Journal of Mechanical Science and Technology 26 (9) (2012) 2903~2911

www.springerlink.com/content/1738-494x
DOI 10.1007/s12206-012-0711-1

Analysis of wire-drawing process with friction and thermal conditions obtained by

inverse engineering
Changsun Moon and Naksoo Kim*
Department of Mechanical Engineering, Sogang University, 121-742, Korea

(Manuscript Received September 30, 2011; Revised March 7, 2012; Accepted April 13, 2012)

----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Abstract

In cold wire-drawing process, which is performed at room temperature, heat is generated because of plastic work and friction at the
workpiece-die interface. Temperature distribution in both the workpiece and the die affects thermal expansion, deformation pattern, and
elastic recovery. These effects produce the final dimension of the drawn products. We propose inverse engineering procedures to deter-
mine friction and thermal conditions by comparing simple measurements with the computational results of the drawing power and the
temperature changes of the die. The conditions were then used to simulate numerically the deformation behavior of the wire and the tem-
perature distribution in the die. The thermal effects on the quality of drawn products were investigated based on the prediction of the final
dimensions of the products. Therefore, thermal effects should not be ignored even in cold wire-drawing process because reasonable nu-
merical results were acquired in comparing the experiments.

Keywords: Wire-drawing; Dimensional change; Quality of drawn product; Friction condition; Thermal condition; Inverse engineering
----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

the acceleration of the wire as it passes through the die [2].

1. Introduction
Lucca and Wright discussed the assumptions that may be con-
In wire-drawing process, the diameter of a wire is reduced sidered in predicting the increase in temperature due to fric-
by pulling the wire through a conical die. Major variables in tional heating in the wire drawing [3]. They mentioned that
drawing process include reduction ratio, die angle, friction at the coefficient of friction at the wire-die- interface is constant
the interface of the wire and the die, and drawing velocity. and independent of pressure and temperature. They also re-
Plastic deformation of the wire and heat generation due to fric- ported that frictional heating is concentrated on the interface
tion between the wire and the die increase the temperature of between the wire and the die, which results in severe tempera-
the die, which results in thermal expansion. The trend of using ture gradient.
high speeds in the wire-drawing process to meet the demands Many process variables, besides heat from drawing process,
of increasing productivity results in the difficulty of manufac- affect the quality of drawn products. U.S. Dixit and P.M. Dixit
turing drawn products with a designated diameter because of studied the effect of process variables, such as reduction ratio,
the uncontrolled thermal expansion of the die. The magnitude semi-angle of the die, and coefficient of friction of the interface,
and the distribution of temperature in the wire and the die de- on the quality of the drawn product [4]. Castro et al. analyzed
pend on initial temperatures, heat generation due to plastic the effect of the dies semi-angle on the mechanical properties
deformation in the wire, friction at the wire-die- interface as of annealed copper bars [5]. To identify the effect of inclusion,
well as heat transfer between the deforming wire, the die, and Norasethasopon and Yoshida studied the effect of inclusion
the surrounding environment, such as lubricants and the air. size and parameters of the aspect ratio of drawing stress, the
Heat generation in wire-drawing process was first studied maximum hydrostatic stress, and the maximum die pressure
by Siebel and Kobitzsch [1]. In their analysis, the plastic de- during the single-filament copper wire-drawing process [6].
formation work per unit volume was simply added to fric- Vega et al. measured the temperature and the drawing force
tional work, and both were converted to heat. Snidle further by changing the drawing velocity, while the drawing force
expanded the theory of Siebel and Kobitzsch by considering was measured by using a wire-rolling gauge behind the die [7].
Furthermore, they installed a thermocouple to measure the
*
Corresponding author. Tel.: +82 2 705 8635, Fax.: +82 2 712 0799 temperature increase in the deformation zone. They confirmed
E-mail address: nskim@sogang.ac.kr

