Numerical and experimental investigation of trapezoidal wire cold drawing through a series of shaped dies

Abstract

Trapezoidal-shaped aluminium wires are in demand for the production of the aluminium conductor steel supported/trapezoidal wire (ACSS/TW) conductor. In this work, it is proposed to manufacture such wires by a multipass cold drawing process using a series of shaped dies with an initial aluminium wire, which has an outer diameter of 9.5 mm. The ruled surface partition method is introduced to design the intermediate die profile of the multi-pass cold drawing. It is possible to design the intermediate die profile efficiently according to the suggested reduction ratio and save time regardless of the geometric complexity. A multi-pass drawing machine and a universal testing machine are both used to investigate the drawing process of trapezoidal-shaped aluminium wires. Wire break occurs when a five-pass drawing process is introduced. The six-pass drawing process is suggested to apply in a consideration of die cost. The final production has a good surface finish and a dimensional accuracy, suitable for the production of the ACSS/TW conductor. A finite element method (FEM) simulation approach is used to analyse stress and drawing force for the proposed process. The Von Mises stress values gradually increases and the drawing force values decrease along the pass schedule. The influence of the number of the drawing passes is numerically assessed. The drawing force value and the Von Mises stress value are lower when the number of dies is larger. The numerical compute drawing force of the six-pass drawing process is compared with the experimental ones. A good agreement between the predicted and experimental results can be observed.

Damage and fracture analyses of wire with V‐shaped microcrack on multi‐pass drawing under back tensions

“…In addition, when the lubrication system is poor, the friction generated in the drawing process becomes an obstacle 21 . Meanwhile, drawing is a continuous process, there are a series of wire reels on the equipment for wire winding 22 . If the drawing speeds mismatch, drawing resistance will be produced on the wire line, 23 and these forces of hinder drawing can be uniformly classified as back tension, which increases the fracture probability of wire 24 .…”

“…21 Meanwhile, drawing is a continuous process, there are a series of wire reels on the equipment for wire winding. 22 If the drawing speeds mismatch, drawing resistance will be produced on the wire line, 23 and these forces of hinder drawing can be uniformly classified as back tension, which increases the fracture probability of wire. 24 Specifically, Cho et al 25 studied the effect of applying back tension on wire breakage by DEFORM-2D.…”

Design of an Intermediate Die for the Multi-Pass Shape Drawing Process

“…Recently, studies using the theoretical approach, experiments, and finite element (FE) simulation of the multi-pass shape drawing process have been actively conducted. Lin et al conducted a study on the numerical and experimental investigation of trapezoidal wire drawing through a series of shape dies [ 4 ]. Oduguwa et al performed research on the optimization of sequential process using genetic algorithms.…”

Effect of Al₂O₃ on Evolution of Oxide Inclusions in Tire Cord Steel during Hot Rolling

“…ing hot rolling, a large number of experimental investigations 5,[16][17][18][19][20][21][22][23][24][25] have been reported. Iwai 26) proved that decreasing the melting point and a more homogeneous chemical composition, increased the degree of deformation of the inclusions.…”