Improving Rolling and Drawing Processes - "Dimensional Analysis of Rectangular Copper Wire Drawing and Rolling Processes Using"

Title: Dimensional analysis of the cross section of electrolytic rectangular copper wire produced by drawing and rolling processes.

Authors: OLIVEIRA, RSO 1 ; SILVA, AD 2 , Magalhes, FC 3 ; CETLIN, PR 4 , FIELDS, HB 5

Mechanical Engineer - Master in Mechanical Engineering PPGMEC-UFMG Mechanical Engineer - Master in Mechanical Engineering PPGMEC-UFMG PhD - Postdoctoral Fellow of the UFMG-FAPEMIG PhD - Professor, Department of Metallurgical Engineering, UFMG PhD - Associate Professor, Department of Mechanical Engineering, UFMG

Abstract: This paper presents a study of the dimensional cross-section obtained through the steps of cold rolling and drawing, in the process of manufacture of wires of rectangular final section of 3.5 x 8.8 mm from electrolytic copper rods diameter cylinder of 8 mm. Steps experimental, analytical and simulation are the basis for data collected in the study. In the experimental procedure the wire is processed in a continuous manufacturing line using single pass through the steps of rolling and drawing. Materials are sampled in two steps and made measurements of the profile section. In analytical step to the lamination process, the calculation of prediction dimensional scattering width of the material is performed. In the third step, the simulation of rolling and drawing processes are performed using the finite element method, and the raised profile of the cross section for both cases. The results show consistency between the methods used, but raises greater degree of adjustment in the boundary conditions in numerical simulation and re-use analytical equation for finer degrees of accuracy.

Keywords : Electrolytic copper, Wire Drawing, Rolling, Rectangular Copper Wire, Finite Element Method, Implicit Formulation.

Abstract: This paper presents a study of the cross-sectional profile Obtained During the cold rolling and drawing stages related to the process of manufacturing wires with rectangular end section of 3.5 x 8.8 mm, starting from electrolytic copper rod of diameter 8 mm. This study relies upon the experimental and analytical data for the simulation stages to be Necessary Surveyed. In the experimental procedure, the wire is processed in a continuous production line, using a single pass in the cold rolling and drawing stages. During These two stages, the material is sampled and measurements are made on the cross-sectional profile. Now in the analytic stage, the predicted dimension of the lateral spread is Calculated in order to Understand the cold draw process. In the third stage, the simulation of the cold rolling and drawing process is October Carried by using the finite elements method. In addition, the cross-sectional profile is Measured for Both cases. Obtained results show the coherence among the methods used. However, the results point Out The need for a higher degree of adjustment for contour conditions in the numeric simulation and re-evaluation of the analytic equation in order to Obtain more accuracy.

Keywords : Electrolytic copper, Drawn, Rolling, rectangular copper wire, Finite Element Method, Implicit formulation

Introduction: The electrical transformer industry widely uses the copper windings in the construction of electrical coils (Utsunomiya and Hartley, 2001). The service dimensions specified in the product design is critical to ensure achievement of proper dimensional and electrical losses of the windings (Kazeminezhad and Taheri, 2005a, b; Iankov, 2003). To determine dimensional wires can be used different methods such as empirical, analytical and experimental (Utsunomiya and Hartley, 2001; Kazeminezhad and Taheri, 2005a, b; Carlsson and Lagergren, 1996; Carlson, 1998; Iankov, 2003). The choice of method to be adopted depends on the level of accuracy desired. A simple solution with less precision and processing time can be more interesting than a more elaborate work, which needs more time. Thus the different methods should be evaluated to choose the best option to provide the desirable condition of precision (Kazeminezhad, Taheri and Tieu, 2008). There are different methods in the literature prior to calculating the cross section of material as the empirical formula for lamination (Kazeminezhad and Taheri, 2005a), the numerical method using the tools of the finite element method (Utsunomiya and Taheri, 2001, Carlsson and Lagergren, 1996, Carlsson, 1998; Iankov, 2003; Kazeminezhad, Taheri and Tieu, 2008), and the experimental evaluation of the results. This study aims to compare the capabilities and accuracy of different methods in relation to the experimental procedure for the steps of rolling and drawing in the manufacture of copper wire to wire rectangular section 3.5 x 8.8 mm.

Materials and Methods: Figure I shows the profile of the material at various stages of processing: (a) raw materials, (b) laminate and (c) material drawn.

