing of high carbon music and spring wire.
Properties of heat treated alloy steels

Maximum reduction per pass (with friction)
The assumptions made are:

• Ideal flow (non-work-hardening).
• Constant die angle,
• Tresca's Yield Criterion.
• The two principal stresses involved (p and σx).
• The metal strip is wide enough (plane strain conditions).
• Internal distortion of the metal (redundant work) is ignored.
Strip model
σ xdh + h.dσ x + 2 p tan α .dx + 2 µpdx = 0

where, dh = 2dx tan α
σ xdh + h.dσ x + p (1 + µ cot α ) dh = 0
σ x − (− p) = σ o' p = 1.155σ o − σ x


if µ cot α = B dx dh
=
σ x.B + σ o' (1 + B ) h
Considering σ o' and B as constants and integrating
 2B

1+ B    ha    
B
'  1 + B  D
σ xa = σo   1-   
a
σ xa = σ o'   1- h   or
 B    b    B    Db  
σ xa = 1.155σ o 
1+ B  
 1- (1 − r ) 
B
For µ = 0.09 & die angle =12
 B  Then B = 0.8571
σ xa 1+ B 
σo
=1= 
 B 
[
 1 − (1 − r )
B
] rmax = 0.51
Analysis of wire drawing with error less than ±20% of the
real case is rather difficult.
Drawing defects
Defects in the starting rods (seams, sliders, …) or from the

deformation itself.
Deformation defects (center bursts or cupping, chevron

cracking). Due to tensile forces at the center and low die angel
or low reduction.
With increasing the die angel the critical reduction takes place
before occurring the center cracking.

Drawing defects: Residual stresses
For reduction per pass less than 1 %, or for localized

deformation on the surface layer, the longitudinal residual
stresses are compression at the surface and tensile at the axis. The
radial stress are tensile at the axis and drop to zero on the surface,
the circumferential stresses are like the longitudinal stresses.
For larger commercial reduction the residual stress pattern will

be opposite to the first pattern. The longitudinal residual stresses
are tensile at the surface and compression at the axis.
The radial stresses are compressive at the axis. The circumferential
stresses are like the longitudinal stresses.

Drawing defects: Residual stresses
Residual stresses of
brass wire drawing
Maximum residual stresses

are obtained for reduction at
the range 15 – 35 %
Lower die angle produces

lower residual stresses.


Wire Drawing 2011

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Drawing

Suez Canal University

In wire drawing operation the diameter of a cylindrical piece of

Suez Canal University

Swift or capstan to hold the coil of rod ready for drawing,

Suez Canal University

Continuous drawing machine continue

A continuous machine, which holds several dies, will also

Suez Canal University

Suez Canal University

Continuous drawing machine

This results in friction and the evolution of heat which is

Suez Canal University

Suez Canal University

Wire drawing die continue

The profile of the die consists of:

Suez Canal University

The optimum angle: UF

Suez Canal University

Ideal drawing work,

Suez Canal University

Suez Canal University

Wire drawing & Patenting heat treatment

Nonferrous wire and low-carbon steel wire are produced in a

This consists of heating above the upper critical temperature

Suez Canal University

Maximum reduction per pass (with friction)

The assumptions made are:

σ xdh + h.dσ x + 2 p tan α .dx + 2 µpdx = 0

Suez Canal University

Maximum reduction per pass (with friction)

Defects in the starting rods (seams, sliders, …) or from the

Deformation defects (center bursts or cupping, chevron

Suez Canal University

Drawing defects: Residual stresses

For reduction per pass less than 1 %, or for localized

For larger commercial reduction the residual stress pattern will

Suez Canal University

Maximum residual stresses

Lower die angle produces

Suez Canal University

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