Exercise 1.

Wire is drawn through a draw die with entrance angle = 15o. Starting
diameter is 2.5 mm and final diameter = 2.0 mm. The coefficient of friction
at the work-die interface = 0.07. The metal has a strength coefficient K =
205 MPa and a strain hardening exponent n = 0.20. Determine the draw
stress and draw force in this operation.
 Wire Drawing, Kalpakjian’s formula

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Wire Drawing, Schey’s formula

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Example 1

• Wire is drawn through a draw die with entrance angle = 15 ° . Starting diameter is
2.5 mm and final diameter = 2.0 mm . The coefficient of friction at the work–die
interface = 0.07. The metal has a strength coefficient K = 205 MPa and a strain-
hardening exponent n = 0.20 . Determine the draw stress and draw force in this
operation.
• Solution

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Solution Using Kalpakjian’s method

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Exercise 2.
Wire is drawn through a draw die with entrance angle = 15o. The coefficient
of friction at the work-die interface = 0.05. The metal has a strength
coefficient K = 205 MPa and a strain hardening exponent n = 0.20. The
starting diameter is 3 mm and final diameter is 1.3 mm.
(a) Check if the drawing can be performed in one pass.
(b) If the drawing can not be conducted in one pass, try two passes
operation by dividing the diameter ranges as follows:
- Pass 1: to = 3 mm, tf = 2 mm.
- Pass 2: to = 2 mm, tf = 1.3 mm
(c) Check if both pass operation in (b) can be performed.
(d) If (c) can be performed, calculate the required force of each pass
operation by using Schey’s method.
 Exercise 3
(Take Home Assignment)
Wire is drawn through a draw die with entrance angle = 15o. The coefficient
of friction at the work-die interface = 0.05. The metal has a strength
coefficient K = 205 MPa and a strain hardening exponent n = 0.20. The
starting diameter is 3 mm and final diameter is 1 mm.
(a) Proof that the drawing can be performed only by a minimum of 3 passes
operation
(b) Calculate the required force of each pass operation by using Schey’s
method.