During wire drawing processes a critical parameter is the micro-hardness distribution imposed. The present numerical and experimental investigation focused on the effects of and interdependence between processing parameters such as die angle, bearing length, lubrication, and draw speed during wire drawing. The micro-hardness distribution imparted by the drawing process was selected as the focal product quality attribute. The goal of the study was to evaluate the ability to create desired hardness levels in a drawn wire product. The numerical component of the study was performed using DEFORM-2D™, a commercially available metal forming software package based on the finite element method. In addition, experimental verifications of the software predictions were completed wherever possible. Full factorial designs of the processing parameters were studied, and it was found that the final hardness distribution was primarily affected by the die angle. Interactions between the four processing parameters were negligible. Based upon this finding, it was concluded that strength and hardness variations inherent to stock wire could be detected and minimized during wire drawing through the appropriate science-based selection of die angle. This could dramatically enhance the consistency of the wide range of common metal products that are manufactured from wire stock.
Two different heats of heading quality 302 stainless steel wire were drawn through three different conical die geometries. The microstructural response of the material was investigated via measurement of microhardness and grain size. The measurements across the transverse and longitudinal axes of the wires were then compared with strain measurements predicted through finite element modeling. Accuracy of the different measurements are compared, and an optimum ''watchdog'' parameter for the verification of the modeling results is proposed.
Weld quality in Resistance Spot Welding is directly influenced by competing process transients. These transients are caused by electrical, thermal, mechanical and metallurgical interactions. Controlling the process variables such as current, clamping force and welding time requires good understanding of how these interactions evolve during the welding process. In order to better understand the process and to control the final product quality in an efficient manner, a comprehensive process model that can account for these multi physics phenomena is required. This paper describes a general methodology that is used in the commercial Finite Element code, DEFORM TM to model the resistance spot welding process incorporating all the basic mechanics of deformation, thermal, electrical and microstructure models. Modeling process is illustrated using an example from the published literature. A detailed discussion of the process mechanics based on the observed transients during various stages of the spot welding process are presented. Model predictions on the thermal, mechanical and evolving microstructural phases during the welding process are also discussed.
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