Introduction

Drawing is an operation in which the cross-sectional area ofa bar

or tube is reduced or changed in shape by pulling it through a
converging die (dies are usually tapered).

The drawing process is somewhat similar to extrusion,except that

in drawing,the bar is under tension, whereas in extrusion it is
under compression.

Die Land
Wire or rod
angle

A A,

Die
Prof Naman M.Dae
 Introduction

Although drawing appliestensile stress,compression also plays a

significant role since metal is squeezed as it passes th rough die
opening.
Rod and wire drawing are generally finishing process, and the
product is eitherused as produced or is further processed into
other shapes, such as by bending or machining.

Rods are used forvarious applications, such as small pistons,

structural members,shafts, spindles, and as raw material for
making fastenerssuch as bolt and screws.
Wire and wire product have a wide range of applications, such as
electrical wiring,electrical equipment's, cables,springs, fencing,
welding electrodes and shopping carts.

Wire diameter may be as small as 0.025mm

 Drawing

• Large quantitiesof wires, rods, tubes and other sectionsare

produced by drawing process which is basically a cold working
process (Drawing is usually performed at room temperature, thus
classified a cold working process, but it may be performed at
elevated temperatures for large wires to reduce forces). Inn this
process the material is pulled through a die in order to reduce it to
the desired shape and size.
In atypical wire drawing operation, once the wire is gripped and
pulled to pass through the opening of the die,its diameter
reduced to the desired one.
Die
Dwn wire
Dave
 Drawing
The concept of drawing involves pullingwire,rod, or bar though a
die, or converging channel to decrease cross-sectional area in
increase length.
Inthe majority of the cases the cross section is circular, although
none-circular cross sections may be drawn/ or created by
drawing.
• In acomparison to rolling, drawing offers
1. Much better dimensional control.
2. Lower capital equipment cost.
3. And extension tosmallcross sections.
• In comparison to extrusion, drawing offers
1. Continuous processing.
2. Lower equipment cost.
3. And extension to small cross sections.
 Wire Drawing

•Fine wiredrawing typically refers to round

wire with a diameter of less than 0.1 mm.

• Ultra fine wiredrawing typically refers to

round wire as fine as 0.0025 mm
in diamet

Lubrca box

Dre de
 Entry

Approach
Back relief
Bearing surface (land)
Approach angle

Draw die for drawing of round rod or wire

 Lubricant box
Inital wire stook (in coil form)
Draw die

V V2, F V3. F

+ + +
Capstan drum (hodsmultiple loogs of wire)
(1) (2) (3)

Continuousdrawing of wire
The Major Processing Parameter
[1]Draw Dies:

> Four regions of the diecan be distinguished: (1)entry, (2) approach angle, (3)
bearing surface (land), and (4)back relief.
The entry region is usually a bell-shaped mouth that does not contact the work. Its
purpose is to funnel the lubricant into the die and prevent scoring of work and die
surfaces.

The approach is where the drawing process occurs. It iscone-shaped with an angle

(half angle) normally ranging from about 6 to 20.

The proper angle varies according to work material. The bearing surface, or land,
determines the size of the final drawn stock. Finally, the back relief is the exit zone.

Enery

Approach
Back rlf
Bearing suace(land)
Aporoach ang
4]DIE ANGLE:
Die angle iscrucial for the success ofany wiredrawing operation. Based on the fact that
frictional work increases with decreasing die angle and redundant work increases with
increasing die angle, an optimum approach angle should exist-one which minimizes both

frictional and redundant work and,as aconsequence, the drawing force.

15TEMPERATURE:
Mostly it is a cold working extnusion process.

> The final operation before drawing is drying above 100 degree Celsius.

> Lubricant mostly used for control the temperature.

16JLUBRICATION METHOD:
Wet drawing, in which the dies and the rod are immersed completely in the
Lubricant

Dry drawing,in which the surface of the rod to bedrawn is coated with a lubricant
by passing it through a box filled with the lubricant
Metal coating, in which the rod or wire is coated with a soft metal, such ascopperor
tin, that acts as a solid lubricant.

