Compiled by:

Norliana Mohd Abbas

Sources:
1. Manufacturing Engineering & Technology 5th Edition, Serope
Kalpakjian, Steven Schmid, Prentice Hall, 2006
2. Fundamentals of Modern Manufacturing: Materials, Processes

and System, Mikell P. Groover, John Wiley & Sons (Asia),

2007

Introduction
In drawing, the cross-section of a long rod or wire

typically is reduced or changed by pulling (hence

the term drawing) it through a die called a draw
die.

The die angle, the reduction in cross-sectional area per pass, the
speed of drawing, the temperature, and the lubrication all affect
the drawing force, F.

Introduction
Similar to extrusion except work is pulled through

die in drawing (it is pushed through in extrusion)

Although drawing applies tensile stress,

compression also plays a significant role since

metal is squeezed as it passes through die opening

Change in size of work is usually given by area

reduction:

Ao Af
r
Ao

where r = area reduction in drawing; Ao = original area of work; and

Ar = final work

Introduction
The major processing variables in drawing are

similar to those in extrusion that is, reduction in

cross-sectional area, die angle, friction along the
die-workpiece interfaces, and drawing speed.

Drawing Equipment

A draw bench contains a single die, and its design is

similar to that of a long, horizontal tension-testing
machine.

Figure shows the cold drawing of an extruded channel on

a draw bench to reduce its cross-section. Individual
lengths of straight rods or of cross-sections are drawn by
this method.

Drawing Equipment

Very long rods and wire (many kilometers) and wire of

smaller cross-sections, usually less than 13 mm , are
drawn by a rotating drum (bull block or capstan.

The tension in this setup provides the force required for

drawing the wire, usually through multiple dies (tandem
drawing).

Drawing Equipment

Figure shows an illustration of multistage wire drawing

typically used to produce copper wire for electrical
wiring.

Drawing Process
Figure shows the examples of tube-

drawing operations, with and without an

internal mandrel.

Drawing Process

Note that a variety of diameters and wall thicknesses

can be produced from the same initial tube stock
(which has been made by other processes).

Wedge-shaped dies are used for the drawing of flat

strips and are used only in specific applications.

However, the principle of this process is the

fundamental deformation mechanism in ironing,
used extensively in making aluminum beverage
cans.

Drawing Process

In drawing, reductions in the cross-sectional area

per pass range up to about 45%.

Usually, the smaller the initial cross-section, the

smaller the reduction per pass.

A light reduction (sizing pass) also may be taken

on rods to improve surface finish and dimensional
accuracy.

Drawing speeds depend on the material and on the

reduction in cross-sectional area.

Drawing Practice
Drawing practice:
Usually performed as cold working
Most frequently used for round cross sections
Products:
Wire: electrical wire; wire stock for fences, coat
hangers, and shopping carts
Rod stock for nails, screws, rivets, and springs
Bar stock: metal bars for machining, forging,
and other processes

Drawing Practice

Because the product does not have sufficient

time to dissipate the heat generated,
temperatures can rise substantially at high
drawing speeds and can have detrimental
effects on product quality.

Drawn copper and brass wires are designated

by their temper (such as 1/4 hard, 1/2 hard,
etc.) because of work hardening.

Bundle Drawing

One method employed to increase productivity

is to draw many wires (a hundred or more)
simultaneously as a bundle.

The wires are separated from one another by a

suitable metallic material with similar properties
but lower chemical resistance (so that it
subsequently can be leached out from the
drawn-wire surfaces).

Bar Drawing
Accomplished as a singledraft operation the

stock is pulled through one die opening

Beginning stock has large diameter and is a

straight cylinder
Requires a batch type operation

Bar Drawing

Hydraulically operated draw bench for drawing metal bars.

Wire Drawing
Continuous drawing machines consisting of

multiple draw dies (typically 4 to 12)

separated by accumulating drums
Each drum (capstan) provides proper force to

draw wire stock through upstream die

Each die provides a small reduction, so desired
total reduction is achieved by the series
Annealing sometimes required between dies to
relieve work hardening

Wire Drawing

Continuous drawing of wire.

Wire Drawing vs. Bar

Drawing
Difference between bar drawing and wire
drawing is stock size
Bar drawing - large diameter bar and rod stock
Wire drawing - small diameter stock - wire sizes

down to 0.03 mm (0.001 in.) are possible

Although the mechanics are the same, the

methods, equipment, and even terminology

are different

Features of Draw-Die
Entry region - funnels lubricant into the die to

prevent scoring of work and die

Approach - coneshaped region where
drawing occurs
Bearing surface - determines final stock size
Back relief - exit zone - provided with a back
relief angle (halfangle) of about 30
Die materials: tool steels or cemented
carbides

Die Design
Figure shows the terminology of a typical die

used for drawing a round rod or wire.

A set of dies is required for profile drawing,

which involves various stages of deformation

to produce the final profile.

Die Materials

Die materials for drawing typically are tool steels and carbides.

Because of their lack of tensile strength and toughness,

carbide and diamond dies typically are used as inserts or
nibs, which are supported in a steel casing.

Figure shows the tungsten-carbide die insert in a steel casing.

Diamond dies used in drawing thin wire are encased in a

similar manner.

Lubrication

Proper lubrication is essential in drawing in

order to improve die life and product surface
finish and to reduce drawing forces and
temperature.

Lubrication is critical, particularly in tube

drawing, because of the difficulty of maintaining
a sufficiently thick lubricant film at the mandrel
tube interface.

Lubrication

1.
2.

3.

4.

The following are the basic methods of lubrication used

in wire drawing:
Wet drawing in which the dies and the rod are
immersed completely in the lubricant
Dry drawing in which the surface of the rod to be
drawn is coated with a lubricant by passing it through a
box filled with the lubricant (stuffing box)
Metal coating in which the rod or wire is coated with a
soft metal, such as copper or tin, that acts as a solid
lubricant
Ultrasonic vibration of the dies and mandrels, where
vibrations reduce forces, improve surface finish and die
life, and allow larger reductions per pass without failure.

Defects

Typical defects in a drawn rod or wire are similar to those

observed in extrusion, especially center cracking.

Another major type of defect in drawing is seams, which

are longitudinal scratches or folds in the material.

Because they undergo non-uniform deformation during

drawing, cold-drawn products usually have residual
stresses.

Rods and tubes that are not sufficiently straight (or are
supplied as coil) can be straightened by passing them
through an arrangement of rolls placed at different axesa
process similar to roller leveling.

END OF PART E