Recommended by Editor Sung-Lim Ko
from their experiment that the temperature and the drawing
KSME & Springer 2012 force were dependent on interface conditions. Leu evaluated
2904 C. Moon and N. Kim / Journal of Mechanical Science and Technology 26 (9) (2012) 2903~2911

friction coefficient by using a model of plastic hemispherical

contact against a rigid flat [8]. To describe the deformed
hemispherical shape, he utilized the fractional profile of an
ellipsoid and simultaneously defined the contact area ratio. To
investigate dependence of the shear friction factor on d/t and
L/1000, Ajiboye et al. conducted an ANOVA and compared
two regression models [9]. Based on the statistical results of
the investigation, the model that used d/t as the independent
variable was valid in successfully predicting the shear friction
factor at the punch interface compared with other models that
used that use L/1000 kN. Obi and Oyinlola investigated fatty-
based oils for metal-forming applications [10]. By measuring
the coefficient of friction, grading these oils according to their
lubricating capabilities becomes possible since one of the
qualities of a good lubricant is the ability to reduce friction
and applied to apply load. Luksza et al. focused on the defor-
mation behavior of the wires while conducting experiments on (a)
both the single- and the multi-pass- drawing processes [11].
Corra et al. analyzed the influence of structural features of
the drawn wire on the strain-softening phenomenon [12].
They also conducted micro-structural and X-ray diffraction
analyses to evaluate the drawing stress. Son et al. investigated
the deformation behavior of surface defects with a notch shape
on the wire in a multi-pass hot-rolling process by using a finite
element code called CAMProll [13].
Residual stress on the drawn products has a significant ef- (b)
fect on post-deformation. verstam examined the effect of
Fig. 1. (a) Schematic outline of the model used in the experiments and
bearing geometry of the die on residual stress of the drawn
in FEA; (b) parameters that define the die geometry.
wire [14]. Atienza et al. studied the influence of residual
stresses on environmentally assisted cracking of the wire [15].
Carpinteri et al. investigated the effect of fatigue crack propa- ture and products in the wire-drawing process primarily ad-
gation in a metallic-cracked round bar with a V-shaped dressed the increase in temperature in the die because of de-
circumferential notch on residual stresses [16]. Ripoll et al. formation and generated frictional heating as the wire passes
proposed a reduction of circumferential residual stresses dur- through the die. Related literature also discussed the increase
ing wire drawing using advanced die geometry and perform- in temperature due to process variables such as reduction ratio,
ing bending operations under favorable conditions [17]. El- reduction angle, and drawing velocity. In contrast, no informa-
Domiaty and Kassab studied ways to minimize the energy tion is available about FEA procedures for the conduct of
required for the wire-drawing process [18]. To minimize the practical analysis of temperature distribution in the die, which
drawing force, they determined the reduction ratio and the considers friction condition and heat transfer to the surround-
coefficient of friction between the wire and the die. Shinohara ings, such as in the air. This study proposes a procedure that
and Yoshida carried out a multi-pass drawing of stainless steel utilizes measured drawing power and temperature curves of
wire with an artificial crack, and then investigated the growth the die at a certain position in determining friction and thermal
and the disappearance of the crack from both sides through conditions by inverse engineering. The obtained process vari-
experiments and the finite element analysis (FEA) [19]. Ko- ables will be used to simulate numerically the deformation
mori presented a new equation that denoted a change in the behavior of the workpiece and the die temperature distribution
void volume fraction such fracture defects in high-carbon- by FEA. Hence, the investigation on the effect of temperature
steel wires can be investigated [20]. McAllen and Pheland distribution on the final dimensions or quality of the drawn
analyzed the ductile fracture initiation and propagation by products can consequently proceed.
central bursting in 2011 Aluminium wire, while the damage
