Abstract
Ultrasonic drawing is a new technology to reduce the cross-section of a metallic tube, wire or rod by pulling through vibrating dies. The addition of ultrasound is beneficial for reducing the drawing force and enhancing the surface finish of the drawn wire, but the underlying mechanism has not been fully understood. In this paper, an axisymmetric finite element model of the single-pass ultrasonic drawing was established in commercial FEM software based on actual wire length. The multi-linear kinematic hardening (MKINH) model was used to define the elastic and plastic characteristics of titanium. Influences of ultrasonic vibration on the drawing process were investigated in terms of four factors: location of the die, ultrasonic amplitude, drawing velocity, and friction coefficient within the wire-die contact zone. Mises stresses, as well as contact and friction stress, in conventional and ultrasonic drawing conditions, were compared. The results show that larger ultrasonic amplitude and lower drawing velocity contribute to greater drawing force reduction, which agrees with former research. However, their effectiveness is further influenced by the location of the die. When ultrasonic amplitude and drawing speed remain unchanged, the drawing force is minimized when the die locates at the half-wavelength position, while maximized at the quarter-wavelength position.
Highlights
Titanium wires are widely used in various industries, including aerospace, automobile, biomedicine, petrochemistry, fishery, due to their exceptional characteristics, such as high strength, lightweight, good corrosion resistance, excellent biocompatibility, etc. [1,2,3,4]
Unlike many other metallic wires, the manufacturing of titanium wire is usually conducted at elevated temperature, as their cold workability is degraded by high yield stress to tensile strength (Y/T) ratio and the strain hardening phenomenon [5]
The results indicated that longitudinal vibration is more beneficial for reducing the friction force and improving the surface finish of the drawn wire than composite vibration
Summary
Titanium wires are widely used in various industries, including aerospace, automobile, biomedicine, petrochemistry, fishery, due to their exceptional characteristics, such as high strength, lightweight, good corrosion resistance, excellent biocompatibility, etc. [1,2,3,4]. In 1999, Susan et al conducted the ultrasonic drawing experiment of steel ball-bearing steel wire They attributed the drawing force reduction to the surface effect of ultrasound utilizing the friction reversion mechanism [15]. The ultrasonic drawing process was described as contact and friction problems between the elastic-plastic traveling string and the rigid vibrating die. The length of the on the ultrasonic drawing process, the uncoiled drawn wire should be modeled with the raw wire, denoted as l, has little influence on simulation results and is assigned full length. Considering kinematic hardening (MKINH) model was employed to describe the plastic behavior of the material the changing stress state at the wire-die interface caused by the oscillation of the die, the simulation [22].
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