Scribd
Upload
81 views7 pages

Chapter 6 - Notes

This document discusses various metal drawing processes. It describes rod and wire drawing where rods and wires are drawn through progressively smaller dies to reduce their diameter. It also describes different tube drawing processes like tube sinking, plug drawing, and moving mandrel drawing where tubes have their wall thickness reduced. Residual stresses from drawing are also discussed, with different patterns for small vs large reductions per pass. Key drawing equipment like draw benches and stepper cones for wire drawing are shown.

Uploaded by

Praneeth
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
81 views7 pages

Chapter 6 - Notes

This document discusses various metal drawing processes. It describes rod and wire drawing where rods and wires are drawn through progressively smaller dies to reduce their diameter. It also describes different tube drawing processes like tube sinking, plug drawing, and moving mandrel drawing where tubes have their wall thickness reduced. Residual stresses from drawing are also discussed, with different patterns for small vs large reductions per pass. Key drawing equipment like draw benches and stepper cones for wire drawing are shown.

Uploaded by

Praneeth
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 7

Theory of Metal Forming (MME4045)

CHAPTER 6: DRAWING PROCESS


Metal drawing
Drawing operations involve pulling metal through a die by means of a tensile force applied to the
exit side of the die. The plastic flow is caused by compression force, arising from the reaction of
the metal with the die. The starting materials include hot rolled stock (ferrous) and extruded stock
(non-ferrous). Material should have high ductility and good tensile strength. Drawing of bar, wire
and tube drawing are usually carried out at room temperature, except for large deformation, which
leads to considerable rise in temperature during drawing. Metal usually has a circular symmetry
(but not always, depending on requirements).

Rod and wire drawing


The same principals can be applied for drawing bars, rods, and wire but equipment is different in
sizes depending on products. Rods are relatively larger diameter products whereas, wires are small
diameter products, with diameter typically less than 5 mm.
Rods which cannot be coiled are produced on draw benches as shown in figure 6.1. The rod is
pointed with a swager, inserted through the die and clamped to the jaws of the drawhead. Drawhead
is moved by a chain drive or a hydraulic mechanism. Draw speed varies from 150-1500 mm.s-1

Figure 6.1 Draw bench

Conical drawing die


Figure 6.2 shows the section view of a drawing die. The entrance of the die is shaped so that the
wire entering the die will draw lubricant with it. Shape of the bell causes hydrostatic pressure to
increase and promotes the flow of lubricant into the die. The approach angle is the section where
the actual reduction in diameter occurs. The bearing region produces a frictional drag on the wire
and also removes any surface damage due to die wear, without changing dimensions at die exit.
The back relief allows the metal to expand slightly as the wire leaves the die and also minimizes

Department of Mechanical & Manufacturing Engineering, MIT, Manipal


Theory of Metal Forming (MME4045)

abrasion if the drawing stops or the die is out of alignment. The die nib made from cemented
carbide or diamond is encased for protection in a thick steel casing.

Figure 6.2 Cross section of drawing die

Wire drawing
Wire drawing involves reducing the diameter of a rod or wire by passing through a series of
drawing dies or plates. The subsequent drawing die must have smaller bore diameter than the
previous drawing die. Wire drawing starts with a coil of hot-rolled rod. The rod is first cleaned by
pickling to remove any scale which would lead to surface defects or excessive die wear due to
abrasion. The next step is to prepare the rod so that the lubrication is effective. Copper and Tin are
used as lubricants for high strength materials. Even conversion coating such as sulfates or oxalates
may be applied on the rod. These are used in conjunction with a lubricant, typically soap in dry
drawing. In wet drawing the dies and the rod are completely immersed in an oil lubricant
containing EP additive
When the rod diameter is sufficiently small to permit coiling, block drawing is usually employed
because it allows generation of long lengths in a small floor space (Figure 6.3). The reduction per
drawing die is around 30-35%. As a result, many reductions are needed to achieve the desired
overall reduction. Since the diameter reduced after each pass, the velocity and length of the wore
will increase proportionally. Thus the peripheral speed of the draw block must increase in order to
prevent slippage between the wire and the block. This can be achieved by providing motor for
each die block. More economical design is to use a single motor to drive a series of stepper cones

Department of Mechanical & Manufacturing Engineering, MIT, Manipal


Theory of Metal Forming (MME4045)

as shown in figure 6.4. Each cone diameter is designed to produce a peripheral velocity equivalent
to certain size reduction.

Figure 6.3 Wire drawing equipment

Figure 6.4 Stepper cone multi-pass wire drawing

Tube drawing process


Hollow cylinders or tubes which are made by hot forming processes such as extrusion, piercing
and rolling are often cold finished by drawing process. Cold drawing is used to obtain closer
dimensional tolerances, better surface finish and improve the mechanical properties of the tube by
strain hardening, to produce irregular shape tubes, to produce thinner wall tubes or smaller
diameters than one obtained by hot forming processes. There are three basic types of tube drawing
processes. These are sinking, plug drawing and mandrel drawing.

