Wire Drawing Process Research Articles

Finite element analysis of multi-pass dry wire drawing process of steel cord for tire reinforcement considering Al2O3 inclusion

Finite element analysis of multi-pass dry wire drawing process of steel cord for tire reinforcement considering Al2O3 inclusion

Evaluation of acoustic emission for monitoring wire drawing process

Acoustic emission (AE) technology is sensitive to high frequency waves generated in physical mechanisms as friction contact and plastic deformation, both present in the wire drawing process. In this regard, experimental measurements with this technology have been conducted to wire drawing in an industrial environment, in order to prove the technology validity to monitor this manufacturing process. The correlation of the results with the parameters defining the operation (as drawing speed, die temperature or lubricant type) and production (e.g. wire diameter, die status or incidences) intends to stablish the main aspects to develop a correct monitoring for this application. Due to the complexity of the wire drawing and the interrelated parameters, tendencies in AE signal have been assessed under certain conditions in base to the experimental results. The study developed in tests with controlled-parameters for same single wire reel reveals a clear correlation between AE amplitude and lubricant chemical composition, as well as between AE amplitude and die temperature. Furthermore, the employment of another wire material or different die set makes the analysis more complex, revealing AE spectral variations and patterns that reflect slight changes of the process.

Influence of the Straining Path during Cold Drawing on the Hydrogen Embrittlement of Prestressing Steel Wires

Cold drawing is a commonly used technique for manufacturing the prestressing steel wires used as structural elements in prestressed concrete structures. As a result of this manufacturing process, a non-uniform plastic strain and residual stress states are generated in the wire. These stress and strain fields play a relevant role as the main cause of the in-service failure of prestressing steel wires in the presence of an aggressive environment, hydrogen embrittlement (HE). In this paper, hydrogen susceptibility to HE is compared in two different commercial cold-drawn wires with the same dimensions at the beginning and at the end of manufacturing that follow different straining paths. To achieve this goal, numerical simulation with the finite element (FE) method is carried out for two different industrial cold-drawing chains. Later, the HE susceptibility of both prestressing steel wires was estimated in terms of the hydrogen accumulation given by FE numerical simulations of hydrogen diffusion assisted by stress and strain states, considering the previously obtained residual stress and plastic strain fields generated after each wire-drawing process. According to the obtained results, the hardening history modifies the residual stress and strain states in the wires, affecting their behavior in hydrogen environments.

SYSTEM DESIGN AND PROTOTYPE MANUFACTURING FOR THE RECOVERY OF LUBRICANT POWDER USED IN WIRE DRAWING PROCESS

Recycling processes have gained great importance for both environmental and economic sustainability and development. A prototype system was developed using physical separations including size sieving and magnetic separation for the recycling of solid die soaps used as lubricants in industrial wire drawing processes. The chemical composition of the waste obtained after the wire drawing process was elucidated by using X-ray fluorescence (XRF) analysis and extraction methods. The results showed that there was 67% reusable soap in the waste, and most of the remaining waste was made up of metals. Parameters such as particle size, sieve pore diameters, shaking time and magnetic field strength were optimized and an industrial scale prototype recycling system was designed. Finally, a prototype recovery system was established. Scanning electron microscopy (SEM), light microscopy, thermogravimetric/differential thermal analyzes (TGA/DTA), X-ray fluorescence spectroscopy (XRF) and Fourier transform infrared spectroscopy (FTIR) were used for the characterization. 88% of the soap in the waste was recovered, and the soap obtained was successfully used in wire drawing process without causing any deformation in the wire. These findings clearly demonstrate that offered system design engineered solution has a great potential to become a way out point for the waste recycling gain in the recovery and reuse of lubricant powder

Experimental-numerical analysis to determine the efficiency of industrial lubricants in wire drawing process

Drawing is a manufacturing process that consists of indirect deformation by pulling the material through a tool with a conical geometry. The process is usually performed at room temperature (cold forming), so the selection of effective lubricants is critical. If lubrication is inadequate, there is a high risk that both, tool and the manufactured wire, will fail. In this study, annealed AISI 1020 steel rods were drawn and the effectiveness of three different industrial lubricants was tested. During the process, the drawing force values were recorded and used to determine the friction coefficient that developed under each lubrication condition. Numerical simulations were performed to further understand the process. Based on the experimental and numerical results, qualitative and quantitative analysis were performed for each condition. Among the different lubricants used in this study, zinc stearate showed the lowest value for drawing force, 18.8 kN, followed by Lub A and B with values of 20 kN and 20.6 kN, respectively. The numerical models showed excellent approximation to the force values determined in the tests. The values for the coefficient of friction obtained by both the numerical analysis and the empirical model indicate that zinc stearate has the highest lubricating effect among the lubricants focused on this study.

