Manufacturing Technology I

ME 303
Chapter # 19-3

2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
BULK DEFORMATION PROCESSES
IN METALWORKING
Rolling
Other Deformation Processes Related to
Rolling
Forging
Other Deformation Processes Related to
Forging
Extrusion
Wire and Bar Drawing

2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Wire and Bar Drawing
Cross-section of a bar, rod, or wire is reduced by
pulling it through a die opening
Similar to extrusion except work is pulled
through die in drawing (it is pushed through in
extrusion)
Although drawing applies tensile stress,
compression also plays a significant role since
metal is squeezed as it passes through die
opening
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Figure 19.40 Drawing of bar, rod, or wire.
Wire and Bar Drawing
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Process Variables in Wire Drawing
Figure 15.18 Process variables in wire drawing. The die angle, the reduction in cross-sectional area
per pass, the speed of drawing, the temperature, and the lubrication all affect the drawing force, F.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Wire Drawing vs. Bar Drawing
Difference between bar drawing and wire
drawing is stock size
Bar drawing - large diameter bar and rod
stock
Wire drawing - small diameter stock - wire
sizes down to 0.03 mm (0.001 in.) are
possible
Although the mechanics are the same, the
methods, equipment, and even terminology are
somewhat different.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Wire Drawing vs. Bar Drawing
Bar drawing is generally accomplished
as a single-draft operation
the stock is pulled through one die
opening.
Because the beginning stock has a
large diameter,
it is in the form of a straight cylindrical
piece rather than coiled (therefore
limited length of the work, i.e. a batch
type operation)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R.
Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Extruded Channel on a Draw Bench
Figure 15.22 Cold drawing of an extruded channel on a draw bench to reduce its
cross-section. Individual lengths of straight rods or of cross-sections are drawn by
this method. Source: Courtesy of The Babcock and Wilcox Company, Tubular
Products Division.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Wire Drawing vs. Bar Drawing
Wire is drawn from coils (several
hundred or even thousand feet) passed
through a series of draw dies. (between
4 12).
continuous drawing
long production runs
wire coils can be butt-welded to
make the operation truly
continuous.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Multistage Wire-drawing Machine
Figure 15.23 Two views of a multistage wire-drawing machine that typically is used in the
making of copper wire for electrical wiring. Source: After H. Auerswald
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Area Reduction in Drawing
Change in size of work is usually given by area
reduction:



where r = area reduction in drawing; A
o
=
original area of work; and A
r
= final work

r=
A
o
A
f
A
o
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Analysis of Drawing
The draft


Mechanics of Drawing
The true strain (no friction)
(19.30)

The stress that results from ideal deformation
(19.31)
d=D
0
D
f
=ln
A
0
A
f
= ln
1
1 r
=Y
f
=Y
f
ln
A
0
A
f
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Analysis of Drawing
The draw stress (equation suggested by Schey)
(19.32)


where = die-work coefficient of friction; = die angle
(half-angle); and = factor that accounts for
inhomogeneous deformation (for a round cross section)
(19.33)


where D = average diameter of work during drawing; and
L
c
= contact length of the work with the draw die.
r=
A
o
A
f
A
o
=0. 88 0. 12
D
L
c
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Analysis of Drawing
(19.34a)


(19.34b)
The corresponding draw force (the area of the
drawn cross section multiplied by the draw
stress)

(19.35)

The power required is the draw force multiplied
by exit velocity of the work.
D=
D
0
+D
f
2
L
c
=
D
0
D
f
2sin
F=A
f

d
=A
f
Y
f
1

tan
ln
A
0
A
f
Example 19.4
Stress and Force in Wire Drawing
Wire is drawn through a draw die with
entrance angle=15. Starting diameter is
2.5 mm and final diameter = 2.0 mm. The
coefficient of friction at the workdie
interface = 0.07. The metal has a strength
coefficient K = 205 MPa and a strain-
hardening exponent n = 0.20. Determine
the draw stress and draw force in this
operation.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Maximum Reduction Per Pass
Why is more than one step required to
achieve the desired reduction in wire
drawing?
Why not take the entire reduction in a
single pass through one die, as in
extrusion?
As the reduction increases, draw stress
increases.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Maximum Reduction Per Pass
If the reduction is large enough, draw stress
will exceed the yield strength of the exiting
metal.
the drawn wire simply elongate instead of new
material being squeezed through the die
opening.
For wire to be successful drawing, maximum
draw stress must be less than the yield
strength of the exiting metal.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Analysis of Drawing
Maximum Reduction Per Pass
In ideal case (n = 0, , no friction, no
redundant work) the draw stress


This means that

Hence must equal the natural logarithm base
e. That is, the maximum possible strain is 1.0:

Y
f
=Y

d
= Y
f
ln
A
0
A
f
=Y ln
A
0
A
f
=Y ln
1
1 r
=Y
ln A
0
/ A
f
= ln 1/ 1 r = 1

max
= 1. 0
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Analysis of Drawing
The maximum possible area ratio
(19.36)