incurred before the ductile fracture was studied by using a 2. Drawing conditions
modified damage model [21]. 2.1 Process parameters
Since the increase in temperature in the die affects the lubri-
cating condition, the equipment life, and the quality of the The dimensions of tooling that is used in wire-drawing
drawn products, the accurate prediction of the temperature process are schematically illustrated in Fig. 1. As shown in Fig.
distribution in the die is crucial. Previous studies on tempera- 1(a), the inlet and the outlet diameters of the die are D0 =
 C. Moon and N. Kim / Journal of Mechanical Science and Technology 26 (9) (2012) 2903~2911
Table 1. Thermal properties of selected materials.
Material S45CS WC AISI-H-13
Heat conductivity (W / mK ) 51.9 59
Heat capacity ( J / mmK ) 0.486 15
Thermal expansion coefficient
1.397e-05 5e-05 1.17e-05
(1/ K )
Fig. 2. True stress-strain curve of S45CS.
10 mm and D f = 8.1 mm, respectively. The height of the die
and case assembly (h) is 30.95 mm and the width of the case
(w) is 35 mm. The wire, the die, and the case were made of
S45CS, WC, and AISI-H-13, respectively. Fig. 1(b) shows the
die geometry. The parameters that defined the die geometry
include the back relief angle, the reduction angle, the entrance
angle, and the bearing length.
Fig. 2 exhibits the flow stress of S45CS at 20C and 200C.
Table 1 displays the thermal properties of the selected materi-
als that are used as workpieces or tools in the wire-drawing
process. The drawing velocity was 916 mm/s, the initial tem-
perature of the tools was 30C, and the environmental tem-
perature was 20C.
2.2 Experiments
In the wire-drawing process, wires were pulled out through
a die at constant drawing velocity. Friction acted on the inter-
face between the wire and the die, and disrupted the relative
motion of the wire. The difference in the drawing force de-
pended on the magnitude of the friction. To estimate friction
stress, we used a simple friction model with a constant friction
factor. The friction stress in the actual process can be inversely
determined by measuring the drawing power using the draw-
ing equipment [22]. The drawing power was measured by
using a wire-rolling gauge behind the die. The drawing pow-
ers were measured by using several combinations of the di-
ameter of the wires, the inner diameter of the die, and the re-
duction ratio. Fig. 3(a) contains the schematic diagram that
illustrates the measurement of temperature on the die in the
wire-drawing process. A thermocouple was installed to meas-
ure the die temperature at a certain position. For approxi-
mately 4000 sec, the wire was pulled through a die and the
temperature at a specific position was recorded. Fig. 3(b)
2905
24
2.7
(a)
(b)
Fig. 3. Measurement of the die temperature during the wire-drawing
process: (a) experimental setup; (b) temperature transition at channel 1.
shows the temperature curve measured for 4000 sec. The tem-
perature reached as high as 107.4 C during the wire-drawing
process.
3. Inverse engineering for determination of experi-
mental conditions
Friction conditions can be determined by comparing the
drawing power obtained from the experiments with a calcu-
lated drawing power using FEA with an assigned friction fac-
tor. Similar methods were employed to determine thermal
conditions by comparing the measured temperature curves of
the die with those of the calculated ones that will be described
later. In FEA computations, we evaluated the heat transfer
coefficients for all parts. We used DEFORM 2D (ver. 9.0,
Scientific Forming Technologies Co., USA) for the wire-
drawing process simulation. The die and the case were as-
sumed elastic, while the wires exhibited elastic-plastic defor-
mation behavior. The drawing analysis was conducted based
on the two-dimensional axisymmetric model.
3.1 Friction conditions
Pressure and a sliding motion at the interface between the
wire and the die resulted in wire deformation, and generated
frictional heating that led to an increase in temperature. The
elevated temperature affected the drawn products. Friction,
while by itself influenced the wire deformation pattern, and
served as another important factor that affected temperature.
2906 C. Moon and N. Kim / Journal of Mechanical Science and Technology 26 (9) (2012) 2903~2911

Table 2. Friction factors calculated by Eq. (3) and a comparison of the drawing forces between the experiments and FEA (m f = 0.1765).

