Three Dimensional Finite Element Analysis of Wire Drawing Process

Hassan, Abdul Kareem F.; Hashim, Alyaa S.

doi:10.13189/ujme.2015.030302

Cited by 15 publications

(6 citation statements)

References 4 publications

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“…On the other hand, the bearing length (0.3 d → 0.2 d) was reduced in order to protect the tantalum wire from damage. In the case of ductile metals, there is the possibility of a fault occurring in the wire during drawing due to the drawing force [32]. Therefore, we concluded that shortening the bearing length was advantageous for processing.…”

Section: Resultsmentioning

confidence: 87%

Archives of Metallurgy and Materials

Yu¹,

Choi²,

Sim³

et al. 2019

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Electron beam melting(EBM) is a useful technique to obtain high-purity metal ingots. It is also used for melting refractory metals such as tantalum, which require melting techniques employing a high-energy heat source. Drawing is a method which is used to convert the ingot into a wire shape. The required thickness of the wire is achieved by drawing the ingot from a drawing die with a hole of similar size. This process is used to achieve high purity tantalum springs, which are an essential component of lithography lamp in semiconductor manufacturing process. Moreover, high-purity tantalum is used in other applications such as sputtering targets for semiconductors. Studies related to recycling of tantalum from these components have not been carried out until now. The recycling of tantalum is vital for environmental and economic reasons. In order to obtain high-purity tantalum ingot, in this study impurities contained in the scrap were removed by electron beam melting after pre-treatment using aqua regia. The purity of the ingot was then analyzed to be more than 4N5 (99.995%). Subsequently, drawing was performed using the rod melted by electron beam melting. Owing to continuous drawing, the diameter of the tantalum wire decreased to 0.5 mm from 9 mm. The hardness and oxygen concentration of the tantalum ingot were 149 Hv and less than 300 ppm, respectively, whereas the hardness of the tantalum wire was 232.12 Hv. In conclusion, 4N5 grade tantalum wire was successfully fabricated from tantalum scrap by EBM and drawing techniques. Furthermore, procedure to successfully recycle Tantalum from scraps was established.

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Section: Resultsmentioning

confidence: 87%

Archives of Metallurgy and Materials

Yu¹,

Choi²,

Sim³

et al. 2019

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“…The wire drawing is one of the most process which are widely used in metal forming [1]. It is a process of reducing the wire diameter by drawing it through a conical die [2].…”

Section: Introductionmentioning

confidence: 99%

Analysis of Tool Geometry and Lubrication Conditions Effect on the Forming Load During Wire Drawing Process

Shukur¹,

Khudhir²,

Abbood³

2022

Adv. Sci. Technol. Res. J.

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Most of wire drawing processes is performed at room temperature, causing rising up the heat due to the plastic deformation and the generated friction at the work piece-tool interface. In the poor lubrication conditions, there is a likelihood that both the die and the drawn wire will be damaged. This is because the drawing load is greatly influenced by tool geometry and lubrication conditions, The research work conducted in this paper focuses on drawing of 3 mm diameter Electrolytic tough pitch (ETP) cooper wire to perform 20% reduction in cross sectional area through a conical die. Various parameters have been tested to study the effect of them on the forming load during wire drawing including die angle (4°,6°,8°), bearing distance (1.2, 1.5, 1.8) mm, and lubricant types (Lithium-based greases, soap powder, oil HP). The first phase of this paper is conducted to estimate the coefficient of friction for each lubricant type, Utilizing the experimental values of drawing force in theoretical formals. Based on the estimated values obtained, the second phase was creating numerical model to extend the work to more parameters level as well as check the results validation. The results demonstrated that the drawing force increases with increasing of bearing distance and friction coefficient.

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“…It is so that, by the use of numerical models and methods, Chen and Huang [3] and Majzoobi et al [4] determined that 2β, Hc and the temperature profile into the die have a significant effect on the drawing process, but it is very important to consider the effect of the wire-die contact length (l) which determines the contact surface at the interface and has a direct effect on the lubrication conditions and, as a consequence, on the value of the friction coefficient µ, involved in the process. Another consulted works demonstrated the feasibility of the use of FEM applied to model the wiredrawing process and focused on the improvement of the geometry of the die [13], on the analysis of the strain distribution in the wire during the process [14] or even to analyze the distribution of residual stresses accumulated in the product once it has been shaped [15], among other output variables. On the other hand, considering all the input factors previously exposed, the effect of drawing speed (v) on the tribological system must be considered since previous works demonstrated that, at high drawing speeds, a localized and intense heating effect is implied in the contact zone which can be detrimental to maintain the properties of the lubricant, worsening the tribological conditions [16,17].…”

Section: Introductionmentioning

confidence: 99%

The influences of the variable speed and internal die geometry on the performance of two commercial soluble oils in the drawing process of pure copper fine wire

Martínez

Rodríguez‐Alabanda

Prisco

et al. 2021

Int J Adv Manuf Technol

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The cold wiredrawing process constitutes a classical-tribological system in which a stationary tribe-element (die) is in contact with a tribe-element in relative motion (wire) and both interacting with the interfacial tribe-element (lubricant). This condition is reflected in the effect of friction as a function of the drawing speed and temperature, and directly affects the wearing of the surface into the die and the final quality on the drawn wire. The aim of this work has been to determine the best conditions to process ETP-copper using two different types of oil/water emulsion lubricants. For this purpose, six different die geometries have been proposed and a set of tests have been carried out at different speeds (between 1 and 21 m/s) to determine those combinations that give a lower value in the required drawing force (Fd). The experiments allowed to know the friction coefficient (µ), the temperature profile inside the drawing die and in the lubricant and also the mean roughness (Ra) in the drawn product. The results have shown that drawing speeds above 10 m/s significantly decrease the drawing force and, as a consequence, the friction effect on the interface. The best results have been achieved in the combinations of the lower die angle (2β = 14°) with drawing speeds between 17 and 18 m/s with both types of lubricants used, obtaining the lower values of the friction coefficient between µ = 0.10–0.15 with the lubricant type D (Agip S234-60 oil at 7% concentration). It has been found that those tests carried out with dies with a smaller approach angle have generally made it possible to obtain better qualities in the final product. Additionally, FEM simulations have been done to analyse those cases with the lower values of µ, throwing values of Fd that are consistent with those measured in the experimental setting and allowing to better understand the behavior of the material as it passes through the die.

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Three Dimensional Finite Element Analysis of Wire Drawing Process

Cited by 15 publications

References 4 publications

Archives of Metallurgy and Materials

Archives of Metallurgy and Materials

Analysis of Tool Geometry and Lubrication Conditions Effect on the Forming Load During Wire Drawing Process

The influences of the variable speed and internal die geometry on the performance of two commercial soluble oils in the drawing process of pure copper fine wire

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