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PNU-IFAM Joint Research Center, Pusan National University, 30 Jangjeon-Dong, Kumjeong-Gu, Busan, 609-735, South Korea
Faculty of Mechanical and Automotive Engineering, Keimyung University, 2800 Dalgubeoldaero, Dalse-Gu, Daegu, 704-701, South Korea
School of Mechanical Engineering, Pusan National University, 30 Jangjeon-Dong, Kumjeong-Gu, Busan, 609-735, South Korea
a r t i c l e
i n f o
Article history:
Received 23 September 2009
Received in revised form
30 December 2009
Accepted 15 January 2010
Keywords:
Wet wire drawing
Drawing speed
Wire temperature
Pass schedule
Wire drawing machine
a b s t r a c t
The objective of this study is the design of a multi-stage wet wire drawing process for improving the
drawing speed for high carbon (0.72 wt% C) steel wire. In this study, the pass schedule and the design of a
multi-stage wet drawing machine have been executed for achieving the objective. In the high-carbon steel
wet wire drawing process under high speed, the excessive rise in the wire temperature not only increases
the wire-breakage but also worsens the qualities of the drawn wire. In this study, a wire-temperature
calculation model for the wet wire drawing process is established. An appropriate pass schedule, which
can control the wire temperature, is achieved by using the temperature calculation model. Moreover,
a new multi-stage wet wire drawing machine is designed for carrying out a wire drawing experiment
to verify the new pass schedule. From the result of the experiment, the nal drawing speed can be
approximately doubled in relation to that of the current drawing process.
2010 Elsevier B.V. All rights reserved.
1. Introduction
To maximize the productivity of a wire drawing process, the
drawing speed has to be increased as fast as possible without wirebreaks or deterioration of the qualities of the nal drawn wire.
In a multi-stage drawing process, using a series of dies, the wire
diameter is reduced in stages from the initial diameter to the nal
diameter. The wire drawing process can be classied according to
the nal diameter of the wire: large wire pertains to nal diameters of 1.58.0 mm, medium wire to 0.351.5 mm, and ne wire
to 0.010.50 mm (Phelan et al., 2001). Further, the multi-stage
drawing process can be classied into two types according to the
drawing condition: dry drawing and wet drawing (Hollinger et al.,
2003). Generally, ne wire is manufactured by a multi-stage wet
drawing process. In this process, the reduction ratio from the initial
to the nal wire is more than 90% and the nal drawing speed is very
fast. Specically, the nal drawing speed for ne high carbon steel
wire is over 1000 m/min. Therefore, if wire-breaks occur during
the process, the drawing process stops and signicant downtime
occurs owing to the need to thread the wire through the dies. This
causes a signicant decrease in the productivity.
Corresponding author. Tel.: +82 51 510 2319; fax: +82 51 581 3075.
E-mail addresses: o3man@pusan.ac.kr (S.-K. Lee), seonbong@kmu.ac.kr
(S.-B. Lee), bmkim@pusan.ac.kr (B.-M. Kim).
0924-0136/$ see front matter 2010 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2010.01.007
S.-K. Lee et al. / Journal of Materials Processing Technology 210 (2010) 776783
777
the nal drawing speed from 1100 m/min to 2000 m/min without
wire-breaks and the deterioration of qualities of the drawn wire.
2. Calculation of the wire temperature for wet wire
drawing
In the drawing process, heat is generated due to the plastic
deformation of the wire and the friction between the wire and
the die. As a result, the wire temperature increases, which has
a detrimental effect on the drawing process. From the studies of
Nakamura et al. (1976), Lee et al. (2009), Raemdonck et al. (1994),
and Geleji (1960), an excessive rise in the temperature can not only
cause wire-breaks during the drawing process but also decrease the
ductility of the drawn wire due to static or dynamic strain aging.
Therefore, it is important to keep the wire temperature as low as
possible during the drawing process. In this study, a model for calculating the wire temperature is established to predict the wire
temperature during the wet wire drawing process for wet wire
drawing. The model has been developed in light of the temperature rise in the deformation zone as well as the temperature drop
in the lubricant.