D0 Df V P (kw) F(N) mf F(N) Differences (%)

CASE
(mm) (mm) (mm/s) (Experiment) (Experiment) Eq. (3) (FEA) (Experiment vs FEA)
CASE 1 10 8.1 25565 27904 0.086 28298 1.3
CASE 2 12 10 916 35214 38437 0.093 38309 0.3
CASE 3 14 13 30563 33366 0.091 32725 1.9
Average 1.2

(a) (b)

Fig. 4. (a) Temperature distribution of die after 2.25 sec; (b) temperature curves of nodes 1, 2, and 3.

If a wire is pulled through a die at a constant velocity in the Eerror = 43.947 m f 2 15.526m f + 1.387 (4)
wire-drawing process, the pulling force varies depending on
the lubrication status. Drawing power, Pdrawing, drawing force The friction factor can be determined as a value that is clos-
Fdrawing, and drawing stress d can be calculated using Eqs. est to the drawing force obtained from the experiments. The
(1)-(3), respectively [23]. value minimizing the difference in the equation above was
m f = 0.1765 , which gives a good correlation among the three
cases but the value is twice as much as the value obtained
Pdrawing = Fdrawing Vdrawing velocity (1)
using Eq. (3). Since Eq. (3) does not consider the decrease in
Fdrawing = d Af (2) flow stress due to temperature rise, m f is underestimated. In
m R0 2 the cold wire-drawing process, thermal effect should therefore
d = Y0 2(1 + f
) ln + tan (3) not be ignored.
sin 2 Rf 3

3.2 Thermal conditions

If we measure the drawing power Pdrawing at constant
Vdrawing velocity , the drawing stress d can be easily estimated
using Eqs. (1) and (2). Ideally, the friction factor m is cal-
culated by Eq. (3). However, since Eq. (3) does not consider
excessive or redundant deformation and ignores temperature
effects on yield stress Y0 , the estimated value of friction fac-
tor using Eq. (3) is expected to have a discrepancy with the
actual value.
We measured the drawing powers for three cases with the
same materials and the same conditions of lubrication, except
geometrical dimensions such as the diameter of the wire, the
inner diameter of the die, and the reduction ratio (Table 2).
We assumed that the same friction condition applied to all
three cases, which resulted in one value of friction factor m .
The difference between experimental and calculated draw-
ing forces can be expressed as a quadratic function of m as
expressed in Eq. (4). Multiple simulations of FEA with differ-
ent values of m near the minimum, obtained this difference.
f
3.2.1 Temperature at the wire-die interface
f
Heat is generated by plastic deformation and friction in the
wire-die interface. Then, the heat is transferred to the die and
to the environment. The temperature at the wire-die interface
becomes constant within a short time period. In other words, a
thermally steady state at the interface is attained in the wire-
drawing process.
The calculated friction factor (m f = 0.1765) was used to
obtain the temperature transition curve at the interface by car-
rying out a FEA simulation for deformation and to determine
the temperature of the workpiece and the die. Fig. 4(a) shows
the temperature distribution in the die and three specific points
f
at the interface. Fig. 4(b) shows the increase in temperature at
three points. Temperature verifiably becomes constant in less
f
than 2.5 sec.
The temperature distribution along the wire-die interface,
after attaining a thermally steady state condition, was used as a
 C. Moon and N. Kim / Journal of Mechanical Science and Technology 26 (9) (2012) 2903~2911 2907

Fig. 5. Model of heat transfer on the surface during the FEA simulation in wire-drawing process.

