Comparison between Neutron Diffraction measurements and numerical simulation of residual stresses of a Wire-Drawing process

Abstract

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.

Strain Hardening of Carbon Steel During Wire Drawing

“…To calculate the friction coefficient many method had been proposed: for example, Leu 7 used a model of plastic hemispherical contact against a rigid flat and described the deformed shape as the fractional profile of an ellipsoid, while Ajiboyeet al 8 performed an ANOVA analysis comparing two regression models to predict the shear friction factor at the punch interface. Similar models and experimental analyses are presented by Parida et al 17,18 , Souza et al 13 and Andrade et al 14 . The principal aim of this paper is to compare the hypothesis of strain hardening used by Avitzur in the model proposed in 1 for the calculation of the force in wire drawing with the real behaviour of a carbon steel subjected to an industrial drawing process.…”

“…A series of tensile tests for a 0.8 carbon steel wire in various steps of a complete drawing process were carried out, according to the industrial practise 13,14,15 . From the results of the tests it was possible to evaluate deformation and strain hardening effects on the mechanical characteristics of materials 11, 12,16 .…”

Turning parameters effects in residual stresses of AISI 1045 steel

“…A characterization of the material properties, including the resulting residual stresses from the drawing process has been investigated by our group in previous works, so that the initial state of the material for the present work is well known, and these details can be found in. 15–19 ; however, the present evaluation emphasis on turning parameters effects in residual stress states.…”

Analysis of Residual Stress in Steel Bar Processed by Cold Drawing and Straightening

“…15) On the other hand, in most neutron diffraction experiments, d 0 is determined from the stress balance without measuring d 0 experimentally. 9,10,16) Following the work of Holden et al, in which they prepared strain-free standard samples from the objects being measured and successfully measured them with excellent stress balance, 15) samples were prepared in the same manner. The samples fabricated for a second time after each process are shown in Fig.…”