MULTISTAGE WIRE DRAWING PROCESS ANALYSIS AND OPTIMIZATION OF PROCESS PARAMETERS
Keywords:
Wire drawing, Load value Multistage Wire Drawing, Drawing Speed, Die angle, Reduction ratio, Load, Stress- Effective, Strain-Effective, Strain Rate –Effective, DamageAbstract
Aluminium multistage wire drawing process is challenging in the surface as the wire is hard and abrasive and the dust and powder generation is higher. A lower tensile strength requires accurate tension control to avoid lack of roundness of the finished wires in reels. Here Deform 3DVer.10.2 application software was used to optimize the process parameters, unnecessary tension which cause damage in the Al 1080A wire was analysed and load and amount of strain generation was also evaluated so that a high strength wire production was possible. Thesis work was carried out to develop new process design by optimization of process parameters for aluminium 1080A. The work aim was to analyse and numerically study the process parameters using finite element model and also to investigate the effect of loads on drawing of wire and other process parameter on drawing process.
In experimental methodology, first step was to find out the drawbacks in existing multistage wire drawing process, second step was various cause for low strength in the wire. So a new process design was carried out with optimized process parameters by use of hit and trial method. A shop floor experiment takes lots of time and cost. So simulation was done with use of DEFORM 3D Ver.10.2 application software, where post processing results was analysed and finally optimized new design of process parameter was
obtained by hit and trial method.
In this work the effect of speed drawing (1mm/sec) kept constant only die diameter was changed to see the effect of other parameter. Shear friction is 0.2, reduction of die was taken 15% for three stages of drawing. All stages were compared with each other and analysis was done on load, force, stress effective, strain effective, stress max principal and damage in the wire. A tensile stress produced desired is as needed so strength of wire become high. By hit and trial method an optimized data is obtained for wire drawing process design. Only dimension of dies were changing by 15% to obtain desired diameter of wire 1.8 mm of original diameter 3 mm.
On the basis of analysis of the results. It was concluded that the friction coefficient and drawing speed also kept constant for all stages of drawing. Finally optimised process parameter design was obtained for multistage wire drawing.
