Deformation Processing Drawing

ver. 1

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

Overview

Description
Characteristics
Mechanical Analysis
Thermal Analysis
Tube drawing

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

Geometry
Db

Da
Fa, xa

Fb, xb

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

Equipment

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

Cold Drawing

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

A. Durer - Wire Drawing Mill

(1489)
(copper wire)

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

Characteristics
Product sizes:
0.0002 (5m) to several inches (100-150
mm)

Mostly cold (T < 0.4 Tmelting)

below recrystallization point

Small diameter (wire):

uses a capstan

Diameter > 1 inch (25 mm) (rod):

bull blocks on a draw bench
length up to 40 feet (12 m)
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton

Characteristics
Fine wire done through several
dies
Speeds
large diameter: 30 feet per minute
(9 m/min)
small diameter: 300 feet per minute
(90 m/min)
fine wires: 5,000 feet per minute
(60 mph 100 km/h)
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton

Die Materials
Large diameter
high carbon steel
high speed steel

Moderate diameter
tungsten carbide (WC)

Small diameter
diamond inserts

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

10

Characteristics
Lubrication
Coatings
Oil

Die angle ()
typically small: 4-6o

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

11

Mechanical analysis (round wire /

rod)
Reduction in area (RA)

Db
Fb, xb

Da
D D

RA =
1
D
Db2
b
2
b

2
a

Da
Fa, xa

Db
1

t = ln
= 2 ln
1 RA
Da
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton

12

Slab analysis
p

D + dD

x + dx

dx

Assume p, x are
uniform
OK for small ,

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

13

Equilibrium

( x + d x ) (D + dD )

D2

D dx
D dx
+p
sin + p
cos = 0
cos
cos
Expanding

( x + d x )

(
D
4

+ 2 DdD + dD x
2

D dx
D dx
+p
sin + p
cos = 0
cos
cos
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton

D2

14

Equilibrium
small

[
(

small

small

) (

2
2
2
2
+
2

+
2

D
DdD
dD
d
D
d
DdD
d
dD
x
x
x
x
x
x

)]

D dx
D dx
x D + p
sin + p
cos = 0
4
cos
cos

Eliminating higher order terms, dividing by D & , multiplying by

4 and canceling

dx
dx
2 x dD + d x D + 4 p
sin + 4 p
cos = 0
cos
cos
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton

15

Equilibrium
dD/2

dx

Noting
dD
2
tan =
dx

dD
dx =
2 tan

sin dD
cos dD
2 x dD + d x D + 4 p
+ 4 p
=0
cos 2 tan
cos 2 tan
or

dD
2 x dD + d x D + 2 pdD + 2 p
=0
tan
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton

16

Equilibrium
Finally

2 x dD + D d x + 2 p 1 +
dD = 0
tan

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

17

Maximum shear stress (Tresca)

criterion

x + p = 2 flow = flow

tan

flow

B
p

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

18

Differential form
dD
dp
=
D 4 flow + 2 pB
d x
dD
=
D 2 B x 4 flow (1 + B )

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

19

Integrating
Db

Da

dD
=
D

xb

d x
2 B x 4 flow (1 + B )

xa

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

20

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

21

Drawing stress
xa
2 flow

2B
2B

Da
xb Da
1+ B

+
1
=
B Db 2 flow Db

where:
xb = back stress (tension)
xa = pulling stress (tension)

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

Db

xb

Da

xa

22

Strain hardening
(cold below recrystallization
point)
For round parts - Tresca

2 flow = flow

K
=Y =
n +1
n

average flow stress:

due to shape of element

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

23

Strain rate effect

(hot above recrystallization point)
2 flow = flow

m
&
= Y = C

For a round part (derived for extrusion)

& =

2
6vb Db tan
3
3
Db Da

Ab

ln

A
a

average strain rate due to shape of element

vb = velocity of b side
A = area
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton

24

Value for p
flow

p=Y
p

or

p = 2flow
maximum at entrance

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

25

Effect of back tension

die pressure
without back tension

drawing stress

entry

with back tension

exit
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton

26

Maximum RA
Solve previous equations with:
= 6o (typical value)
= 0.1
B=1
xb = 0
For failure: draw stress = material flow {yield} stress

xa = = K n

K n
2 flow = flow = Y =
n +1

here, say K = 760 MPa, and n = 0.19

Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton

27

Maximum RA
K

K n
n +1

2B

1 + B Da
=
1
B Db

2

Da
0.19 + 1 1 + 1

=
1
1
1 Db

Yields RA = 0.6
must be solved for each , , xb
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton

28

Energy / unit volume (u)

u = F V / Aa V = xa
(with no back stress)
V= volume

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

29

Rod/Wire Drawing Analysis

Ideal deformation
External work = Work of ideal plastic
deformation
d (A f L ) = u (A f L )
t

d = u = t d t
t = K
for

n
t

A0
K tn
d =
t = Y f t = Y f ln
n +1
Af
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton

30

Rod/Wire Drawing Analysis

Ideal deformation
Drawing force, Fd = dAf
Drawing power, Pd = Fd Vf

Source: S. Kalpakjian & S. Schmidt, 4th ed. 2003

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

31

Drawing Limit
Ideal deformation of a perfectly
plastic material

d = Y ln

Ao

Af

= Y
Ao
Ao
d = ln = 1
=e
Af
Af

Maximum reduction per pass

Ao Af
1
=
= 1 = 0.63 = 63%
Ao
e
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton

32

Drawing Limit
Ideal deformation of a strain
hardening material
Ao
d = Y ln
Af

= K n

d =

K
=
n +1

n +1

= n +1

Maximum reduction per pass

Ao Af
=
= 1 e ( n +1)
Ao
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton

ideal+friction

ideal

n+1

33

Example Problem

Assuming zero redundant work and frictional work to be 20% of

the ideal work, derive an expression for the maximum reduction
in area per pass for a wire drawing operation for a material with
a true-stress strain curve of =Kn
Total work = Ideal work + frictional work + redundant work
Total work = Ideal work + 0.2 x Ideal work = 1.2 x Ideal work
Or, Total work of deformation = 1.2 [u x volume]
(1)
In drawing, external work of deformation = d x volume (2)
Equating (1) and (2), we get

d = 1.2u or

d = 1.2Y 1

n +1

K
d = 1.2 t d t = 1.2 K tn d t = 1.2 1
n +1
0
0

A0
where 1 = ln
Af

(3)

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

34

Example Problem
Max reduction occurs when total drawing stress, d =
Flow stress of material at die exit, Y

d = Y
1.2Y 1 = K 1n
K 1n +1
= K 1n
1.2
n +1
n +1
A
A
n +1
n +1
1 =
ln 0 =
0 = e 1.2
1.2
1.2
Af
Af
max reduction per pass =

A0 A f
A0

= 1 e

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

n +1

1.2

35

Drawing - Ex. 1-1

Determine power, and plot x and p
along die length.
Drawing steel rod from = 13 mm
to = 12 mm @ 1.5 m/s
K = 760 MPa, n = 0.19
= 0.1, = 4o, xb = 0

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

36

Drawing - Ex. 1-2

First, we must see if we can do the
process, the limit is

xa = max = K

RA = 1 - (Da/Db)2 = 0.15 = 15%

t = ln{1/(1-RA)}
= ln {1/(1-0.15)} = 0.16
B = /tan = 0.1 / tan 4o = 1.43
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton

37

Drawing - Ex. 1-3

xa
2 flow

2B
2B

Da
xb Da
1+ B

+
1
=
B Db 2 flow Db

2 flow

K
=Y =
n +1

max = K

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

38

Drawing - Ex. 1-4

So, equating the equations (with no
back stress) yields
2B

Da
1 1+ B

1=
1

n + 1 B Db

21.43

1 1 + 1.43 Da min

1=

0.19 + 1 1.43 13

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

39

Drawing - Ex. 1-5

Solving gives Da-min = 8.53 mm, so we can
do the process and proceed with the
analysis

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

40

Drawing - Ex. 1-6

xa
2 flow

2 flow

21.43

1 + 1.43
12
1
+ 0 = 0.35
=
1.43 13

K n 760 (0.16 )0.19

=Y =
=
= 446 MPa
n +1
0.19 + 1

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

41

Drawing - Ex. 1-7

xa = 0.35 x 2flow
= 0.35 x 446 MPa = 156 MPa
Fdraw = xa x Area = 156 x (12/2)2
= 17.6 kN = 3938 lbf
Power = Fdraw x speed
= 17.6 kN x 1.5 m/s = 26.4 kW = 35.4 hp