2.1. Temperature rise in the deformation zone
About 95% of the mechanical energy in the deformation zone is
transferred into heat in the drawing process. Therefore, the wire
temperature depends on the following parameters: the initial wire
and die temperatures; the heat generation due to the plastic deformation of the wire; the frictional heat on the interface between the
wire and the die; and the heat transfer from the wire to the die and
the surrounding lubricant.
Fig. 1 shows the geometry of the drawing die and a schematic
diagram of the rise in the wire temperature in the deformation zone.
As shown in Fig. 1, the rise in the wire temperature is attributed
to the volumetric deformation energy (WV ), the internal shear
deformation energy (WS ), and the frictional energy at the diewire
interface (WF ). Therefore, the total generated energy (Wt ) is calculated by:
WT = WV + WS + WF .
(1)
1
F km v z.
A
(2-a)
WS =
1
0.77 kfm f2 v z.
A
(2-b)
WF =
1
km Q v z.
A
(2-c)
f2 c z(Texit Tinlet )
1
F km + 0.77 f2 kfm + m Q km ,
A
where is the density of the wire, c is the specic heat of the wire,
Texit is the wire temperature at the exit of the die, Tinlet is the wire
temperature at the inlet of the die, and m (the heat partition coefcient) denotes the quantity of heat that is transferred to the wire
due to friction at the interface. Geleji (1960) and Jo et al. (2002) proposed that about 80% of the heat generated by friction is transferred
to the wire and the rest is transferred to the die in dry steel wire
drawing. However, in this study, a heat partition coefcient of 0.6
is applied because the liquid lubricant interrupts the heat transfer
between the wire and the die in wet wire drawing. Therefore, the
wire temperature at the exit of the die is calculated as follows:
Texit = Tinlet +
Fig. 1. Rise in the wire temperature in the deformation zone. (a) Geometry of the
drawing die. (b) Schematic diagram of the rise in the wire temperature.
(3)
1
A f2 c
F km + 0.77f2 kfm + m Q km .
(4)
778
S.-K. Lee et al. / Journal of Materials Processing Technology 210 (2010) 776783
Ui+1 Ui
100
Ui
[%],
(6)
where Ui+1 is the speed of the (i + 1)th capstan and Ui is the speed
of the (i)th capstan. Ui+1 is always greater than Ui . Thus far, often
the speed ratio between the (i)th capstan and the (i + 1)th capstans
is equal. Therefore, the machine ratio is equal in the all passes of a
wet drawing machine.
The reduction ratio, RA, of the drawing die is given by:
RA =
ing process. In the cooling zone, the wire temperature drops rapidly
because the wire contacts directly with the liquid lubricant after
passing through the drawing die. Therefore, only convection heat
transfer from the wire to the lubricant is considered. The heat transfer between the wire and the capstan is ignored. To calculate the
wire temperature in the cooling zone, the time-dependent temperature is examined for the extremely small wire, which is exposed
to the lubricant. The following equation is used to calculate the
time-dependent wire temperature.
4h
lub
dc
t + Tlub .
f2
f1
100
[%].
(7)
(5)
In Eq. (5), Ti+1,inlet is the wire temperature at the (i + 1)th die inlet,
Ti,out is the wire temperature at the (i)th die exit, hlub is the convection heat transfer coefcient of the lubricant, d is the diameter of
the wire, and t is the time while the wire is exposed in the lubricant.
3. Basic theory of the wet wire drawing process
Fig. 3 shows the layout of a multi-stage wet drawing process. The
wire wraps around capstans and each capstan provides a tensile
force on the wire at the exit of the corresponding die. The diameter of the wire reduces as it is drawn through the die. The drawing
speed depends on the capstan speed. Both the wire and capstan
speeds increase continuously from the rst to the last pass. Therefore, the latter capstan is faster than the former capstan. Terragna
(1976) calculated the basic parameters of the multi-stage wet
drawing process. In a multi-stage wet drawing process, the relationship between the former and latter capstan speeds is dened by
Svel =
Uv
100
UFinal
[%],
(8)
where U and v are the capstan speed and the wire speed at each
pass, respectively. UFinal is the speed of the nal spool. From the
study of Hisakatsu (2000), the wire-breaks decreased dramatically
when Svel was 38%.
