Finite Element Simulations
Problem Description--Wire Drawing of Copper Jacketed Steel Wire
The initial size of the wire was 2.906 mm in total diameter, with diameter of the steel taken as 2.724 mm with a copper thickness of 0.0908 mm.
The finite element analysis was conducted using ABAQUS Explicit 6.9-1.
An axi-symmetric model was constructed for the bi-metallic wire was
modeled using 4-noded axi-symmetric reduced integration elements.
The die was modeled using 2-noded axi-symmetric rigid elements.
The model was made of elements that were 0.0227 mm in the radial direction
and 0.0496 mm in the axial direction. In all, 56 elements of steel
were used in the radial direction and 4 elements of copper were used
in the radial direction. The length of wire that was modeled was
26.3 mm.
The total number of elements used to represent the section of wire
was 31,680.
The boundary conditions of the wire were set to an initial velocity
of the wire of 15 m/s, and a pressure on the lower end of the wire of 200
MPa
and a pressure on the upper end of the wire of 10 MPa, both directed
in the vertical direction. Radial displacements were restrained for
nodes
on the axi-symmetry line.
The die was initially offset from the surface of the wire by 0.0455
mm and moved radially into the wire by a distance of 0.2 mm.
The interaction between the surface of the die and the contact surface
of the wire was modeled with a coefficient of friction of 0.01.
The bearing length of the die was taken as 1 mm, and the bell angle and back relief angle were 60º.
After the wire moved through the die, the reduction of area was 20%.
Movies:
Plots: Original Mesh, Axisymmetric Model and Stress Results, 180-degree 3-D Mesh Sweep Stress Results