Analysis of The Effect of Ultrasonic Excitation on The Wire Drawing Process for Aluminium Wire Using Finite Element Method

The utilization of aluminium wires is widespread in the electrical energy transmission industry as well as in various other applications. Wire drawing are used to decrease the diameter of the wires. Simulations are conducted utilizing simulation software to imitate the drawing process of a 2.6 mm diameter Aluminium wire and reducing it to 2.2 mm through both conventional drawing methods and simulation that includes excitation of ultrasonic stimulation. The study of adding ultrasonic stimulation focuses on two critical elements, the draw force and its impact on the energy consumption during the drawing process, and the stress induced on the aluminium wire. The results of the simulation demonstrate a reduction in both the energy consumption and the stress levels on the Aluminium wire as a result of incorporating ultrasonic technique in stimulation of the drawing process.

Effects of Contact Conditions at Wire–Die Interface on Temperature Distribution during Wire Drawing

The effects of contact conditions at the wire–die interface on the temperature distribution of the specimen and die are investigated to understand the wire drawing process. Finite element analysis and experiments are performed to analyze the temperature distribution of a drawn wire and die based on different contact conditions using a low-carbon steel wire. The maximum temperature (Tmax) of the die decreases as the contact heat transfer coefficient at the wire–die interface increases, whereas that of the wire increases with the contact heat transfer coefficient. The Tmax of the die and wire decreases with the thermal conductivity of the die. As the thermal conductivity of the die increases, the heat generated by friction is rapidly absorbed into the die, and the Tmax of the die decreases, thus resulting in a decrease in the surface temperature of the wire. The Tmax of both the die and wire linearly increases with the friction factor. In particular, the Tmax of the die more sensitively changes with the friction factor compared with that of the wire. The Tmax of the die linearly increases with the drawing velocity, whereas that of the wire parabolically increases with the drawing velocity. The influence of bearing length on the temperature increase in both the wire and die is insignificant.

An LSTM-based adaptive prediction control model for the wire diameter control of high-precision optical fiber drawing machines

Reducing inconsistencies in fiber diameter has always been a focus of research on optical fiber drawing machines (OFDM). Based on an established mathematical model for OFDM, we adopted a long short-term memory (LSTM)-based neural network to predict fiber wire diameter and utilized these results to feedback and control the drawing speed, thereby achieving high precision control of the wire diameter. We trained the proposed network using relevant data from two different fiber drawing processes, allowing it to learn the long-term and short-term correlations in the data. Additionally, we evaluated the performance of the model using root mean square error (RMSE) and R2 as indicators. The experimental results show that network complexity has a considerable impact on the precision of fiber wire diameter prediction. We also established that two LSTM hidden layers with 64 neural units in each layer are the most suitable for the proposed network structure. The network with such a structure has the smallest RMSE value in the validation set and the largest R2 in the testing set. Subsequently, the optimal network structure was used to conduct a multi-timespan wire diameter prediction experiment. According to the experimental results, the LSTM-based wire diameter prediction model still has a satisfactory predictive effect when the time is as long as 50 s, suggesting that the precision and robustness of this network are high. When this method is applied to the actual wire drawing process, the wire diameter error can be controlled to within ± 1.8 μm when the target wire diameter is 0.66 mm, indicating that the wire diameter precision is greatly enhanced. Results indicate that using LSTM-based prediction and control effectively avoids the interference of other factors in the process of wire drawing. Therefore, we remedied the time delay issue of conventional wire diameter control methods. Also, compared with conventional methods, we achieved more precise and robust control of wire diameter.

