Module 4: Bulk Deformation Processes

in Metal Working
Manufacturing Processes
AERO315

UAE University
College of Engineering
Department of Mechanical & Aerospace Engineering

1
 Introduction

Bulk deformation processes in metal

working include:

• Rolling.
• Other deformation processes related to
rolling.
• Forging.
• Other deformation processes related to
forging.
• Extrusion.
• Wire and Bar Drawing
 Bulk Deformation Processes
Process 4: Wire and Bar Drawing

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Wire drawing process

• https://www.youtube.com/watch?v=YlLWBM2e5qg

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Wire and Bar Drawing
• Bar drawing: the term used for large diameter bars.

• Wire drawing: applies to small diameter bars (wire sizes down to

0.03 mm are possible in wire drawing).

• Two stress components are present in drawing; tensile stresses due

to the pulling action and compressive stresses because the metal is
squeezed down as it passes through the die opening.
Ao − A f
• Change in size of work (given by area reduction): r=
Ao
• Draft: difference between original and final diameter: d = Do − D f
 Drawing vs Extrusion

• Pull force • Pushing force

• Long/slender base metal • Short base metal
• Usually Multiple Pass operation • Single Pass operation
• Cross section profile is simple • Cross section profile can be
(e.g circle) complicated

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Example 1
A spool of wire has a starting diameter of 2.5 mm. It is drawn through a die
with an opening that is to 2.1 mm. The entrance angel of the die is 18°
degrees. Coefficient of friction at the work-die interface is 0.08. The work
metal has a strength coefficient of 450 MPa and a strain hardening
coefficient of 0.26. The drawing is performed at room temperature.
Determine (a) area reduction, (b) draw stress, and (c) draw force required for
the operation.
(C)

F A
= = Y f  = Y f ln o
Af Af
 Exercise
Wire is drawn through a draw die with entrance angle = 15o. Starting
diameter is 2.5 mm 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.
 Summary of the Drawing Analysis

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Wire Drawing, Kalpakjian’s formula

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Wire Drawing, Schey’s formula

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Example 1

• Wire is drawn through a draw die with entrance angle = 15 ° . Starting diameter is
2.5 mm 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.
• Solution

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Solution Using Kalpakjian’s method

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Tube-Drawing Operations

Figure 15.19 Examples of tube-drawing operations, with and without an internal

mandrel. Note that a variety of diameters and wall thicknesses can be produced
from the same initial tube stock (which has been made by other processes).

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Drawing Dies

Figure 15.20 Terminology of a Figure 15.21 Tungsten-carbide die

typical die used for drawing a insert in a steel casing. Diamond
round rod or wire. dies used in drawing thin wire are
encased in a similar manner.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Multistage Wire-drawing Machine

Figure 15.23 Two views of a multistage wire-drawing machine that typically is used
in the making of copper wire for electrical wiring. Source: After H. Auerswald

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Midterm

• MT 13 March

– All analysis
• 1. Welding
• 2. Rolling
• 3. Extrusion
• 4. Drawing

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.