(a) (b)

(c)

Fig. 6. Two models: (a) one-object model; (b) two-object model, and the effects of interfacial heat transfer coefficient; (c) temperature curves with
different hlub values.

boundary condition of temperature in inverse engineering to
identify heat transfer coefficients at the other boundary.
3.2.2 Boundary conditions for wire-drawing model
For the relevant simulation of heat transfer in wire-drawing
process, appropriate heat transfer coefficient at each boundary
of tool fragment needs is necessary to be applied, as shown in
Fig. 5.
The interface of the wire and the die a-b in comparison with
the interface of the die and case c-g-f has the same interface
heat transfer coefficient defined as hlub . This assumption is
reasonable considering that the interfaces are closely influenced
by high pressure. Heat transfer coefficient at the case boundary
d-e to the support is defined as hlub1 . b-c-d and e-f-a of the case
that comes in contact with the air comprise the convective heat
transfer coefficient h1 . The support of the case is assumed to
have the same temperature as the air in the environment.
3.2.3 Determination of hlub
The convective heat transfer coefficient ( h1 ) is between
0.02-0.025 kW / m 2 K when in contact with air of 1 atmos-
phere pressure, with the assumed value to be 0.025 kW / m 2 K
[24, 25].
As shown in Fig. 6, a simple method was used to determine
2908 C. Moon and N. Kim / Journal of Mechanical Science and Technology 26 (9) (2012) 2903~2911

Table 3. Levels of design variables.

Design variables Initial value Level 0 Level 1 Level 2

hlub1 (kW / m 2 K ) 0.101 0.100 0.101 0.102
h1 (kW / m 2 K ) 0.025 0.020 0.025 0.030

Table 4. Orthogonal arrays for the optimization of the area.

Object
Exp. hlub1 h1
function Error (%)
No. (kW / m 2 K ) (kW / m 2 K )
area (mm 2 )
1 0.100 0.020 393,927 3.40
2 0.100 0.025 392,099 2.92
Fig. 7. Temperature transition curves obtained by experiment and 3 0.100 0.030 390,296 2.45
computation. 4 0.101 0.020 389,404 2.22
5 0.101 0.025 382,639 0.44
6 0.101 0.030 380,947 0.0007
hlub . Fig. 6(a) is a one-object model using two different mate- 7 0.102 0.020 379,276 0.43
rials, whereas Fig. 6(b) is a two-object model using two dif- 8 0.102 0.025 378,449 0.65
9 0.102 0.030 372,160 2.30
ferent materials. As shown in 6(a), the model was heated at a
certain temperature, and the temperature at a certain position
was measured. The model in Fig. 6(b) was heated at the same
temperature as the model in Fig. 6(a), but hlub was changed
to compare the temperature curve of the models in Fig. 6(a)
and 6(b). As illustrated in Fig. 6(c), temperature curves coin-
cided with that of the one-object model for hlub of more than
10 kW / m 2 K . Thus, hlub of 10 kW / m 2 K can be reasonably (a)
assumed as applicable.

