Wire Drawing Process

Group: 17 Under Supervision of: Dr. Mohamed A. Daha 12/24/2013

INTRODUCTION
Drawing is a metalworking process which uses tensile forces to stretch metal. It is broken up into two types: sheet metal drawing and wire, bar, and tube drawing. The specific definition for sheet metal drawing is that it involves plastic deformation over a curved axis. For wire, bar, and tube drawing the starting stock is drawn through a die to reduce its diameter and increase its length. Drawing is usually done at room temperature, thus classified a cold working process, however it may be performed at elevated temperatures to hot work large wires, rods or hollow sections in order to reduce force.

Types of drawing processes:

Sheet metal Deep drawing : as piercing, ironing, necking, rolling, and beading. Bar, tube & wire Bar, tube, and wire drawing all work upon the same principle: the starting stock drawn through a die to reduce the diameter and increase the length. Usually the die is mounted on a draw bench. The end of the work piece is reduced or pointed to get the end through the die. The end is then placed in grips and the rest of the work piece is pulled through the die. Steels, copper alloys, and aluminum alloys are common materials that are drawn. Drawing can also be used to produce a cold formed shaped crosssection. Cold drawn cross-sections are more precise and have a better surface finish than hot extruded parts. Inexpensive materials can be used instead of expensive alloys for strength requirements, due to work hardening.

Wire drawing:
Is a metal working process used to reduce the cross-section of a wire by pulling the wire through a single, or series of, drawing dies. There are many applications for wire drawing, including electrical wiring, cables, tension-loaded structural components, springs, paper clips, spokes for wheels, and stringed musical instruments. Although similar in process, drawing is different from extrusion, because in drawing the wire is pulled, rather than pushed, through the die. Drawing is usually performed at room temperature, thus classified as a cold working process, but it may be performed at elevated temperatures for large wires to reduce forces. More recently drawing has been used with molten glass to produce high quality optical fibers. In wire drawing, differences are made according to the dimensions of the wire between: coarse drawing: d = 16 to 4.2 mm medium drawing: d = 4.2 to 1.6 mm fine drawing: d = 1.6 to 0.7 mm ultra-fine drawing: d < 0.7 mm, and according to the machine used, between: single-draft drawing tandem drawing.

Products:
Wire and rod drawing are used to produce Wires and rods with smooth surfaces and low tolerances for various fields of application.

Figure 1: : fields of application of drawn wires and rods

Permissible deformations :
In single drawing, the permissible deformations are around: Steel wires =150 200 % Cu materials = 200 %

Drawing force:
According to Siebel, the drawing force can be calculated with the following equation.

The mean coefficient of friction is around = 0.035 (= 0.02 to 0.05). The optimum drawing angle, requiring the least force, is around 2 = 16o. From this it follows for the angle in radians:

If these values are brought into the above equation, then the drawing force during wire drawing can be determined approximately with the simplified equation and the deformation efficiency = 0.6

Die design: The drawing die consists of three zones. These are the cone cone-shaped shaped intake with the entry angle 2 and approach angle 2, the bearing land l3 and the conecone shaped back relief l4 with the back relief angle 2. The length of the cylindrical guide bush l3 is around:

The approach angle 2 influences the drawing force and the surface finish of the wire.

Die life and die wear:

Two primary variables that control die life in any metal forming operations are pressure and temperature a) Pressure: pressure acting on the die in wiredrawing is much lower than that found in other cold forming operations , such as cold heading and backward extrusion b) Temperature: temperature is often a far more critical factor in controlling die life. Although it would seem logical that wear would occur uniformly along the approach zone, this is not the case in practice. Maximum wear (measured in volume loss) normally occurs at the point at which the wire initially contacts the die. There, a deep annular crater is formed, which is referred as a wear ring

Figure 2 : Wear Formed By Ringing In A Drawing Die

Ringing results when the plane of impingement of wire on the die oscillates about a mean position because of irregularities of size and vibration of the wire. As a consequence, a narrow zone of the die bore is subjected to a cyclic load with eventual subcutaneous failure by fatigue.

