Principle of the process

Metal
forming

Structure

Process modeling

Drawing

Defects

Design For Manufacturing (DFM)

Process variation
Handout 8 c

Bulk Drawing: Engineering Analysis

1. Introduction
In the bulk deformation processes, drawing is an
operation in which the cross section of a bar, rod, or
wire is reduced by pulling it through a die opening, as
shown in Figure 1.

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Extrusion

Drawing

Has pushing force

Has pulling force

Figure 1 here

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Bulk Drawing: Engineering Analysis

2. Objectives of the Analysis
Rolling process

Drawing process

Torque (force)

Pulling force

Power

Power

Velocity (productivity)

Pulling velocity

Max draft

Max draft
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3. Mechanics Phenomenon
There is a tensile stress due to pulling force, but
compression still plays a significant role since the
metal is squeezed down as it passes through the
die opening.

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4. Parameters
r=(A0-Af)/A0

r: area reduction

Contact length

A0: initial area of work

Die angle

Af: final area

Friction between work

and die

d=D0-Df, draft
Drawing stress

Force
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5. Drawing stress, drawing force, power

Accounts for inhomogeneous deformation

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5. Drawing stress, drawing force, power

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Allowable power

6. Limit of Drawing

Yield stress
Maximum power < Allowable power of a drive system

Maximum stress < Yield stress

If not, material goes into

plastic region & no drawing
occurs, just elongation

- If done, as Reduction , draw stress also

Entire reduction not done in a single pass (done in steps)

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6. Finding Max draw stress & Max reduction (1 pass)

Assumption: no friction, no strain hardening (n=0),
no redundant work (perfectly plastic)
Max. draw stress = Yield Strength

d Y
Also,

Yf Y
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because (n=0)

10

d Y
A0
A0
1
d Y f ln
Y ln
Y ln
Y
Af
Af
1 r

A0
e
Af

1
e
1 r
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e 1
rmax
e
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Example
Wire stock of initial diameter = 0.125 in. is drawn
through two dies each providing a 0.20 area reduction.
The staring metal has a strength coefficient = 40,000
lb/in.2 and a strain hardening exponent =0.15. Each die
has an entrance angle of 12o, and the coefficient of
friction at the work-die interface is estimated to be 0.10.
The motors driving the capstans at the die exists can
each deliver 1.50 hp at 90% efficiency. Determine the
maximum possible speed of the wire as it exits the
second die.
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From this calculation, the velocity of the second die is the

limiting velocity. That is to say, the velocity of the whole
system should take 3.47 ft /s. As a result,
1.the first operation would have to be operated at well below
its maximum possible speed; or
2.the second draw die could be powered by a higher
horsepower motor; or
3.the reductions to achieve the two stages would be
reallocated to achieve a higher reduction in the first drawing
operation.
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