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Drawing of Rod-Wire and Tubes
Drawing of Rod-Wire and Tubes
• Introduction/objectives
• Rod and wiredrawing
• Analysis of wiredrawing
• Tube drawing processes
• Analysis of tube drawing
• Residual stress in rod, wire and tubes
Drawing die
Undrawn
Drawn wire
wire
http://en.wikipedia.org
• The cross section can be circular, Brass tubes for heat exchanger –
square hexagonal or in any shapes. cheap, strong, good corrosion
resistant
Metal wires
Metal rods
Rod is swaged
Machine capacity :
Insert though the die • 1 MN drawbench
• 30 m of runout
Clamped to the jaws of the drawhead • 150-1500 mm.s-1 draw speed
• The back relief allows the metal to expand slightly as the wire leaves the die
and also minimises abrasion if the drawing stops or the die is
out of alignment.
Drawing die
Undrawn
Drawn wire
wire
http://en.wikipedia.org
• The wire is first passed through the overhead loop and pulley, brought down
and then inserted through the die of the second drum and drawn through this
die for further reduction.
• Thus, the wire is drawn through all the wire drawing drums of the set in a
continuous manner to get the required finished diameter of the wire. Speed
of each draw block has to be synchronised to avoid slippage between the
wire and the block.
• The drawing speed ~ up to 10 m.s-1 for ferrous drawing
~ up to 30 m.s-1 for nonferrous drawing.
D
2
% RA = 1 − Outlet ×100
coil
Bull
DInlet
block
Top view Side view of bull block
Suranaree University of Technology Tapany Udomphol Jan-Mar 2007
Example: Drawing of stainless wire
www.metalwire-mesh.com
• Stainless steels: 304,
304L, 316, 316L
• Applications: redrawing,
mesh weaving, soft pipe,
steel rope, filter elements,
making of spring.
www.metalwiremesh.com
Stainless steel rope
• Larger diameter stainless wire is first surface
examined, tensile and hardness tested, diameter size
measured.
• Surface preparation by pickling in acid (ferrictic and
martensitic steels) and basic solutions (austenitic steels).
The prepared skin is then coated with lubricant.
• Cold drawing is carried out through diamond dies or
tungsten carbide dies till the desired diameter is Stainless steel meshes
obtained.
• Cleaning off oil/lubricant is then carried out and the wire is
heat-treated (annealing at about 1100oC or plus skin pass).
Suranaree University of Technology Tapany Udomphol Jan-Mar 2007
Stepped-cone multiple-pass wiredrawing
Good combination of
strength and ductility.
Suranaree University of Technology Tapany Udomphol Jan-Mar 2007
Defects in rod and wiredrawing
• This defect will occur for low die angles at low reductions.
• For a given reduction and die angle, the critical reduction to
prevent fracture increases with the friction.
_ Ab 1
σ xa = σ o ln = σ o ln …Eq.1
Aa 1− r
p
• A wide strip is being drawn
w σxa through a frictionless die
sα
dh/2 α
σx+dσx with a total included angle of
/c o
hb h dx σx 2α
ha
dx
dh/2 2α .
dx
α p
x
• Plane strain condition is
p cosα
p
x=0 applied (no strain in the
width direction.)
The equilibrium of forces in the x direction is made up of two components
1) Due to the change in longitudinal stress 2) Due to the die pressure at the two
with x increasing positively to the left. interfaces.
(σ x + dσ x )(h + dh )w − σ x hw dx
2 p sin α w
cos α
Taking the equilibrium of force in the x direction and neglect dσxdh
dσ x dh …Eq.4
=
σ x B − σ o' (1 + B) h
h
B
' 1+ B 1+ B
σ xa =σo 1 − a
B hb
= σ o' [
1 − (1 − r ) B ]
B
1 + B Da
2B
σ xa =σo 1 − …Eq.5
B Db
Ab − Aa …Eq.6
S=
sin α S
Pd
Ab Aa
p is the mean normal pressure on this area.