Microstructural, textural, and residual stress evolution alongside the magnetic properties through isothermal static recrystallization of cold-drawn Fe–Cr–Si–S–C ferritic high-alloy stainless steel and by JMAK modelling

The evolution of microstructures, textures, and residual stresses scale of cold-drawn (CD) 18%Cr ferritic stainless steels (FSS) round bars under isothermal static recrystallization annealing are investigated. As for determination of the new grains' formation, the size, growth, and orientation, as well as the nucleation of grains, alongside revealing the recrystallization fractions are studied by a mixed experimental and theoretical work. The recrystallization kinetics are calculated according to the Johnson-Mehl-Avrami-Kolmogorov theory. Electron backscatter diffraction (EBSD) analyses are applied for the actual specimens of an industrial wire drawing process with 20 and 35% reduction rates. The heat treatment has been implemented at three different set ratio temperatures of 0.65, 0.68, and 0.71, defining as a ratio between the temperatures of annealing and melting point (TRAM). According to the results, the nucleation is occurred at faster incubation time with higher temperature and reduction rate. The grain average size (AGS) increases gradually whereas the temperature increases. This is while the 0.71TRAM-scale annealed samples illustrate finer and more equiaxed recrystallized grains. Following recovery, recrystallized grains, and the grain growth, the overall varied AGS of 27–86 μm in the core region are achieved. Moreover, the JMAK model agrees well with the obtained experimental data. All in all, this 18Cr-FSS material is taken into account for the optimal industrial annealing production as well as the targeted material selection of the market applications. It is observed that the higher recrystallization leads the higher magnetic permeability, lower coercivity, and lower residual stresses compared to the unheated specimens.

On the Use of Multi-Step Dies for Improving the Performance against Hydrogen Embrittlement of Cold Drawn Prestressing Steel Wires.

The main cause of in-service failure of cold drawn wires in aggressive environments is hydrogen embrittlement (HE). The non-uniform plastic strains and residual stresses generated after cold drawing play a significant role in the matter of HE susceptibility of prestressing steels. In this paper, a new and innovative design of the drawing scheme is developed, geared towards the reduction in both manufacturing-induced residual stresses and plastic strains. To achieve this goal, three innovative cold drawing chains (consisting in diverse multi-step dies where multiple diameter reductions are progressively carried out in a single die) are numerically simulated by the finite element (FE) method. From the residual stress and plastic strain fields revealed from FE numerical simulations, hydrogen accumulation for diverse times of exposure is obtained by means of FE simulations of the hydrogen diffusion assisted by stress and strains. Thus, an estimation of the HE susceptibility of the cold drawn wires after each process was obtained. Results reveal that cold drawn wire using multi-step dies exhibits lower stress and strain states nearby the wire surface. This reduction causes a decrease in the hydrogen concentration at the prospective damage zones, thereby improving the performance of the prestressing steel wires in hydrogenating environments promoting HE. Thus, the optimal wire drawing process design is carried out using special dies with several reductions per die.

Fabrication of multi-filament(Ba,A)Fe2As2 (A: Na, K) HIP round wires and a small superconducting coil

We report the fabrication and systematic characterizations of multi-filament (Ba,A)Fe2As2 (A: Na, K) round wires processed under high pressure. The evaluated transport and magnetic critical current density show clear core-number dependence. This trend originates from degradation of the superconducting core during the wire-drawing process, degradation of the concentric texturing of the core, and the enhanced sausaging effect of the core (revealed by x-ray tomography) as the number of cores increases. Details of the characterizations and suggestions for the improvement of the fabrication process are discussed. We constructed a superconducting magnet using seven-filament (Ba,K)Fe2As2 hot-isostatic pressed round wires. The generated magnetic field and critical current (I c) of the coils at 4.2 K are 1.0 kOe and 18 A, respectively. Measurements of the I c of short segments picked up from the coil show that there is enough room for improvements.

