An analysis of wire manufacture using the dieless drawing method

Abstract

An experimental program of a novel wire manufacturing process known as dieless drawing has been conducted. The process has the capability to effect a reduction in the diameter of a wire without the use of conventional wire drawing dies. Reduction in diameter is achieved by heating the wire, which is mechanically loaded parallel to its longitudinal axis, to a temperature that initiates plastic deformation. Both mathematical and finite element (FE) modeling of the process have been undertaken. An analysis of the wire deformation is presented and discussed. The maximum reduction in diameter achieved, effect of drawing velocity, temperature, and uniformity of resulting wire diameter are investigated. The mechanics and operational features of the experimental machine manufactured to facilitate the experimental program of dieless drawing are described. The mathematical model presented can be used to describe the occurrence of deformation during the process. This model has been validated by experiments carried out on the wire drawing machine. The primary observation from the experimental program was that uniformity of wire diameter after dieless drawing decreased with an increase in reduction ratio. Results obtained from the experimental work confirm that a complicated interdependence of the process parameters exists during the dieless drawing process.