WIRE DRAWING Contents ———— 6.0 General ; 6.1 Drawing Ratio ; 6.2 Steps in Wire drawing ; 6.3 Work done in Homogeneous deformation ; 6.4 Work formula for wire drawing ; 6.5 Maximum possible reduction of area in drawing ; 6.6 Expression for true strain and fraction reduction ; 6.7 Drawing die details ; 6.8 Drawing speed ; 6.9 Drawing stress ; 6.10 Expression for Drawing force in wire drawing ; 6.11 Frictionless drawing of cylindrical rod ; 6.12 Tube drawing process ; Worked Problems ; QuestionsWire Drawing 199 6.0 General Wire drawing is an operation wherein the workpiece in the form of a rod/thick wire is pulled through a die opening to get a reduced diameter. It is carried out in cold state The mechanical work required is greater than in rolling operation. Compressive forces acting at the contact surface causes plastic flow of metal. ‘The central portion of the work does not undergo any deformation, Only the outer forces are severely deformed, This is due to frictional forces acting at the contact surface. Fig, 6.1 shows the process. work Die — J—» pulling Ve force yf / MY) Fig. 6.1 wire drawing process Difference between wire and rod is somewhat arbitrary. In general wire refers to small diameter products under 5 mm. es 6.1 Drawing Ratio (DR) ‘The ratio of final diameter to the initial diameter in drawing operation is referred to as limiting ratio or drawing ratio d Drawing Ratio (DR) = 7 (6.1) i final dia of wire where d, d, = initial dia of work DR = 0.95 for steel = 0.925 for copper 0.9 for Iron ¢ To draw arod into a wire of given diameter, the rod must be passed through a series of dies of gradually decreasing diameter. + when repeated drawing is done, the tensile strength is greatly increased and ductility is reduced in the same ratio. ¢ Hence, after each drawing operation, the wire is annealed to restore ductility before commencing the next drawing operation. Annealing is normally carried out in a closed atmosphere. # Scale formed on the surface is removed by pickling using very dilute 1,50,200. Manufacturing Process - I 6.2 Steps Involved In Wire Drawing Rod ——» cleaned by___» Toremove___» Coated with» Drawn Hat rolled] pickling scale/oxide Lime or Cuor Sn through in dilute, H,SO, Layer Lime neutralises the die (which causes the residue of seeassalde ei | wear and surface defects) Annealed before Steps repeated till the given drawing size of the wire is obtained again Reduction] Coarse - 20-50% Foneech paserthe valet por pass [Fine wires - 10-25% and length of the wire will increase proportionately 6.3 Work Done in Homogenous deformation Let A - Area of specimen and L = Length of specimen & - Instantaneous yi € - Strain stress Fig. 6.2 Deformation Process Increment of W.D in increasing the length of the specimen by ‘8’ beyond the strain € is bW = (oA). 8 = (6.2) 4 Increment of work per unit volume is bw bw (o.A)8E 235 o.- 63) Vv AL Al l i) # Assume no volume change and integrating we get Rh xy i w 3 f 5 8 vo Jey y8 Se asde= 7 (64) - Original length 1, - final length - initial strain €, - final strain201 Wire Drawing jomogenous deformation is equal to the area of o-€ curve between ¢ ie., W.D/unit volume in Hi d directly from the dimensional change the appropriate strain values, This may be evaluate assuming an average yield stress 6,,. ty w él — : iF ---- (6.5) LA + Fig. 6.3 Stress Vs Strain w © = Fue I 4) gives reasonable approximation for a metal which has been work hardened f before tensile stretching. since Ajl, = Ajl, ~~ (volume is constant) | Ls 8 ---- (6.6) hy A, = 9,,,I0 A --- (6.7) se 6.4 Work formula for wire drawing F = drawing force in moving from 1-2 J, = Length of the drawn wire ¢ WD by drawing force --- (6.8)202 Manufacturing Process - I but we know that for homogeneous deformation per unit volume the W.D in forming the wire in the die w h ¢ — =o,, In 1 from sec 6.3 v ae 0 4 W = Vo, In | aie | In the absence of friction wew, Fl, = Vo, inh is hy v v F= So. Ina ~~ (6411 yoy Since V = 4,4,=1,A, in plastic deformation we get oe rettg nh 4 4 L A, 6,,.In 2 (6.12) vind replacing 4. by a from constant volume relation. pA F = A,o,,.In 4 (6.13) a AA: but r= =1- A F/ JA, ~. Drawing stress 0, 1 o,=9,,In without friction = (6.14) yg orWire Drawing 203 6.5 Maximum Possible reduction of area (one pass) in drawing Drawing of wire is limited by the tensile failure