Comparison of Temperature Distribution between TWIP and Plain Carbon Steels during Wire Drawing

The effect of the thermal properties of steels on wire drawing behavior has been investigated to understand and improve the wire drawing process. Finite element analysis and experimental tests were conducted to analyze the temperature distribution of the deformed specimens with different thermal properties. The thermal properties of twinning-induced plasticity (TWIP) steel were measured and compared with those of plain carbon steel. Based on the measurement of thermal properties, wire drawing behaviors were systematically compared with thermal conductivity of the specimen (k) using plain low-carbon steel with high k and TWIP steel with low k. The results revealed that the k of TWIP steel was approximately one third of that of low-carbon steel, and the thermal expansion coefficient of the TWIP steel was approximately 50% higher than that of low-carbon steel in the temperature range of 26-400 °C. The temperature distributions in the wire strongly depended on the k of the wire during wire drawing. TWIP steel exhibited higher maximum temperature, and took a longer time to attain the equilibrium temperature than low-carbon steel during wire drawing owing to the low k. The maximum temperature of the die increased with decreasing k of the wire, indicating that die wear can increase with decreasing k of the wire. Therefore, reducing the drawing speed is suggested for a wire with low k, such as high-alloyed metals, especially for TWIP steels.

Optimization of wire drawing process in terms of rheological characteristics of stretching material and refinement of die hole geometry

The article discusses the improvement of the analytical method for calculating the wire drawing force, taking into account the rheological properties of the material being pulled and clarifying the geometry of the die hole, provides a new analytical model for calculating the drawing force, describes the algorithm for calculating the drawing force, analyzes the results of modeling the drawing process for round products.

Multi-pass cold rolling and wire drawing process of gadolinium and its magnetocaloric effect

Owing to low ductility of magnetocaloric material (MCM)s, the plastic deformation process is quite challenging, and information available on the deformation process of MCMs is limited. In this study, the cold rolling and wire drawing processes of Gd wire including heat treatment were conducted. Uniaxial compression test of as-cast and heat treated Gd rod was conducted to evaluate the material property. The magnetocaloric effect (MCE) of drawn Gd wire was indirectly measured using a vibrating sample magnetometer (VSM). Pass schedule of cold rolling and wire drawing process for the Gd wire of Ø1.0 was designed. Finite element (FE) simulation of drawing process was conducted to investigate the drawing force for each drawing pass and strain distribution. Friction coefficient between the drawing die and Gd wire was evaluated via FE simulation and drawing experiments using a lubricant. Magnetic properties of the deformed and annealed Gd wire were evaluated and compared. The evaluated magnetic properties have shown that the presented process schedule is reasonable for manufacturing magnetocaloric wire without diminishing the magnetocaloric effect.

Optimization of wet drawing according to the ratio of breaking stress to draw stress

The paper continues the previous authors’ works in the field of wet wire drawing. The process of wet fine brass-plated steel wire drawing is considered. The subject of the paper is increase of the wire die wearability. The analysis of various wire drawing tools (hard alloy dies, synthetic diamond dies, natural diamond dies) was carried out for the relevance of its application for small diameter wire drawing. The authors studied the wire die wearability. The research methodology is presented, which include the procedure and conditions for measurements, industrial equipment and type of wire drawing machine. In the paper, the comparative analysis of the experimental data with the results of other authors for similar wire drawing tool was carried out. The authors calculated the main characteristics of the wire die wearability distribution (asymmetry, kurtosis, coefficient of variation). A statistical analysis of the array of experimental data for selection of more than 500 samples was performed. A high correlation of the drawing die wearability with the ratio of breaking stress to draw stress and a weak correlation with the drawing force and stress were revealed. The highest and most stable die life results are achieved when ratio of breaking stress to draw stress has values of 1.9 – 2.5. A formula was proposed for determining the optimal value of the ratio of breaking stress to draw stress, depending on the wire diameter. The formula allows one to determine the maximum die wearability values, depending on the wire drawing schedule. The work results can be used when designing new wet wire drawing schedules using synthetic diamond dies.