The maximum possible reduction
(19.37)
A
0
A
f
=e=2.7183
r
max
=
e 1
e
= 0.632
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Maximum Reduction Per Pass
This value of r is often used as the theoretical
maximum reduction possible in a single draw.
Although it ignores
1. the effects of friction and redundant work,
reduces the maximum possible value,
and
2. strain hardening,
Increases the maximum possible
reduction because the exiting wire would
be stronger than the starting metal.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Maximum Reduction Per Pass
In practice, draw reductions per pass
are quite below the theoretical limit.
Upper reduction limits in industrial
operations
0.50 for single-draft bar drawing and
0.30 for multiple-draft wire drawing
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Drawing Practice and Products
Drawing practice:
Usually performed as cold working
Most frequently used for round cross
sections
Products:
Wire: electrical wire; wire stock for fences,
coat hangers, and shopping carts
Rod stock for nails, screws, rivets, and
springs
Bar stock: metal bars for machining, forging,
and other processes
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Advantages of Drawing
(1) close dimensional control,
(2) good surface finish,
(3) improved mechanical properties such as
strength and hardness, and
(4) adaptability to economical batch or mass
production.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Drawing speeds depend on the material and cross-
sectional area.
They may range from 1 m/s to 2.5 m/s for heavy
sections to as much as 50 m/s for very fine wire.
Reductions in cross-sectional area per pass range
from near zero to about 45 percent.
Fine wires are usually drawn at 15 to 25 percent
reduction per pass, and larger sizes at 20 to 45
percent.
Drawing large solid or hollow sections can be done
at elevated temperatures.
Drawing Practice and Products
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Lubrication
Wet drawing
Dry drawing (the surface of the rod to be drawn
is coated with a lubricant such as soap by
passing it through a box filled with the lubricant
(stuffing box)
Coating (the rod or wire with a soft metal, such
as copper or tin)
Ultrasonic vibration
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Hydrodynamic Lubrication
At about 3 m/s, the
pressure that build up the
approach to the die reached
70 to 275 MPa, and liquid
formed a film between the
wire and the die.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Bar Drawing
accomplished on a machine called a draw
bench.
Powered by hydraulic cylinders or motor-driven
chains, the carriage is used to pull the stock
through the draw die.
Accomplished as a single-draft operation - the
stock is pulled through one die opening
Beginning stock has large diameter and is a
straight cylinder
Requires a batch type operation
The die stand is often designed to hold more
than one die, so that several bars can be pulled
simultaneously.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Figure 19.41 Hydraulically operated draw bench for drawing metal bars.
Bar Drawing Bench
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Extruded Channel on a Draw Bench
Figure 15.22 Cold drawing of an extruded channel on a draw bench to reduce its
cross-section. Individual lengths of straight rods or of cross-sections are drawn by
this method. Source: Courtesy of The Babcock and Wilcox Company, Tubular
Products Division.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Wire Drawing
Continuous drawing machines consisting of
multiple draw dies (typically 4 to 12) separated
by accumulating drums
Each drum (capstan) provides proper force
to draw wire stock through upstream die
Each die provides a small reduction, so
desired total reduction is achieved by the
series
Annealing sometimes required between dies
to relieve work hardening
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Figure 19.42 Continuous drawing of wire.
Continuous Wire Drawing
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Multistage Wire-drawing Machine
Figure 15.23 Two views of a multistage wire-drawing machine that typically is used in the
making of copper wire for electrical wiring. Source: After H. Auerswald
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Features of a Draw Die
Entry region - funnels lubricant into the die to
prevent scoring of work and die
Approach - cone-shaped region where drawing
occurs. with an angle (half angle) about 6-20
Bearing surface - determines final stock size
Back relief - exit zone - provided with a back
relief angle (half-angle) of about 30
Die materials: tool steels or cemented carbides
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Figure 19.43 Draw die for drawing of round rod or wire.
Draw Die Details
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Drawing Dies
Figure 15.20 Terminology of a
typical die used for drawing a
round rod or wire.
Figure 15.21 Tungsten-carbide die
insert in a steel casing. Diamond dies
used in drawing thin wire are encased in
a similar manner.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Preparation of Work for Drawing
Prior to drawing, the beginning stock must be
properly prepared. This involves three steps:
1.Annealing to increase ductility of stock
2.Cleaning - to prevent damage to work surface
and draw die. It involves removal of surface
contaminants (e.g., scale and rust)
3.Pointing to reduce diameter of starting end to
allow insertion through draw die.
usually accomplished by swaging, rolling, or
turning
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Drawing can be used to reduce the diameter or
wall thickness of seamless tubes and pipes,
Tube drawing can be carried out either with or
without a mandrel.
Without mandrel:
used for diameter reduction.
lacks control over the inside diameter and wall
thickness of the tube.
Tube Drawing
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Tube Drawing
Fig 19.44 Tube drawing with no mandrel (tube sinking)
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
With mandrel:
controls the inside diameter and wall thickness of
the tube.
(a)fixed mandrel
attached to a long support bar
Practical limitations on the length of the
support bar
(b), floating plug
shape is designed so that it finds a natural
position in the reduction zone of the die.
no limitations on work length
Tube Drawing
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Tube Drawing
Fig 19.45 Tube drawing with mandrels: (a) fixed mandrel,
and (b) floating plug
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Defects and Residual Stresses
Defects in drawn rod and wire are similar to those observed in
extrusion, especially center cracking (fig 19.39).
An additional type of defect in drawing is seams, which are
longitudinal scratches or folds in the material.
Various other surface defects, such as scratches and die
marks, can also result from improper selection of process
parameters, poor lubrication, or die condition.
Residual stresses are usually present in cold-drawn products.
For light reductions of a few percent, the longitudinal surface
residual stresses are compressive, while the middle is in
tension, thus improving fatigue life. Heavier reductions induce
tensile surface stresses, while the middle is in compression.
Residual stresses can be significant in stress-corrosion
cracking of the part over a period of time.
Rods and tubes that may not be sufficiently straight, or are
supplied as coil, can be straightened by passing them through
an arrangement of rolls placed at different axes (fig 15.28).