of the drawn wire. For such a heavy pass the maximum tensile stress will be nearly equal to the Y.S (because of severe strain hardening of wire). At the limiting reduction 6, = 5,=0, ---- (6.15) The rate of strain hardening will be small so that the mean y.s, 6,,, Will also be equal to 0, (o,,, =6,). The maximum reduction r,, is thus given by the condition. ‘we St 2130, = --- Put r=, in equation 6.14 Sy 6, = ° Si ty ----(6.16) Oy 1- ie, ioe Fg SB 27 ie,r, = 0.63 (6.17) «. The maximum possible reduction with perfect lubrication strain hardening is appreciable). But internal distortion and friction, limits this. Under favourable circumstances, wire may be drawn with reductions of area well over 50%. ~ 63% or slightly more (if theManufacturing Process - I 204. 6.6 Expression for true strain and fraction reduction ‘The most basic relationship for plastic deformation is the constant volume relationship. Since large deformations are involved in mechanical working, it is important to express strain in terms of True or Natural strain For constant volume relationship, the sum of total strains in any three mutually perpendicular direction is zero. €,+€,+6,=0 ---- (6.18) Compressive stresses and strains predominate in metal working process Ifa block of height ‘h’, is compressed to height ', then the axial compressive True strain fi €,= fe aie hy> h, ---- (6.19) pa ty hy Conventional Strai e = Moe A (620) nventional Stra 2 Z a ‘onventi in om Th calculated strains will be negative, indicating compressive strains In metal working, the convention is reversed so that compressive stresses and strains are defined as positive. e In & fg—hy * (comp) =" (comp) ~ hy Fraction reduction in area = but volume is constant Aj, = Ag Ay A, = final area of C.S 1, = Initial length J, = final length from (6.21) és ee ae ceWire Drawing ---- (6.23) 6.7 Drawing Die details Steel Casing Entrance angle Back relief approach ——~ angle 2 Bearing Surface o = 30-45° * Lubricant Cu, Sn for high strength materials Die material - Tungsten carbide HSS (diamond for small wires) Fig. 6.4 Drawing Die Details Regions in the die Zone 1 :- A bell shaped entrance zone for proper guidance of the work piece. ‘The entrance angle is made large enough to allow sufficient space for the lubricant to adhere to the die206: Manufacturing Process - Ill Zone 2:- A conical working zone Approach angle - In this region, the actual reduction in diameter takes place. Zone.3 :- A straight short cylindrical zone to add stability to the operation. Bearing surface - guides the product as it comes out of the die. No reduction takes place. Zone 4:- A bell shaped exit zone Back relief Allows the metal to expand slightly us the wire leaves the die. prevents abrasion of the die. 6.8 Drawing Speed Drawing speed varies from 10m/min for larger diameter to 1800 m/min for a very thin wire, Speed of drawing is limited mainly by the heat generated due to friction in the die. The temperature rises to hundreds of degrees. Finer the wire higher the speed of drawing. Drawing speed —=—=—=—= Dia of wire Fig. 6.6 Variation of drawing speed wart wire dia Table 6.1. Drawing speed ft/min (M/min) Wire diameter | Wire diameter | Steel, cel Tron and Brass (mm) (in) (M/min) Ftmin (M/min) 6.25 0.250 300 (90) 350 (105) 400 (120) 3.12 0.125 500 (150) 600 (180) 500 (150) 1.56 0.0625 800 (240) 1000 (300) 1200 (360) 6.9 Drawing Stress ‘The actual force required for drawing is much more than the theoretical force because friction has to be overcome and redundant work is present. Redundant work does not participate in drawing operation.Wire Drawing 207 A, = area before reduction A, = area after reduction 6, = average yield stress @&Q = Drawing stress with friction and redundant work metal i y.s of without friction and redundant Drawing Stress tog,| 2. Strain “Nol Fig. 6.6 Drawing Stress Vs. strain Theoretical work per unit volume = ©,. log, Ar (6.24) Refer Fig. 6.6 Y.S of the material increases with strain hardening. Drawing stress also increases with increase in strain. ‘The intersection of these two curves determine the maximum possible reaction. Friction and redundant work reduces the maximum possible reduction limit. 