In this work, a drawing processed was simulated to calculate forces and the resulting residual stresses in the material. The calculated residual stresses were compared with experimentally measured residual stresses by the Neutron Diffraction Method. The modeled process was the Wire Drawing. The necessary parameters to model the process were taken from an industrial currently used process. Rods of an AISI 1045 steel with nominal diameters of 21.46 mm were reduced to 20.25 mm by drawing with an drawing angle of 15°. Compression tests were used to determinate flow curves of the real material an used in the simulation models. The possibility to estimate drawing forces by numerical simulation was evaluated by comparing simulated results with values from empirical equations given by the literature. The results have shown a sufficient accuracy for the calculation of forces, but the comparison of residual stresses has shown differences to the experimentally determined ones that can be minimized by the consideration of high strain rates in the compression tests, anisotropy of the material and kinematic hardening.
Influência do ângulo e do coeficiente de atrito nas tensões residuais geradas na trefilação de barras de aço AISI 1045 Die angle and friction coefficient influence on residual stresses generated in wire drawing in bars of AISI 1045 steel
ResumoBarras trefiladas podem não apresentar o perfil desejado pelos seus fabricantes após o processo de produção, por isso, este trabalho tem por objetivo avaliar diferentes geometrias de ferramentas, mais precisamente, o ângulo de entrada e região de calibração (Hc) da mesma. Para modelamento numérico do processo, foi utilizado o software Deform TM , que possibilitou este estudo, com simulações da influência da ferramenta no perfil de tensões residuais dos produtos (barras de aço AISI1045). Foram analisados os diferentes comportamentos do material para processos com fieiras de ângulos de 15° e 20°, com foco nas variações de tensões residuais visando investigar o produto final da trefilação. Em uma das principais comparações entre as fieiras anteriormente mencionadas, observou-se uma diferença de tensões residuais de aproximadamente 206MPa no centro das barras trefiladas, resultado que somado a distribuições assimétricas de tensões em relação ao ponto central de determinado corte da barra, podem ocasionar o seu empenamento. Palavras-chave: Simulação computacional; Trefilação; Fieira.
ANALYSIS OF THE INFLUENCE OF THE DRAWING DIE GEOMETRY BY MEANS OF COMPUTER SIMULATION AbstractDrawn bars may not present the required profile for their manufacturers after its production process. For this reason this paper has as objective to study different die geometries, more precisely the drawing angle and bearing zone (Hc) of the tool. For the numeric model process was used the Deform TM software which has enabled this study with die influence simulations for the products residual stress (AISI1045 still bars). Were analyzed the different material behavior in process with die angle of 15 and 20 degrees. The focus is on variations of residual stresses and to investigate the changes in the final product. In one of the main comparison between the drawing dies before said, was observed a difference of residual stress with nearly 206MPa in the drawing bar center, result which added with asymmetric stress distributions, in relation to the determined bar central point, may cause its bowing.
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