Mostly various kind of mineral and vegetable oils, animal fats, graphite ,soap and
certain emulsions are applicd as drawing lubricant
[2]Die Material:
> Die materials for drawing typically are tool Steels and carbides. For hot drawing.
cast-steel dies are uscd because of their high resistanceto wear at clevated

temperatures.

High-carbon steels- Rod material for automatic processing, wire cables

* Alloy steels-Industrial springs, welding wires

Cu and Cu alloys- Wires,wire meshes, screws, bolts and shaped parts, parts for the

electrical Industry

Aland Al alloys -Serews and bolts, shaped parts, clectrical lines, ete

[3]Forcesand Energy in Wiredrawing:

> The forces and power in wiredrawing could be analysed by using simple tension,
deformation conditions in wire are, in fact, far more complex dueto compressive

and drag forces generated by the die surface.

Die Force, N

ErictionForce, a

Draw Force,F
(FLOWCHART OF PROCESS OF WIRE DRAWING)

Rolled coil

>Oil and greases for

wire drawing
Cleaning
Mulsifiable oils for wet
wire drawing.

Descaling > Soap fordry wire

drawing

Remove Scale - Annealing

causing surface
defects
Lubricating

Drawing
Principle of the process for wire drawing

Vire

But

Te vle Sie vie

The wire drawing die is conical shape. The end of the rod or wire, which is to be

further is reduced is made into a point shape and insertad through the die opening.

>Before the wire is drawn, The stock needs to be prepared for wire drawing. The
material should be sufficiently ductile since it pulled by the tensile forces. Hence, the
wire may have to annealed properly to provide the necessary ductility.Further.the wire
is to go through the conical portion and then pulled out through the exit by the gripper
In thisprocess ,there is no force applied for pushing wire into thedie from the entrance
side.

>The other aspects of preparation needed are the cleaning of the wire and lubricating it

as it flows through the die. Cleaning is essentially done to remove any scale and rust
present on the surface which may severely affect the die.
Working principle of drawing dies

•Wire drawing is doneon continuous drawing machines that consist of multiple draw
dies, separated by accumulating drums between the dies.

•Each drum,called a capstan, is motor driven to provide the proper pull force to draw

the wire stock through the upstream die.

*lt also maintains a modest tension on the wire as it proceeds to the next draw die in the
series.

•Each die provides a certain amount of reduction in the wire, so that the desired total
reduction is achieved bythe series.

•t is dependingon the metal to be processed and the total reduction, annealing of the
wire is sometimes required between groups of dies in the series.
 BarDrawing
Bar drawing usually involves stock that is too large in cross
section, and hence must be drawn straight.
Round bar stock may be 1 to 10 cm in diameter and even larger.
Accomplished as a single-draft operation - the stock is pulled
through one die opening
Beginningstock has large diameter and is a straight cylinder

Suyk y
•Hydraulically De sand

operated draw
Carege
bench for
drawing metal
bars
Drawing Application
Drawing is usually performed as a cold working operation. It is most frequently used
to produce round cross sections, but squares and other shapes are also drawn.

>Wire drawing is an important industrial process, providing commercial products such

as electrical wire and cable; wire stock for fences; and rod stock to produce nails,
screws, rivets,
springs.

Advantages of wire drawing

>Close dimensional control.

Improved mechanical properties such as strength and hardness.

Adaptability to economical batch or mass production.

 Tube drawing
•Tube drawing is also similar to wire drawing,
except that a mandrel of appropriate diameter is

required to form the internal hole.

• Here three arrangements are shown in figure (a)

with a floating plug and (b) fixe plug drawing(c)
with a moving mandrel

Die

Die Die

Mandrel Stationary
mandrel Moving mandre
 Tub Drawing
O Tubes produced by extrusion or other process(such as shape rolling)

O Also tubes can be reduced in thickness or diameter by tube drawing.

O The shape of tubes can be changed by using dies and mandrels with
various profiles

Die
De
-
Stationary
mandrel
(a) (b)

Die Die

(c)
Mandrel

( Moving
mandrel