Abstract
In this work, a drawing processed was simulated to calculate forces and the resulting residual stresses in the material. The calculated residual stresses were compared with experimentally measured residual stresses by the Neutron Diffraction Method. The modeled process was the Wire Drawing. The necessary parameters to model the process were taken from an industrial currently used process. Rods of an AISI 1045 steel with nominal diameters of 21.46 mm were reduced to 20.25 mm by drawing with an drawing angle of 15°. Compression tests were used to determinate flow curves of the real material an used in the simulation models. The possibility to estimate drawing forces by numerical simulation was evaluated by comparing simulated results with values from empirical equations given by the literature. The results have shown a sufficient accuracy for the calculation of forces, but the comparison of residual stresses has shown differences to the experimentally determined ones that can be minimized by the consideration of high strain rates in the compression tests, anisotropy of the material and kinematic hardening.
Highlights
The use of drawn products has increased in the last years[1]
When a material is processed by plastic deformation, as in the case of wire drawing, residual stresses arise, which can affect mechanical properties and the behavior of the material in distortion, sometimes they can lead to catastrophic failure of a component in service
Residual stresses interfere in later steps of the manufacturing route of a particular component, due to a redistribution of these stresses that occurs as a result of mechanical and thermal loads and metallurgical transformations, at each manufacturing step
Summary
The use of drawn products has increased in the last years[1]. Drawn bars with different diameters are used in the manufacturing of automotive parts, reducing subsequent machining steps, costs and energy consumption. The wire drawing can be defined as a manufacturing process by plastic deformation in which the raw material (wire rod) is pulled through a die, causing a reduction in cross sectional area and an increase in the length. Some of the main features of the wire drawing process are the achievement of an excellent surface finishing and good dimensional accuracies, increase in mechanical strength and high processing speeds[2]. The main raw material used in the drawing of bars is the wire rod, i.e., rolled steel of continuous section, usually cylindrical, supplied as coils. When a material is processed by plastic deformation, as in the case of wire drawing, residual stresses arise, which can affect mechanical properties and the behavior of the material in distortion (dimensional and shape changes after heat treatment), sometimes they can lead to catastrophic failure of a component in service. Residual stresses interfere in later steps of the manufacturing route of a particular component, due to a redistribution of these stresses that occurs as a result of mechanical and thermal loads and metallurgical transformations, at each manufacturing step
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