Figure I - Cross section of the material in the three stages of manufacturing the rectangular wire.

For the experimental procedure, the material basis for this study for the fabrication of the rectangular wire was electrolytic copper rods 8 mm, commercially produced according to ABNT NBR 14733. To prove the mechanical characteristics of the material were carried out tensile and hardness, and raised the same diameter measurements. The tensile test was performed on a traction machine INSTRON model 5582 system with data acquisition and MERLIN INSTRON extensometer axial electron model 2630-100 of 25 mm and load cell of 100 kN. The test speed was constant 4 mm / min.Os specimens were machined as shown in Figure II. The test was conducted to the region of necking and thereafter used the correction of Bridgman (Dieter, 1981) for data up to failure.

Figure II - Test specimen for tensile test.

In this study, the raw material (Fig. I (a)) is processed in the rolling plan duo type, the cylinder diameter of 162.4 mm molten steel, to obtain an intermediate profile 4.15 x 11.30 mm (Figure I (b)). The rod is fed at a speed of 50m/min. The lamination takes place in single pass and without lubrication. We produced two different lots of materials for this process being sampled two specimens for dimensional measurement of the material.

The drawing process is performed immediately after the roller mill. The profile chosen for study has a die hard metal (hardness 91.5 HRA) and housing in carbon steel, with the final section of the wire laid down to 3.5 x 8.8 mm (Figure I (c)). The process occurs in commercial lubricating oil, the die being fully immersed in it. Also sampled were two samples for measurement of material for each batch. In the empirical procedure / analytical rolling, the equations presented below, and developed by Taheri Kazeminezhad (2005a, b, 2008) for the lateral spreading (1) and the width of contact with the drum roller mill (2) and (3) were used as dimensions shown in Figure III.

(1) (2) (3)

Figure III - Sketch of the rolling process of rectangular wire.

In the numerical procedure, the finite element method was used to simulate the processes of rolling and drawing, and made measurements of the profile obtained in both cases for comparison with previous methods. The software used was the DEFORM 3D version 6.1.

The simulation of the rolling mill was used for the module "shape rolling" for defining the geometry of the elements, and the copper rods of 8 x 50mm length, the roller rolling plane 160.2 mm and 15 mm wide and the pusher dimensional 10 x 10mm. Due to the symmetry of the profiles, the simulation was performed considering "of the original geometry of each piece. The simulation parameters in preprocessor DEFORM 3D are calibrated with the following boundary conditions: lamination with incremental plastic deformation (rolling Lagrangian) process with a constant temperature of 25 r C (isothermal), and the roller pusher were considered hard materials, the copper rod is defined as a material with plastic behavior. was adopted hexadrica mesh with the formation of elements 34 in section 2D (light ) for 75 "layers," providing the formation of 3D elements in the section 2550 equivalent to 3496 nodes. objective of this section to obtain the approximate dimensions of elements on all sides of the material and the best contour profile of the elements in the same section As shown in Figure IV (a). The angular speed of the laminating cylinder was kept constant at 87.42 rpm (50 m / min). The linear velocity of the pusher rod in copper was adopted constant 366.64 mm / s. The coefficient of friction between the adopted roll mill and the material of Q = 0.9. The mechanical properties were imported from the results obtained in the tensile test of the raw material. The simulation of the drawing, the geometry of the die was designed in SolidWorks software and imported into the preprocessor of DEFORM 3D. The dimensional and mechanical characteristics of the output of the rolling simulation were used as input of the drawing. The simulation was performed considering "the original profile, due to the symmetry of the process. The simulation parameters in preprocessor of DEFORM 3D are calibrated with the following boundary conditions: process with constant temperature of 25 r C (isothermal), the the drawing die was considered as rigid material, the copper wire rectangular laminate was defined as a material with plastic behavior. a tetrahedral mesh was adopted with the formation of elements 8000 and factor of size ratio of 2, for a total of 10,422 nodes 10,952 and poly surface, 43 022 total elements in the 3D surface. objective of this point to obtain elements of approximate dimensions on all sides of the best material and the contour profile of the elements in the same section as shown in Figure IV (b). For prevent distortion and get the best result in the simulation was carried out condensation of holes at the edges of sheet material due to the small radius (0.5 mm) in the string of drawing this point. was used to supply constant linear velocity of the string of drawing 115 m / min. To start the operation of drawing printed on the simulator was a constant force of 100 N on the surface of the entrance surface in the die. The friction between the die and the copper material was judged to be Q = 0.09 (Hensel and Spittel, 1978).

