Typical Solutions of HW-5

Q1: Complete the Following Sentences:

1. In bar drawing machine, the carriage is used ….… through draw die. It is powered
by … …... or …….
2. In wire drawing process, the capstan function is (1)…... and (2)…….

3. The draw die is consisted of four regions are (1)…, (2)…, (3)… and (4)…..

4. In drawing of low carbon steel bar, the machinability is improved due to increase …
……. and …….

5. There are various criteria used to evaluate machinability, the most important of
which are: (1)…, (2) …, (3) …, and (4) ….

6. For successful drawing process, the 𝜎𝑑 must be less than ……….…………

7. The function of entry zone of draw die is ….……………….

8. The preparation of w.p. for drawing process includes (1)…., (2) …. and (3) …...

9. If 𝜎𝑑 exceeds the yield strength of exiting w.p. then the drawn w.p. will …………
rather than new w.p. being ……..….. through die opening.

10.Cleaning of w.p. before drawing process is required to…….….…..

11.Theoretical max. reduction ignores two important points which are:

1- …….., 2- …….
12. Reductions of …….... for single-draft bar drawing and …….... for multiple-draft
wire drawing seem to be the upper limits in industrial operations.
13. The wire pointing process involves … ….. of starting end of w.p. so that it can be
… ……. the draw die.
14. The problem in tube sinking process is that ……..... the …….... and ……....of
tube.
15. In ………. process, there is restriction of the length of tube that can be drawn due
to practical limitations on length of the support bar.

16. Dieless wire/tube drawing process is utilized in initiating continuous deformation

depending on ………... and …………..
local heating local cooling
17. The temperature range in DLD process should not be less than ………
18. To accomplish DLD process, three major components must be integrated; ……,
……….. and ……..
19. The benefit of heating process in DLD is to………….. and benefit of cooling
process is to ………
20. The heating ways in DLD process are: (1) ……, (2) ……, (3) …….. and (4) ….
21. In DLD process, there are different fluids are used in cooling unit such as …….,
……., ……… and ………

22. Because of ……..….. and ……………., this may lead to bamboo shape of drawn
wire during DLD process.

Q2:
In continuous dieless drawing process for stainless steel wire, the original wire
diameter do=2mm, and feeding velocity Vo= 4 mm/s as shown in figure below. The
proposed final wire diameter d1=1.5mm. Calculate: (1) drawing velocity V1, (2) area
reduction RA.
Cooling Heating
Zone Zone

do
d1
V1 Vo

Q3:
In continuous dieless drawing process for stainless steel wire, the original wire
diameter do=2.5mm, the proposed area reduction RA=45%. Calculate: (1) final wire
diameter d1, (2) ratio of drawing velocity to feeding velocity.

Q4:
Wire stock of initial diameter = 3.2mm is drawn through two dies each providing a
0.2 area reduction. The starting metal has a strength coefficient = 276MPa and
a strain hardening exponent = 0.15. Each die has an entrance angle of 12°, and the
coefficient of friction at the work-die interface is estimated to be 0.1. The motors
driving the capstans at the die exits can each deliver 1119W at 90% efficiency.
Determine the maximum possible speeds of the wire as it exits the first and second
dies.
Q5:
Wire stock of initial diameter = 0.125 in is drawn through two dies each providing a
20% area reduction. The starting metal has a strength coefficient = 40,000 lb/in 2 and
a strain hardening exponent = 0.15. Each die has an entrance angle of 12°, and the
coefficient of friction at the work-die interface is estimated to be 0.1. The motors
driving the capstans at the die exits can each deliver 1.5 hp at 90% efficiency.
Determine the maximum possible speed of the wire as it exits the second die.

Q6:
For dieless drawing process of SUS304 stainless steel wire (shown in figure below),
the material properties (A, n, m) are given as in the below equations. The original
wire diameter do=2mm, the feeding velocity Vo=4mm/s. The proposed final diameter
d1=1.3mm. Determine the flow stress required for this process and corresponding
drawing force if deformation length Ld=35mm and forming temperature Tf = 862K.
𝐴 = 0 ∙ 0007𝑇 2 − 2 ∙ 1417𝑇 + 1788 ∙ 3 𝑀𝑃𝑎. 𝑠
𝑛 = 4 ∙ 645 × 10−7 𝑇 2 − 3 ∙ 628 × 10−4 𝑇 + 4 ∙ 367 × 10−1
𝑚 = 4 ∙ 374 × 10−5 𝑇 + 1 ∙ 449 × 10−3
Use the following relations to complete the calculations:
𝜀(𝑉𝑜 +𝑉1 )
𝜀̇ =
2𝐿𝑑
𝐴𝑜
𝜀 = 𝑙𝑛
𝐴1
𝑛 𝑚
𝜎 = 𝐴 𝜀 𝜀̇
𝐹𝑑 = 𝐴1 𝜎
Cooling Heating
Zone Zone

Ld do
d1
V1 Vo