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Keywords = dieless drawing

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12 pages, 3901 KiB  
Article
Experimental and Numerical Study of Surface Roughness of Thin Brass Wire Processed by Different Dieless Drawing Processes
by Andrij Milenin, Mirosław Wróbel, Piotr Kustra and Jiří Němeček
Materials 2022, 15(1), 35; https://doi.org/10.3390/ma15010035 - 21 Dec 2021
Cited by 3 | Viewed by 2753
Abstract
This paper examines the surface roughness of a thin brass wire (140–200 microns in diameter) after two dieless drawing (DD) processes, i.e., conventional dieless drawing (CDD) and incremental dieless drawing (IDD). In incremental dieless drawing, small increments in deformation were applied in several [...] Read more.
This paper examines the surface roughness of a thin brass wire (140–200 microns in diameter) after two dieless drawing (DD) processes, i.e., conventional dieless drawing (CDD) and incremental dieless drawing (IDD). In incremental dieless drawing, small increments in deformation were applied in several passes. It has been proven that the IDD process not only has a greater efficiency but also enables obtaining a wire with significantly lower surface roughness. The explanation for these effects is based on the results of the numerical modeling of both compared processes. The developed numerical model takes into consideration the initial roughness of the wire surface, shape and dimensions of grains, and their diversified mechanical properties. Nanoindentation measurements, microstructure, and plastometric studies allowed us to find the effective flow stress distribution in the grains. The IDD process was found to be much more stable and develop a much more uniform distribution of grain strain than the CDD process. More homogeneous deformation results in surface roughness reduction. Approximately 25–30% reduction in surface roughness of the wire produced by the IDD process was predicted by simulations and confirmed experimentally. Full article
(This article belongs to the Topic Metallurgical and Materials Engineering)
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13 pages, 4701 KiB  
Article
Formability Analysis and Oxidation Layer Effects in Dieless Drawing of Stainless Steel Wires
by Yeong-Maw Hwang and Han-Hsuan Liu
Metals 2019, 9(8), 828; https://doi.org/10.3390/met9080828 - 25 Jul 2019
Cited by 4 | Viewed by 3456
Abstract
In this study, dieless drawing experiments of stainless steel SUS304 wires of 1 mm in diameter were carried out using a self-developed dieless drawing machine. In order to prevent oxidation, argon gas was applied to a self-designed chamber during dieless drawing processes. The [...] Read more.
In this study, dieless drawing experiments of stainless steel SUS304 wires of 1 mm in diameter were carried out using a self-developed dieless drawing machine. In order to prevent oxidation, argon gas was applied to a self-designed chamber during dieless drawing processes. The effects of the forming temperature and the oxide layer on the mechanical properties of the drawn SUS304 stainless wires obtained by tensile tests are discussed in this paper. A finite element model considering the high frequency induction heating mode in the finite element software DEFORM2D was developed to conduct the heat transfer analysis and the formability analysis of the drawn products in dieless drawing of stainless steel wires. The effects of the drawing speed and forming temperature on the maximal reachable area reductions are discussed. Through the comparisons of the maximal reachable area reduction between the finite element simulations and experiments, the finite element modelling for dieless drawing processes was validated. Full article
(This article belongs to the Special Issue Metal Micro-forming)
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14 pages, 4238 KiB  
Article
Study of Deformation Stability during Semi-Dieless Drawing of Ti-6Al-4V Alloy Wire
by Kaisong Li, Zhangke Wang and Xuefeng Liu
Materials 2019, 12(8), 1320; https://doi.org/10.3390/ma12081320 - 23 Apr 2019
Cited by 4 | Viewed by 2481
Abstract
A semi-dieless drawing technology has the advantages of producing a large deformation in a single pass and achieving high-precision dimensions of the finished products. However, instabilities can easily occur in a technique with a large amount of deformation, resulting in its failure. Herein, [...] Read more.
A semi-dieless drawing technology has the advantages of producing a large deformation in a single pass and achieving high-precision dimensions of the finished products. However, instabilities can easily occur in a technique with a large amount of deformation, resulting in its failure. Herein, the deformation behavior of a wire during semi-dieless drawing is studied by finite element simulations. The instability mechanism of the semi-dieless drawing is proposed and validated by experiments. The experiments are conducted under the following conditions: a heating temperature of 950 °C; a distance between the die and heating coil of 20 mm; a feeding speed of 0.25 mm/s; a drawing speed range of 0.38–0.53 mm/s, and a die diameter range of 1.8–2.4 mm. The results show that by increasing the drawing speed or decreasing die diameter, the diameter fluctuation of the dieless drawn wire increases, and the semi-dieless drawing process easily becomes unstable. The diameter of the entering wire shows a fluctuating increasing trend owing to the variation in the drawing speed, which results in the instability during the semi-dieless drawing. The validity of the finite element model is verified by comparing the numerically predicted value and experimentally measured value of the drawn wire diameter. Full article
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