3.2.4 Determination of hlub1 and h1

To obtain the appropriate values of hlub1 and h1 , the de-
sign of the experiments was applied to the function of the area
difference under the temperature transition curves between the
measurement and the computation, as shown in Fig. 7. Based
on the study of Yen et al., initial assumptions of hlub1 and h1
were set as 0.1 and 0.025 kW / m 2 K , respectively [24]. The
constraint condition of hlub1 was set from 0.1 to
0.102 kW / m 2 K , with the relative error set as less than 4% in
the range. Table 3 shows the initial value and the level of the
design parameters. The calculation results using FEA are
summarized in Table 4. The response surface method was
based on orthogonal arrays to obtain an objective function that
comprises the design parameters. The object function for op-
timization is expressed in Eq. (5).
c = 1,142,818hlub1
2
+ 18,480h12 235,274 hlub1
(5)
15,214h1 + 141,057hlub1h1 + 12,118
BFGS was used to minimize the objective function. The
method is an optimization methodology that directly updates a
Hessian matrix. As a result, the design parameter hlub1 was
determined as 0.1011 kW / m 2 K , while h1 was
0.0246 kW / m 2 K . The calculated parameters were compared
with the FEA results. hlub1 and h1 can be considered as
appropriate since the comparison revealed less than 0.05%
margin of error.
(b)
Fig. 8. Measurement method for dimensional change through: (a) the
experiment; (b) FEA.
4. Dimensional changes of the drawn wire
4.1 Definition of dimensional change and numerical steady
state
As the wire passes through the drawing die, the final dimen-
sion of the drawn wire deviates from the designated dimen-
sion or the inner diameter of the die. The die wear is ignored
due to elastic deformation of the die, elastic recovery of the
workpiece, and thermal expansion of both the die and the
workpiece. The dimensional difference between the drawn
wire and the designated dimension is defined as the dimen-
sional change.
In the experiment, dimensional change is measured by sub-
tracting the inner diameter of the die from the average diame-
ter of the drawn wire. Fig. 8(a) demonstrates that the average
diameter was calculated after measuring diameters in the sam-
ple at three points. The size of the population was 50 wire
samples, with 3 m cut off after drawing. The standard devia-
tion was 0.05%.
 C. Moon and N. Kim / Journal of Mechanical Science and Technology 26 (9) (2012) 2903~2911
Table 5. Comparison of dimensional changes.
D0 Df L (Deviation from measurement, %)
CASE
(mm) (mm) (mm) (mm)
CASE 1-1 0 3.645
CASE 1-2 10 8.1 2.4 3.645
CASE 1-3 2.4 5.265
Fig. 9. Drawing force in the steady state of wire-drawing process
(FEA).
The calculation results of FEA for the wire-drawing process
revealed that the nodes, which represent the surface of the
wires, did not have the same dimensions as shown in Fig. 8(b).
Therefore, the numerical average diameter of the drawn wire
must be defined. The calculated diameter is defined as the
volumetric average of the diameter with a certain number,
such as 50 nodes, on the wire surface. The calculated diameter
is meaningful for the comparison with experiments since the
level of the computed deviation was less than 0.1%.
In the wire-drawing process, the deformation pattern in the
wire achieved a steady state after the wire was drawn to a
certain length. In the calculation, the steady state was attained
after the drawing force became constant, as shown in Fig. 9.
4.2 Thermal effect on dimensional change
The effects of thermal deformation and elastic recovery of the
workpiece and the die on the final dimensional accuracy were
investigated in other metal-forming processes [26, 27]. In this
study, friction and thermal conditions obtained from inverse
engineering were used to simulate numerically the deformation
and the occurrence of heat transfer during cold wire-drawing
process using FEA. The thermal effect on the final dimension of
the drawn products is intended to be examined.
The inner diameter of the die with thermal effect was less
than that of the isothermal case, which resulted in the reduced
dimensional change of the wire by 0.003-0.004 mm for three
cases of die geometry, as summarized in Table 5. Table 5 also
shows the dimensional changes of the drawn wire with three
cases of die geometry measured in the experiments, and com-
2909
Dimensional changes (mm),
() () FEA with thermal Isothermal
Experiment
effect FEA
0 0.009 0.008(11%) 0.011(25%)
12 6 0.013 0.011(15%) 0.015(18%)
6 0.010 0.009(10%) 0.012(22%)
putations with and without thermal effect, respectively. The
computation results considering thermal effect is twice closer
than those calculations without thermal effect.
5. Conclusions
Inverse engineering procedures to determine friction and
thermal conditions in wire-drawing process are proposed by
measuring the drawing force and the transition curve of tem-
perature at a certain position of the die assembly. The analysis
tool used in inverse engineering was a commercial FEA pro-
gram based on elastic-plastic deformation and coupled heat
transfer algorithm. Comparison between the calculated results
and the obtained measurements in the experiments, the fol-
lowing conclusions are derived:
(1) With the identified friction factor via inverse engineer-
ing, the calculated drawing forces exhibited a strong correla-
tion. In addition, we obtained close temperature curves for the
experiments with known thermal conditions or heat transfer
coefficients. Therefore, methodology of inverse engineering
reasonably determines friction and thermal conditions. More-
over, since the measurements include the drawing force and
the monitoring temperature at a convenient position, the
method is simple and useful to be applied in actual conditions.
(2) The calculated dimensional changes that considered the
thermal effect were closer to the measurements than those that
did not consider the thermal effect. Thus, simulation of cold
wire-drawing process with FEA should always consider the
thermal effect. Correct values of friction and thermal condi-
tions should be used to yield reliable calculation results.
(3) The calculated dimensional changes reflect thermal and
elastic deformation of the die and elastic recovery of the
workpiece. Since the FEA calculation results conformed to the
experiments, we can utilize FEA to identify the contribution
of each source to dimensional change. We may control di-
mensional changes by varying process parameters, which
results in the enhancement of quality of the drawn wire.
Acknowledgements
We would like to thank the members of the instrumentation
and control team in Dongbu Steel Co. Ltd. for their supporting
in this research. This work was also supported by the National
Research Foundation of Korea (NRF) with the grant provided
by the Korean government (MEST) (No. 2010-0023152) and
2910 C. Moon and N. Kim / Journal of Mechanical Science and Technology 26 (9) (2012) 2903~2911