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

42

Drawing - Ex. 1-8

Dimensionless pressures (divided by 2 flow)
1
0.9
0.8
0.7
0.6

sx

0.5

0.4
0.3
0.2
0.1
0

13

12.8

12.6

12.4

12.2

12

diameter (mm)
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton

43

Limits on analysis
Larger die angles
more redundant work
, p, u will be larger than predicted

Db

Da

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

44

Redundant work
= dm/L
dm = (Da + Db) / 2
p = Qr flow
Db

L (contact length)

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

Da

45

Redundant work factor (Backofen)

(frictionless)

Qr =

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

46

Temperature rise
(1-r)Q

Do/D 6

Do

rQ

kD

kw, w, cw

WIRE
DIE
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton

47

Temperatures
= o + s + f
o = ambient (room) temperature
s = temperature rise in the wire
due to plastic shear energy, us
f = interface temperature rise due
to frictional energy, uf

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

48

Specific energies
u = us + uf
u = xa
us = 2flow

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

49

Specific energies
From the example above (steel rod):
u = xa = 156 MPa
us = 2flow = 446 * 0.16
= 71.4 MPa
uf = u - us = 156 71.4
= 84.6 MPa

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

50

Shear temperature (s)

Since the shear strain is uniform
in the wire
and all the shear energy remains
in the rod as heat
Then, we can obtain the shear
temperature in the wire:

us
s =
w cw
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton

51

Material properties
For this material:
kw = 60 W/m-K
w = 7850 kg/m3
cw = 500 J/kg-K
w = 1.53 x 10-5 m2/s

For a WC die:
kD = 42 W/m-K
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton

52

Shear temperature (s)

us
71.4 10
o
=
= 18.2 C
s =
wcw 7850 500
6

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

53

Frictional heat (Q)

Q represents all heat generated by friction

Q = uf

D v
2

v = velocity
(1-r)Q goes into the die

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

54

Die and wire temperatures ()

ref: Carslaw and Jaeger

For the die (steady):

= o

(
1 r )Q
Do
+
ln
2 k Dl

For the wire (moving):

r Q wl

= o + s + 1.07
2v
Dlk

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

55

Q calculation
Q = uf

D v
2

= 84.6 10
6

0.012 1.5
2

Q = 14352 W

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

56

Dimensions
D = 12 mm
from Do / D 6
Do = 72 mm in this example

l = contact length
= reduction in radius / sin
= 0.5 mm / sin 4o = 7.17 mm

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

dr

57

Die temperature
= o

(
Do
1 r )Q
+
ln
2 k Dl

(1 r ) 14352

72
ln
= 20 +
2 42 0.00717
12
= 20 + 13591 (1 r )

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

58

Wire temperature
r Q wl

= o + s + 1.07

2v

Dlk
w

r 14352

= 20+18.2 +1.07
0.012 0.00717 60
5

1
.
53

10

0
.
00717

2 1.5
= 38.2 + 181 r
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton

59

Heat flow ratio and Temperature

Equating the previous equations yields:
r = 0.99
hence
= 156oC = 429 K
Tmelt = 1500oC = 1723 K
So /Tmelt = 0.25, cold (below
recrystallization point
Prof. Ramesh Singh, Notes by Dr.
Singh/ Dr. Colton

60

Temperature in practice
In practice, r 1
all heat goes into wire

u f D2 v
us

= o +
+ 0.19
l
wcw

c
w
w w

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

61

Tube drawing

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

62

Tube Drawing

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

63

Plane strain / Slab analysis

xa
2 flow

1+ B t f
=
1
*
B ti

B*

die + mandrel
B
tan tan

= semicone angle of die

=semicone angle of plug

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

64

Tube Drawing Special Cases

die + mandrel
B
tan tan
*

Fixed mandrel- same

friction at both interface
(plane tube
B*
is modeled as a
flat section)

tan

Fixed mandrel
(slab circular tube)

Moving mandrel No friction at interface

of mandrel and tube
(plane and slab)
Moving mandrel with friction towards exit,
takes into account motion between mandrel
and tube (B may be negative) (plane)

2
B
2
tan
*

tan

die mandrel
B
tan
*

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

65

Summary

Description
Characteristics
Mechanical analysis
Thermal analysis
Tube drawing

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

66

Prof. Ramesh Singh, Notes by Dr.

Singh/ Dr. Colton

67