Pd is the draw force. µpS µpS cos α
_ _ Ab
Pd = p ( Ab − Aa ) = σ o Aa ln …Eq.8
Aa
Pd _ A
σ xa = = σ o ln b (1 + B) …Eq.9
Aa Aa
1 + B Da
2B
1.8571
[ ]
From Eq.5 _
2×0.8571
σ xa =σ 1 − = 637 1 − 0.8 = 438MPa
B Db 0.8571
~ 20% difference
From Eq.9
_ Ab 1.0 2
σ xa = σ o ln (1 + B ) = 637 ln 2
(1.8571) = 527 MPa
Aa 0.8
Suranaree University of Technology Tapany Udomphol Jan-Mar 2007
If the wire is moving through the die at 3 m.s-1, determine the
power required to produce the deformation.
dis tan ce
Power = force ×
time
Drawing force
π
Pd = σ xa Aa = 438 × (8) 2 = 22.02kN
4
Power
Power = 22.02 × 3 = 66.06kW
Ab
σ xa = φσ o ln (1 + B) …Eq.10
Aa
ε*
φ = f (α , r ) = …Eq.11
ε
Where φ = the redundant work factor.
ε* = the ‘enhanced strain’ corresponding to the yield stress
of the metal, which has been homogeneously deformed
to a strain ε.
A
drawn metal is displaced along
ε* the strain axis = drawing
φ=
ε reduction,
ε = ln (Ab/Aa) = ln [1/(1-r)].
ε
Strain
• Due to redundant work, the yield
ε∗ stress of the drawn metal is above
the basic flow curve .
α
For drawing of round wire ∆ =
r
[
1 + (1 − r ) ]
12 2
…Eq.12
∆
where φ = C1 + C 2 ∆ ≈ 0.8 + …Eq.13
4.4
α*
α
The reduction and the friction α∗
Ao σd A1
ε
ε = lnAo/A1
Entrance Exit
η∫
σdε Flow curve
1
σ d = σε
σ xa =
η ∫ σdε …Eq.14
σε
∫ σdε Where the efficiency of the
deformation process, η = Up/UT
Ideal process
σxa (no friction/ At a given strain ε = ln (Ab/Aa)
redundant work)
ε εmax
draw stress σxa and the flow stress σε.
strain
As the material is being deformed through the die, strain hardening occurs
and if the material is severely strain-hardened necking fracture.
The drawing limit is reached when σd = σε
Since ε = ln (Ab/Aa), Ab
= eη (n +1) …Eq.17
Aa max
B B
[
1173 = 673(2.167) 1 − (1 − r ) 0.8571 ]
637 = 637
1.8571
[
1 − (1 − r )
0.8751
] r = 0.89
0.8571
r = 0.51 Note: in the case of no friction/
or redundant work, η = 1, no strain
1 hardening (n = 0), we have
ε = ln = 0.71
1− r
σ o = 1300ε 0.30 = 1300(0.7) 0.30 = 1,173MPa 1
rmax = 1 − = 0.63
e
Suranaree University of Technology Tapany Udomphol Jan-Mar 2007
Tube-drawing processes
• Sinking
• Plug drawing
- Fixed plug
- Floating plug
• Mandrel drawing.
Tube sinking Fixed plug Floating plug Moving mandrel
www.scielo.br
For tube drawing with a plug, the draw stress can be expressed by
1 + B h
'
B' And
σ xa = σ o' 1 − a µ1 = friction coefficient between tube
B ' hb and die wall.
where µ2 = friction coefficient between tube
and plug.
µ1 + µ 2 α = semi die angle of the die.
B =
'
1 + B Af
B
σ xa = σ o'' 1 − …Eq.23
B Ab
Where σ’’o ~ 1.1σo to account for the complex stresses in tube sinking.
- Surface tensile
Circumferential stresses
- Axis compressive
• At a given reduction,
α longitudinal stress
• Maximum values of
longitudinal residual stress
~ 15-35% reduction in
area.