Prediction of Central Burst Defects in Copper Wire Drawing Process

Abstract

In this study, the prediction of chevron cracks (central bursts) in copper wire drawing process is investigated using experimental and numerical approaches. The conditions of the chevron cracks creation along the wire axis depend on (i) the die angle, the friction coefficient between the die and the wire, (ii) the reduction in crosssectional area of the wire, (iii) the material properties and (iv) the drawing velocity or strain rate. Under various drawing conditions, a numerical simulation for the prediction of central burst defects is presented using an axisymmetric finite element model. This model is based on the application of the Cockcroft and Latham fracture criterion. This criterion was used as the damage value to estimate if and where defects will occur during the copper wire drawing. The critical damage value of the material is obtained from a uniaxial tensile test. The results show that the die angle and the reduction ratio have a significant effect on the stress distribution and the maximum damage value. The central bursts are expected to occur when the die angle and reduction ratio reach a critical value. Numerical predictions are compared with experimental observations.