by the Sogang University Research Program with Grant No. 115-118.

201010042.01. [10] A. I. Obi and A. K. Oyinlola, Frictional characteristics of
fatty-based oils in wire drawing, Wear (194) (1996) 30-37.
[11] J. Luksza, J. Majta, M. Burdek and M. Ruminski, Model-
Nomenclature------------------------------------------------------------------------
ling and measurements of mechanical behaviour in multi-
d : Drawing stress pass drawing process, Journal of Materials Processing
Y0 : Yield stress Technology (80-81) (1998) 398-405.
mf : Friction factor [12] E. C. S. Corra, M. T. P. Aguilar and P. R. Cetlin, The
R0 : Wire radius before drawing influence of cyclic straining on the work hardening behavior
Rf : Wire radius after drawing of AISI 304 stainless steel bars in multiple-pass drawing,
Re : Reduction ratio Materials Chemistry and Physics (106) (2007) 95-101.
D0 : Wire diameter before drawing [13] I. H. Son, J. D. Lee, S. Choi, D. L. Lee and Y. T. Im, De-
Df : Wire diameter after drawing formation behavior of the surface defects of low carbon steel
Af : Wire area after drawing in wire rod rolling, Journal of Materials Processing Tech-
F : Drawing force nology (201) (2008) 91-96.
P : Power [14] H. verstam, The influence of bearing geometry on the
V : Drawing velocity residual stress state in cold drawn wire analysed by the FEM,
Eerror : Average error Journal of Materials Processing Technology (171) (2006)
h1 : Convective heat transfer coefficient 446-450.
hlub : Interface heat transfer coefficient between wire and [15] J. M. Atienza, M. Elices, J. R. Hervias, L. Caballero and A.
dies Valiente, Residual stress and durability in cold drawn eutec-
hlub1 : Interface heat transfer coefficient between dies and toid steel wires, Metals and materials International (13)
case (2007) 139-143.
[16] A. Carpinteri, R. Brighenti and S. Vantadori, Influence of
the cold-drawing process on fatigue crack growth of a V-
References
notched round bar, International Journal of Fatigue (32)
[1] E. Siebel and R. Kobitzsch, Die Erwarmung des Ziehgutes (2010) 1136-1145.
beim Drahtziehen. Stahl U. Eisen (63) (1943) 110-113. [17] M. R. Ripoll, S. M. Weygand and H. Riedel, Reduction of
[2] R. W. Snidle, Contribution on the theory of frictional heating tensile residual stresses during the drawing process of tung-
and the distribution of temperature in wire and strip drawing, sten wires, Materials Science and Engineering: A (527)
Wear (44) (1977) 279-294. (2010) 3064-3072.
[3] D. A. Lucca and R. N. Wright, Heating effect in the drawing [18] A. El-Domiaty and S. Z. Kassab, Temperature rise in wire-
of wire and strip under hydrodynamic lubrication conditions, drawing, Journal of Materials Processing Technology (83)
Journal of Manufacturing Science and Engineering (188) (1998) 72-83.
(1996) 628-638. [19] T. Shinohara and K. Yoshida, Deformation analysis of
[4] U. S. Dixit and P. M. Dixit, An analysis of the steady-state surface flaws in stainless steel wire drawing, Journal of Ma-