Once a wear ring develops, deformation may occur prior to the contact point in the drawing die. This is called bulging and results from backup or upsetting of near-surface regions of the wear as contact is made at the wear ring location in the die. Bulging occurring at the initial of contact in the die throat limits lubricant entry into the die and accelerates the die wear. Lesser amounts if wear occur along the contact length of the approach zone, although here too wear is not uniform and often results in an oval rather than a circular wear surface.

Die material: Industrial diamond:

Industrial diamond is the hardest material known. where hardness is defined as resistance to scratching and is graded between 1 (softest) and 10 (hardest) using the Mohs scale of mineral hardness. Diamond has a hardness of 10 (hardest) on this scale. The hardness of industrial diamond depends on its purity, crystalline perfection and orientation: hardness is higher for flawless, pure crystals oriented to the [111] direction (along the longest diagonal of the cubic diamond lattice). Nanocrystalline diamond produced through CVD diamond growth can have a hardness ranging from 30% to 75% of that of single crystal diamond, and the hardness can be controlled for specific applications. Some synthetic single-crystal diamonds and HPHT nanocrystalline diamonds (see hyperdiamond) are harder than any known natural diamond.

 Tungsten carbide:
Tungsten carbide is approximately two times stiffer than steel, with a Young's modulus of approximately 550 GPa

Sintered tungsten carbide cutting tools are very abrasion resistant and can also withstand higher temperatures than standard high speed steel tools. Carbide cutting surfaces are often used for machining through materials such as carbon steel or stainless steel, as well as in situations where other tools would wear away, such as highquantity production runs. Because carbide tools maintain a sharp cutting edge better than other tools, they generally produce a better finish on parts, and their temperature resistance allows faster machining. The material is usually called cemented carbide, hard metal or tungstencarbide cobalt: it is a metal matrix composite where tungsten carbide particles are the aggregate and metallic cobalt serves as the matrix. Manufacturers use tungsten carbide as the main material in some highspeed drill bits, as it can resist high temperatures and is extremely hard.

 Cemented carbide:

Cemented carbide, also called widia, is a hard material used in machining tough materials such as carbon steel or stainless steel, as well as in situations where other tools would wear away, such as highquantity production runs. Most of the time, carbide will leave a better finish on the part, and allow faster machining. Carbide tools can also withstand higher temperatures than standard high speed steel tools.

Machines:
The high-production Dual Chain draw benches are designed to draw tubing through dies and over internal

dies, as required to reduce diameter and wall as well as improve finish

Bench draw machine

And yield strengths of the tubing.

 Dry Drawing Machine

Dry Drawing Machine for steel wire & rope industry 1.Dia. of Block: 200-1200mm 2.Block number: 2-12Nos 3.Inlet wire: 4~14mm Straight Line Wire Drawing Machine are suitable for the high & low carbon steel wire below size of 14mm, with Siemens PLC & inverter control system to assure high speed & stable operation. Low Carbon steel wire product used Figure 3: wire copper plating machine in mesh net, steel fiber, nail & staple making, construction, agriculture & furniture field, etc. And other steel wire product used in prestressing wire, PC wire, spring, steel rope wire, steel cord & Bead wire for tyre

Figure 4: Electro galvanizing machine

Contents
INTRODUCTION............................................................................................................................................. 2 Wire drawing:............................................................................................................................................3 Products: ...............................................................................................................................................4 Drawing force: ..................................................................................................................................... 5 Die design: .................................................................................................................................................... 6 Die life and die wear: ....................................................................................................................................7 Die material:.................................................................................................................................................. 9 Industrial diamond: ............................................................................................................................... 9 Tungsten carbide: ................................................................................................................................10 Cemented carbide: ..............................................................................................................................11

Machines: ....................................................................................................................................................12