Department of Mechanical & Manufacturing Engineering, MIT, Manipal


Theory of Metal Forming (MME4045)

Tube sinking
In this process, the tube, while passing through the die, shrinks in outer radius from the original
radius Ro to a final radius Rf. Since no internal tooling is used (internal wall is not supported), the
wall may thicken slightly and internal surface become uneven. The final thickness of the tube
depends on original diameter of the tube, the die diameter and friction between tube and die.
Because the shearing at the entry and exit of the die is large, the redundant strains higher for sinking
and limiting deformation is lower than other tube producing processes.

Figure 6.5 Tube sinking


Plug drawing process
In this process, cylindrical / conical plug is used to control the size/shape of inside diameter of the
tube. The drawing loads needed are higher than floating plug drawing process. But, the process
has greater dimensional accuracy than tube sinking. Increase in friction due to the plug limits the
reduction in area (seldom > 30%). The process can draw and coil long lengths of tubing.

Figure 6.6 Plug drawing

Floating plug drawing process


Here, a tapered plug is placed inside the tube. As the tube is drawn the plug and the die act together
to reduce both the outside/inside diameters of the tube. This process provides improved reduction
in area than tube sinking (~ 45%) and the drawing load needed are lower than fixed plug drawing.

Department of Mechanical & Manufacturing Engineering, MIT, Manipal


Theory of Metal Forming (MME4045)

Production of longer lengths of tubing is alos possible. But in this process, design of tooling and
lubrication are very critical.

Figure 6.7 Floating plug drawing

Moving mandrel drawing process


Problems with the friction in tube drawing prcess are minimized in drawing with a long mandrel.
The mandrel consists of a long hard rod or wire which extends over the entire length of the tube
and is drawn through the die with the tube. Draw force is transmitted to the metal by the pull on
the exit section and by the friction forces acting along the tube -mandrel interface. Since the
mandrel is moving with a velocity equal to that of the tube on exiting the die and since this velocity
is higher than the velocity of the metal confined in the die channel, there is a forward frictional
drag at the interface between the mandrel and the tube which tends to cancel the backward friction
drag between the stationary die and the tiube. Since the mandrel is removed by reeling at the end
of the process, it increases the tube diameter slightly and disturbs the dimensional tolerances.

Figure 6.8 Moving mandrel drawing

Residual stresses in drawing process


Two distinct types of residual-stress patterns in cold-drawn rod and wire. The first is for reduction
of less than 1% per pass and the second is for large reduction. This is shown by figure 6.9.

Department of Mechanical & Manufacturing Engineering, MIT, Manipal


Theory of Metal Forming (MME4045)

Figure 6.9 Residual stress pattens in drawing process

The first type of residual stress pattern is characteristics of the forming operations where
deformation is loclized in the surface layers.

Review questions
1. Sketch and explain rod drawing process.
2. Sketch and comment on drawing die used in drawing process.
3. Sketch and explain wire drawing process.
4. With a neat sketch explain, (a) Tube sinking, (b) Plug drawing, (c) Floating plug drawing, (d)
Moving mandrel drawing process.
5. Comment on residual stresses in drawing process.
6. A steel wire is drawn to 24% reduction from initial diameter of 10 mm. The flow stress of the
material is given by Y  1100 0.26 MPa. The semi die angle is 6° and µ is 0.1. Calculate the draw
stress and the power required for the deformation if the wire moves at a speed of 2.5 m/s
ignoring redundant work.
7. A round rod of annealed brass is drawn from a diameter of 6 mm to 3 mm at a speed of 0.6
m/s. Assume that the frictional and redundant work together constitute 35% of the ideal work
of deformation calculate, (a) Power required, (b) Die pressure at the exit of the die if K = 895
MPa and n = 0.49.

Department of Mechanical & Manufacturing Engineering, MIT, Manipal


Theory of Metal Forming (MME4045)

8. Bar stock of initial diameter = 90 mm is drawn with a draft = 15 mm. The draw die has an
entrance angle = 18°, and the coefficient of friction at the work-die interface = 0.08. The metal
behaves as a perfectly plastic material with yield stress = 105 MPa. Determine (a) Area
reduction, (b) Draw stress, (c) Draw force required for the operation, and (d) Power to perform
the operation if exit velocity = 1.0 m/min.

References:
 G.E. Dieter, Mechanical Metallurgy, 3(e), McGraw Hill, New York, 1989.
 M.P. Groover, Fundamentals of Modern Manufacturing, 4(e), John Wiley & Sons, Inc.
USA, 2010.

Department of Mechanical & Manufacturing Engineering, MIT, Manipal

You might also like