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Wire Drawing
It is manufacturing process of making a wire, generally from a rod or a bar. A bulky process involves a large amount of plastic deformation is one of the oldest manufacturing processes known. The conventional technique to draw wire is cold wiredrawing.
cost is associated with pre-cleaning of the wire prior to entry to the die, tooling, and lubrication materials
Problems associated
Die wear due to frictional and heating effects can rapidly diminish tool life.
Basic Elements
All die-less wire drawing systems must contain the some basic elements namely. A heating device oResistance heating oLaser heating oinduction heating A cooling device Purified water and an inert gas
Basic Elements
A method of applying a tensile force Many methods of applying a tensile load have been utilised.
Data Acquisition
The instability of the die-less drawing process coupled with the complex nature of the machine operation necessitated the use of an automated data acquisition and machine control system. Data was acquired for two purposes. Primarily, to record the test parameters of the wire.
Secondly, to record data from the machine transducers to allow machine control and monitoring to be achieved.
The system is designed to sufciently control the roller angular velocities and wire temperature to achieve a desired reduction in the wire diameter. A PC based system was used to achieve the aforementioned requirement due to its cost-effectiveness and exibility. The hardware was controlled by LabVIEW software.
The user interface consisted of numerous controls and indicators. The controls allowed the user to input values and choices
Experiments
Experiments are conducted on low carbon steel wire of nominal diameter 2.65mm.
Results:
Maximum drawing velocity of 1.4 m/s was attained without wire fracture during the drawing process. Maximum reduction achieved in cross sectional area during a single pass was 72%. This reduction was obtained at a test temperature of 780 C.
Advantages
Absence of die makes the process less expensive as compare to conventional processes. Suitable for materials that have high strength and high frictional resistance. A large reduction of area can be achieved in single pass. Process can be applied to variable cross section bars.
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