4. Analysis of the current wet drawing process
First, the current drawing process, which is the nal drawing
process of the three drawing processes for producing high carbon
steel cord wire for reinforcing car tires, is analyzed. The applied
drawing process has 24 passes with a constant semi-die angle of
5 . The initial and nal wire diameters are 1.050 mm and 0.175 mm,
respectively. Therefore the total reduction ratio is 97.22%. The nal
drawing speed is 1100 m/min. The process conditions are summarized in Table 1.
Fig. 4 shows the reduction and machine ratios. The reduction
ratios are 13.015.3%. The machine ratio is a constant value of 12.0%.
The reduction ratio is always higher than the machine ratio because
of the slip (Terragna, 1976).
The material of the initial wire is 0.72 wt% C steel. The ow stress
curve obtained through the tensile test is as follows:
= 2190 0.205 [MPa].
(9)
Fig. 5 shows the calculated wire temperature with a nal drawing speed of 1100 m/min. At the die exit, the wire temperature
increases gradually according to the pass number due to the plastic
deformation and the friction between the wire and the die. The wire
S.-K. Lee et al. / Journal of Materials Processing Technology 210 (2010) 776783
Table 1
Process conditions of the wet drawing process.
Process conditions
Value
Number of passes
Semi-die angle
Dia. of the initial wire
Dia. of the nal wire
Bearing length
24
5
1.050 mm
0.175 mm
0.3Din mm (Din : inlet diameter
of wire)
1100 m/min
20.0 C
45.0 C
0.005 W/mm C
Fig. 4. The reduction and machine ratios of the current drawing process.
temperature after the nal pass is about 150 C. The wire temperature drops rapidly to the lubricant temperature (of about 46 C) at
all passes after the wire passes through the die. In order to evaluate
the inuence of the drawing speed on the wire temperature, the
nal drawing speed is increased from 1100 m/min to 2000 m/min
under the same process conditions. As shown in Fig. 6, the nal wire
temperature increases by up to 235 C. Moreover, the wire temperature at the die inlet increases gradually because of the excessive
generation of heat and insufcient cooling due to the extremely
high drawing speed. Nakamura et al. (1976) proposed that the wire
temperature has to be decreased to prevent static or dynamic strain
aging.
779
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S.-K. Lee et al. / Journal of Materials Processing Technology 210 (2010) 776783
Fig. 11. The wire temperature of the new drawing process with a drawing speed of
2000 m/min.
Fig. 10. The machine ratio and the slip velocity rate of the new drawing process.
S.-K. Lee et al. / Journal of Materials Processing Technology 210 (2010) 776783
781
then tapers down. In this study, the slip velocity rate has been set at
5%. The result of the wire-temperature analysis for the new drawing process with a nal drawing speed of 2000 m/min is shown
in Fig. 11. The wire temperature increases with the pass number up to the 15th pass. The maximum wire temperature is about
167.7 C. Then, the wire temperature shows almost a uniform value
of between 164 C and 167 C. Moreover, it can be inferred that the
wire temperature at the die inlet drops sufciently to the lubricant
temperature of about 48 C. Therefore, it is expected that the new
drawing process can prevent an excessive rise in the temperature
when the drawing speed is 2000 m/min.
6. Experiment in wire drawing
To verify the effectiveness of the new drawing process, a drawing experiment was carried out. The new drawing machine is
shown in Fig. 12.
The drawing experiment was performed in relation to various
nal drawing speeds. After the drawing experiment, the diameter of the wire, tensile strength, number of torsional fractures,
delamination, surface roughness, and the occurrence of wirebreaks were investigated. Fig. 13 shows the drawn wire for various
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S.-K. Lee et al. / Journal of Materials Processing Technology 210 (2010) 776783
783
Table 2
Result of the drawing experiment.
Items
167.5
0.175 0.005
2697
63
No
0.26
1400
1600
1800
2000
167.4
0.175
2766
63
No
0.16
No
167.2
0.174
2776
65
No
0.15
No
167.8
0.175
2737
64
No
0.16
No
169.3
0.175
2786
65
No
0.18
No
170.6
0.175
2776
64
No
0.21
No