wire drawing of strain-hardening materials, Journal of Mate- terials Processing Technology (162-163) (2005) 579-584.
rials Processing Technology (47) (1995) 201-229. [20] K. Komori, Evolution of void volume fraction for simulat-
[5] A. L. R. de Castro, H. B. Campos and P. R. Cetlin, Influence ing inner fracture defects related to in drawing of high-
of die semi-angle on mechanical properties of single and carbon steel wire rods, Theoretical and Applied Fracture
multiple pass drawn copper, Journal of Materials Processing Mechanics (50) (2008) 157-166.
Technology (60) (1996) 179-182. [21] P. J. McAllen and P. Phelan, Numerical analysis of axi-
[6] S. Norasethasopon and K. Yoshida, Influences of inclusion symmetric wire drawing by means of a coupled damage
shape and size in drawing of copper shaped-wire, Journal of model, Journal of Materials Processing Technology (183)
Materials Processing Technology (172) (2006) 400-406. (2007) 210-218.
[7] G. Vega, A. Haddi and A. Imad, Temperature effects on wire- [22] L. Lazzarotto, L. Dubar, A. Dubois, P. Ravassard and J.
drawing process: experimental investigation, International Oudin, Identification of Coulomb's friction coefficient in real
Journal of Material Forming (2) (2009) Suppl 1:229-232. contact conditions applied to a wire drawing process, Wear
[8] D. K. Leu, Evaluation of friction coefficient using simplified (211) (1997) 54-63.
deformation model of plastic hemispherical contact with a [23] G. E. Dieter, Mechanical metallurgy, SI Metric Ed.
rigid flat, Journal of Mechanical Science and Technology McGraw-Hill Book, UK (1988).
(24) (2010) 1697-1707. [24] Y. C. Yen, Sohner, B. Lilly and T. Altan, Estimation of tool
[9] J. S. Ajiboye, K. H. Jung and Y. T. Im, Sensitivity study of wear in orthogonal cutting using the finite element analysis,
frictional behavior by dimensional analysis in cold forging, Journal of Materials Processing Technology (146) (2004) 82-91.
Journal of Mechanical Science and Technology (24) (2010) [25] P. P. Incropera, D. P. Dewitt, T. L. Bergman and A. S.
 C. Moon and N. Kim / Journal of Mechanical Science and Technology 26 (9) (2012) 2903~2911 2911

Lavine, Introduction to heat transfer, fifth Ed. John Wiley & Changsun Moon is currently working for
Sons, USA (2007). LG Electronics after obtaining his
[26] H. Long and R. Balendra, FE simulation of the influence of Masters degree in the Department of
thermal and elastic effects on the accuracy of cold-extruded Mechanical Engineering, Sogang
components, Journal of Materials Processing Technology University. He received his B.S. degree
(84) (1998) 247-260. from the Department of Mechanical
[27] Y. S. Lee, J. H. Lee, Y. N. Kwon and T. Ishikawa, Analysis Engineering, Incheon University, Incheon,
of the elastic characteristics at die and work-piece to improve South Korea in 2009. His research
the dimensional accuracy for cold forged part, Journal of Ma- interests are in the areas of optimal design of forming process
terials Processing Technology (153-154) (2004) 1081-1088. and metal-forming plasticity.