2 Drawing stress = So (0 +H). tog, (*A,} 39] === (6.25) 1 = Coefficient of friction between work and die a= V, die angle208: Manufacturing Process - Ill 6.10 Expression for drawing force in wire drawing Cylindrical rod drawing with a conical die (0, }, D, D. oe Point O Wire Drawing of ..Rod ety GIR Fig. 6.7 Wire Drawing G, are constant) plane strain YS Initial diameter of the work Outlet diameter of the wire half die cone angle virtual apex of the die cone = distance of the virtual apex of the conical die to the point " " of contact at exit plane w.r.t work distance of the virtual apex of the conical die to the point | of contact at entry plane w.r.t work distance from the apex to the point of contact at just outlet where dia = D thickness of the element considered Coefficient of friction on the element surface (slant surface) Normal pressure on the slant surface Drawing force Radial Stress g, and 6, + do, are the stresses on either side of the clementWire Drawing 209 For equilibrium condition of the small element in the working zone. Considering force components acting in the axial direction. T ™ Due to change in longitudinal stress ........... (0, + do,) ri (D+dDY-o, rt Dp dx \.. Due to die pressure on the circumference ............. P| ™D. sina cosa, ge z y dx @ Due to frictional force at the circumference. P| nD. cosa cosa, Under steady condition these must be in equilibrium dx Jeose =0 } sin & + UP (ro cosa au Tog dx (6, +o.) = (D+db?-0," D'+ of ao. A 4 cosa. Neglecting product of dD.do, & dD we get 4.0,.2D.dD+ *D*.do, + P.nD.de.tanc.+uP.mD.de =0 + by D, 20,,dD+ D.do, +4P.dxtana+ 4pP.dx = 0 *. 20,.dD+D.do, +2P.dD+2pP.cotc.dD =0 Rearranging D.do, +2[o, + P(l+pcota)}dD =0 -~- (6.26) or D.do, +2[5, + P+ UP.cota]}. dD =0 a% ta - 2 fan 0 os dD =2dx, tana aD dx =—. cota ss 2 °° Considering Radial forces for equilibrium o,1D.dx + P. (20. ik ) cosa —uP (xo. ae } sina=0 cosa cosa + 1Ddx, Pr+P—P.tana= 0210 Manufacturing Process - I! o, = -P (I-ptana) (6.2) Since pis small and ot is small, 1 tan ois still smaller +. can be neglected (ex: w= 0.1,00=6 tan o.= 0.01) ‘The state of stress is cylindrical and the principal stresses are 6,=6, 6. o,=-P --~- (6.28) H ‘Two principal stresses are equal +. The stress system is equivalent (o uniaxial stress combined with a hydrostatic stress 50 that yield occurs at the value 5, From V.M Criteria E(0,-02) = > = 262 from (6.28) we get for uniaxial tension 2(0,-93) = 205 6,-9, = 6, == (6.29) 6,-(-P) = 6, (6.30) 6, +P = 0, = (6.31) From (6.31) and (6.26) Dido, +2[o,+P+PB\.dD=0 Letpcoto=B Do, +2 [o,+(6,-9) 1 +B))dD=0 Do, +2 [o, +, + 5,8 -5,— 0B) dD=0 Do, - {Bo, -6, (1 + B)}. 26D =0 dD do, _ 9 (632) Tao, —o(1+ B)] by rearrangings If B and o, are constants, equation (6.32) can be integrated 1 2 n[Bo,—9,(1+B)] = 2In D + Constant Solution of this expression is given by Bo, -6, (1 +B) = C.D” ---- (6.33) Assuming that there is no longitudinal stress at the entry 6,=9,,=0, D =D, 0-6, (1 +B) = CD;" sae wg PE ---- (6.34)Wire Drawing an From (6.33) and (6.34) Bo, -9, (1+ B) = oy ©. Drawing stress at D=Da_o,=0 1-8] or, In terms of the reduction of area R (ai) Da)? Db 2. Equation (6.36) becomes Gia Do Drawing force F Power required for drawing P where V Dd, = < | always D, _ (1+ 8) SE [diel] = 6,,Aa = FV = Velocity at exit --~ (6.35) ---- (6.36) ---- (6.37) ~~ (6,38) ---- (6.39) ---- (6.40) (6.41) (6.42)212 Manutacturing Process - Ill ¢ For strip drawing the equation (6.40) can be used but o, is used in place of 6, where 6, = leet) iam (643) B . v3 (1+B 2 Drawing stress, 5, = Bol Ap -0-a) ] D, For Extrusion, ER = 7” =R> Lalways above analysis can be used, G,, = O,...» ++ as compressive stress applied at the entrance. 20 1 1 :. Equation (6.36) = = hee [-(ze) | 0 1+B){)_ Je - (4) (%) Pressure in the die at entry P, ---- (6.44) 6.11 Frictionless Drawing of cylindrical rod (0, is constant) When t= 0 then Bis also equal to 0 since B= pt cot & from equation (6.26) D.do, + 2 (6, + P (1 +H cot | dD =0 reduces to D.do, + 2 [(a, + P)] dD =0 from yield criteria o, + P = 0, substituting we get D.d 0, +20,dD =0 --- (648) since ©, is constant we can integrate after rearranging do, __2dD So D do, _ _,(dD ja = 22Wire Drawing 213 is —2 In D + constant ---- (6.49) So atentry 0, = 6,,=0, D=D, Sri nih -2InD,+C o, $C 22nd, ©. equation (6.49) becomes oy = -2InD+2InD, ---- (6.50) Dy . ei = (6.51) ©. Drawing stress ¢, 6, is given by Sey Bay 52 a Se mene Ay ~ Ay bebe independent of the die angle A. _( Pa ) stl, sila dts an elo er) 4 