(A) (b) Figure IV - Lattice numerical simulation: (a) rolling and (b) Wire Drawing.

Results: Analysis of raw material (copper rods 8mm): results of the tensile test performed on the test specimens were coherent with the specified standard, as shown in Table I.

Table I - Mechanical properties of copper rods Mechanical Property Yield conventional (0.5%) Limit of tensile Uniform Elongation Non-Uniform Elongation Total elongation Value 112.2 214.8 19.6 11.0 30.6 Unit MPa MPa % % %

The dimensions of two different batches of material were measured and are presented in Table II.

Table II - Overall dimensions of the copper rod

Lot "A" Measure 1 Measure Diameter (mm) 2 Measure 3 Measure 4 Average Section (mm 2 ) 7.93 7.93 49.36 7.94 7.94 49.55 7.92 7.94 7.92 7.93 7.94 Lot "B" 7.96

Analysis of the laminating process: The material subjected to the lamination process experiment was measured and the results are shown in Table III.

Table III - Overall dimensions of the rolled profile Dimension (Mm) Measure 1 Dimension (mm) Measure 2 Measure 3 Measure 4 Average Middle section (mm 2 )
Reduction middle section (%)

Lot "A" Thickness 4.17 4.16 4.18 4.13 4.16 Wf b

Lot "B" Thickness 4.17 4.18 4.17 4.16 4.17 Wf b

11.30 10.05 11.33 10.11 11.33 10.15 11.28 9.95 11.31 10.07 45.48 7.85

11.30 10.02 11.29 10.12 11.26 9.97

11.33 10.09 11.30 10.05 45.54 8.08

The calculations performed by the method empirical / analytical are shown in Table IV.

Table IV - Calculation empirical / analytical lamination process Lot "A" (mm) Wf 10.81 b1 7.73 b2 9.26 Wf 10.82 Lot "B" (mm) b1 7.74 b2 9.26

The results of numerical simulation of the rolling process are presented in Table V.

Table V - dimensions obtained in the simulation of the rolling process Difference of standard width: 11.30 mm (Mm) 0.374 % 3.310

Thickness (Mm) 4.137

Difference standard thickness: 4.15 mm

Width (Mm)

(Mm) 0.013

(%) 0.313

10.926

Analysis of the drawing process: The material subjected to the process of drawing experiment was measured and the results are shown in Table VI.

Table VI - Measurement of dimensions of the profile Drawn Dimension (Mm) Measure 1 Dimension (mm) Measure 2 Measure 3 Measure 4 Average Profile section (mm 2 )
Reduction section (%)

Lot "A"

Lot "B"

Thickness Width Thickness Width 3.51 3.50 3.50 3.51 8.74 8.75 8.78 8.75 3.50 3.50 3.51 3.50 8.78 8.77 8.80 8.82

3.51 8.76 30.47 33.00

3.50 8.79 30.58 32.85

The results of numerical simulation of the drawing process are presented in Table VII.

Table VII - dimensions obtained in the simulation of the drawing process Thickness Difference standard Width Difference pattern

(Mm) 3.504

thickness: 3.5 mm (Mm) 0.004 (%) 0.114

(Mm) 8.891

width: 8.8 mm (Mm) 0.092 % 1.045

Discussion: The research showed that the results to be compared require care in the parameterization process simulation and empirical calculations show that the limitations of precision in the results. The following conclusions can be drawn from the results shown:

1. For lamination, the empirical calculations / analytical scattering profile (equation 1) and the width of contact with the laminating roller (equations 2 and 3) have the approximate values obtained experimentally. The advantage of using these calculations is the speed of approach response. However it should be used for purposes requiring no details as to the value obtained.

2. Calculations by the material contact area with the cylinder mill showed greater coherence to the equation 3. The results from the use of equation 2 do not show satisfactory for the requirements of this study.

3. The parameterizations adopted for the simulations of rolling and drawing processes were efficient, considering that the results were very close to the experimental values.

Acknowledgments: The authors thank the board of Toshiba Transmission and Distribution Systems Brazil Ltd. (TTDB) the availability of the facilities of the manufacturing line of rectangular wires to the survey.

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