Analysis of Tool Geometry and Lubrication Conditions Effect on the Forming Load During Wire Drawing Process

Analysis of Tool Geometry and Lubrication Conditions Effect on the Forming Load During Wire Drawing Process

JOB SAFETY ANALYSIS ON MANUFACTURING PROCESS OF HOUSE WIRES

The objective of this project is to analysis of hazards in the process of house wire manufacturing in VGuard industries limited Coimbatore for the purpose of improving safety in the workplace and promoting safety culture among the workers. Manufacturing process involves cold wire drawing process, copper cable bunching process, Insulation process, testing and material handling process all of this process having its own significant hazards. By using the Job safety analysis technique, the analysis was carriedout and the study is submitted as a report to V-Guard industries limited Coimbatore. Here the proposed practical solution in the sequence of Elimination, Substitution, Engineering control, Administrative control, and Personal Protective Equipment using the observation form Job Safety Analysis worksheet

Development of IrO2–WO3 Composite Catalysts from Waste WC–Co Wire Drawing Die for PEM Water Electrolyzers’ Oxygen Evolution Reactions

Recycling waste materials as catalysts in the oxygen evolution reaction (OER) offers an innovative approach to reducing catalyst costs. Scrap tungsten carbide–cobalt (WC–Co) die, used in wire drawing processes in industrial applications, may be recovered as tungsten trioxide (WO3) by the electrolysis method. In this study, all composite catalysts were prepared as their weight percentage IW-x (0 ≤ x ≤ 100). Here, I, W, and x represent IrO2, WO3, and the weight percent of Ir in the mixed composite oxide, respectively. Then, the prepared IW-75, IW-50, and IrO2 catalysts are referred to as 75% IrO2–25% WO3, 50% IrO2–50% WO3, and Ir’s pure oxide form, respectively. These materials are compared with WO3 and IrO2 to investigate their OER performance. According to the linear sweep voltammetry results, the IW-75 catalyst has a 15.03% higher current density than the pure IrO2 catalyst. In the Tafel polarization curve of the catalysts, it is determined that the corrosion potential of IW-75 is enhanced, and the overpotential value is decreased 1.2 times compared to the synthesized IrO2 catalyst sample. As a result, using composite oxide from scrap wire drawing die and IrO2, the cost of the proton-exchange membrane water electrolyzer’s anode catalyst is reduced by more than 25%.

Ön Deformasyona Uğratılmış Hammadde Kullanılarak Paslanmaz Çelik Bağlantı Elemanının Simülasyon Destekli Soğuk Dövme Üretimi

The initial properties of the raw material used while producing by cold forging change the mechanical properties of the final product resulting from deformation. Depending on the amount and speed of deformation, there is an increase in strength and a decrease in formability after cold forging on the basis of the true stress - strain curve of the material. In this study, pre-deformation of 304Cu (1.4567) quality raw material used to produce fasteners in A2-70 class by wire drawing before forging and the change of the mechanical properties of the raw material, on the basis of this change, the simulation supported design of the fastener mold and process was carried out. Simufact.forming software was used in cold forging simulation studies. According to the simulation data, the yield strength value increased from 215 MPa to 620 MPa as a result of thinning the raw material from Ø7.80 mm to Ø6.95 mm with wire drawing operation. In this case, the properties of the raw materials entering the cold forging have changed according to the deformation percentage amount, and the material properties and mold design used in the finite element simulation supported production were made according to this data. As a result of the use of this raw material in the cold forging simulation, the HV10 hardness value in the fastener head region, where deformation is intense on the basis of the die geometry, has reached the levels of 320 to 340 HV. Material flow lines, product dimensional tolerances, rolling and thread cutting processes during deformation were verified in the computer environment and physical product production was made. Hardness, strength and structural checks were performed and compared with numerical model values. Especially, the changing material properties as a result of the wire drawing process applied to the starting raw material and its effect on cold forging were investigated mechanically and metallographically.

The Behavior of a Zn-Al Anticorrosive Coating in the Wiredrawing Process

The present paper describes and quantifies the behavior of a Zn-Al anticorrosive coating deposited on the surface of a steel wire before its drawing process. For the complete evaluation of this behavior, the drawing of these samples was performed on four wiredrawing lines, differing by the deformation angle 2 · α of the component dies of each line. For good agreement with industrial practice, the drawing series used a partial reduction of the section of 20%. Two aspects were analyzed: the evolution of the chemical composition and the structure of the removed layer during the drawing of the coated steel wire, and the drawing force necessary to carry out this process. This article helps to elucidate how the Zn-Al anti-corrosion layer responds to the stresses inherent in the process of drawing the steel wire on which it is deposited.