7D, reduction in strip drawing Plane strain 6, is used in place of 6, 6, = 9, (%a) : + " Do since wide strip is constrained drawing during 6, = Ls drawing by the undrawn elastic material entering the die 28 Sq 14+B |_| Bu from (6.36) “Go = 2 2 D, ---- (6.36)214. Manufacturing Process - Il 6.12 Tube Drawing Processes Hollow tubes and pipes produced by hot forming methods such as extrusion and rolling are cold finished by drawing process. Cold drawing is a process of obtaining very close dimensional tolerances, of obtaining good surface finish and to produce higher mechanical properties in the tube as a result of strain hardening, And to produce tubes of thinner wall thickness or smaller diameters Three basic types of tube drawing process are used in practice 1. Sinking 2. Plug drawing 3. Mandre! drawing Inall these processes larger size (rough) tubes are drawn through the die and close control of dimensions are obtained. « Tube Sinking ‘The tube is simply passed through the die and pulled out as shown in figure 6.8. Since the inside of the tube is not supported, the wall thickness and the inner surface become uneven. The shearing at the entry and exit of the die is large. small tube Pull force Fig. 6.8 Tube Sinking Fixed Plug Drawing A fixed plug is located near the die, leaving an annular clearance. Here both inside and outside diameters are controlled. The plug may be conical or cylindrica Greater dimensional accuracy is obtained. Since the plug offers more friction, the reduction in area is limited to 30%. Fig. 6.9 shows this. Die Small to be Pull force Fixed Fig. 6.9 Fixed plug drawing215 Wire Drawing « Floating Plug Drawing A plug is located at the die and as the pulling takes place the plug seems to be floating, By having a plug floating in the die, higher reduction in area is achieved. The plug has to be carefully and properly designed. Drawing load is lesser than in fixed plug type. Tool design and lubrication are very critical. Fig. 6.10 shows the arrangement. Small Tube Pull force Fig. 6.10 Floating plug drawing ¢ Moving Mandrel Drawing Here friction is reduced appreciably. A long hard rod (mandrel) that extends over the entire length of the tube is drawn through the die with the tube. Both the tube and the mandrel will be moving with the same velocity. Fig. 6.11 shows this. —Tube mandrel Fig. 6.11 Moving Mandrel Drawing Worked Problems Proglem : 6.1 What is the maximum reduction possible per pass in drawing Aluminimum rod through a die of semi die angle 24°, 1» = 0.01. Maximum or Limiting reduction is obtained by the equation o 1+B % 8 (1-(—-R)') where 6, = drawing stress can be written as 6, = ¥S 1-(-RY = — B = cota216 Manufacturing Process - I! canes f-2.] 1+B d-) = Wy (1+ By" 1+B = 1+peoto We (1+ By ie,r = 1- 1 ~ 2,692 1 +0.01 2.246) = 1-03715 Maximum Reduction or ~ 63% = 0.6285 vs (14 BY = (1.0225)45 = 2.692 ow " W fl ~ 0.0225~ semi die angle Coefficient of friction Dy Dd, dia at outlet outlet dia dia at inlet 1+0.01 . cot 24 0.0028 aWire Drawing: 217 6.1 6.2 6.3 64 65 6.6 67 68 6.9 6.1 6.2 6.3 64 6.5 6.6 6.7 61 6.6 QUESTIONS Wire Drawing Explain briefly wire drawing process Explain drawing ratio. With a flow chart briefly explain wire drawing process What is the maximum reduction in area that is possible in drawing for one pass. Draw a neat sketch of a drawing die and show al the zones and other details on it ? Derive an expression in drawing die and show a cylindrical rod using a conical die. 1 26 [Den ont0,8 mM . oe) using regular resin B What will be the drawing stress assuming there is no friction involved. Derive o,, =o, H24l = 1q-\) using regular notions Db 1 Explain clearly how tubes are produced in drawing process. What are the different methods available for tube drawing ? Explain. Objective type of Questions Answer according to each question Wire drawing utilizes push force whereas direct extrusion utilizes pull force. True / False Drawing ratio is the ratio of work piece diameter to final dia of the wire. True / False Wire drawing is a hot working process. ‘True / False Diameter of wire is greater than Smm True / False Higher drawing speeds are required for higher dia wires. ‘True / False Drawing stress increases with strain True / False Tubes can be obtained by drawing process. Yes / No Answers False 6.2 False 6.3 False 6.4 False 6.5 True True 6.7 Yes