Abstract
The efforts to increase the operating speed of the wire drawing process play a crucial role regarding the industrial productivity. The problem is closely related to various features such as heat generation, material plastic deformation, as well as the friction at the wire/die interface. For instance, the introduction of specific lubricants at the interface between the die and the wire may efficiently reduce the friction or in another context, induce a difference in friction among different regimes, as for the case of hydrodynamic lubrication. The present study systematically explores various aspects concerning the drawing process of an electrolytic tough pitch copper wire. To be specific, the drawing speed, drawing force, die temperature, lubricant temperature, and stress distributions are analysed by using experimental as well as numerical approaches. The obtained results demonstrate how the drawing stress and temperature are affected by the variation of the friction coefficient, die geometry, and drawing speed. It is argued that such a study might help in optimizing the operational parameters of the wire drawing process, which further leads to the improvement of the lubrication conditions and product quality while minimizing the energy consumption during the process.
Highlights
Wire drawing is a metal forming process characterized by a high deformation rate
The results regarding the measurements made on a single block drawing machine are presented together with those of finite element method (FEM) simulations
Vega et al [34], Martínez et al [35], and other authors [2,22,24] have shown that the die angle, friction coefficient, and bearing zone length significantly affect the stress during the drawing process
Summary
(a) the properties of the raw material, (b) the die geometries, inclusively the die angle and die length and, (c) the processing conditions such as the drawing speed and friction at the interface between the die and the wire. A classic tribological setup arises [3] This is characterized by friction at the wire/die interface and by the subsequent wear on both the surfaces in contact [4,5,6]. The temperature affects the lubrication conditions, the tool life, and the properties of the final product. This occurs mainly due to the delay in the heat dissipation, as pointed out by El-Domiaty et al [11].
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