.5 The Drawing Process In drawing, the cross-section of a long rod or wire typically i s r e d u c e d o r c h a n g e d by p u l l i n g ( h e n c e t h e t e r m dr a w i n g ) it through a diecalled a draw die ( F i g . 8 . 5 ) .

T h u s , t h e d i f f e r e n c e b e t w e e n d r a w i n g a n d extrusion is that in extrusion the material is pushed through a die, whereasi n drawing it is pulled through it. Rod and wire products cover a veryw i d e r a n g e o f a p p l i c a t i o n s , i n c l u d i n g r o d s f o r s h a f t s f o r p o w e r a n d motion transmissions, machine and structural components, and as blanksf o r b o l t s a n d r i v e t s , e l e c t r i c a l w i r i n g , c a b l e s , t e n sion-loaded structuralmembers, welding electrodes, s p r i n g s , p a p e r c l i p s , s p o k e s f o r b i c y c l e wheels, and stringed musical instruments.T h e m a j o r p r o c e s s i n g v a r i a b l e s in drawing are similar to those inextrusionthat is, reduction in cross-sectional area, die angle, frictionalong the die-workpiece i n t e r f a c e s , a n d d r a w i n g s p e e d . T h e d i e a n g l e influences t h e d r a w i n g f o r c e a n d t h e q u a l i t y o f t h e dr a w n pr o d u c t A s can be seen from these equations, the drawing force i n c r e a s e s a s r e d u c t i o n i n cr e a s e s . H o w e v e r , t h e r e h a s t o b e a l i mi t t o t h e m a g n i t u d e o f t h e f o r c e , b e c a u s e w h e n t h e t e n s i l e stress reaches the yield stress of them e t a l b e i n g d r a w n , t h e w o r k - p i e c e w i l l s i m p l y y i e l d a n d , e v e n t u a l l y , break. It can be shown that, ideally and without friction, the maximumr e d u c t i o n i n c r o s s - s e c t i o n a l a r e a p e r p a s s i s 63%. Thus, for example, a10-mm diameter rod can be r e d u c e d ( a t m o s t ) t o a d i a m e t e r o f 6 . 1 m m in one pass without failure.I t c a n b e s h o w n t h a t , f o r a c e r t a i n reduction in diameter and a c e r t a i n f r i c t i o n- a l condition, there is an optimum die angle a t w h i c h t h e d r a w i n g f o r c e i s a mi n i mu m . T h i s d o e s n o t m e a n that the process should b e c a r r i e d o u t a t t h i s o p t i m u m angle, because there are other p r o d u c t quality considerations

O p t i mu m D i e A n g l e Selection of the proper die angle is crucial for the success of any wiredrawing operation. Based on the fact that frictional w o r k i n c r e a s e s w i t h d e cr e a s i n g d i e a n g l e a n d r e d u n d a n t w o r k i n c r e a s e s w i t h i n c r e a s i n g d i e a n g l e , a n o p t i mu m approach angle should existone which minimizes both frictional and redundant work and, as a consequence, t h e d r a w i n g f o r c e . A n u mb e r o f i n v e s t i g a t o r s h a v e c o n f i r me d that a b a l a n c e b e t w e e n f r i c t i o n a l a n d r e d u n d a n t w or k c a n b e achieved through proper selection of the die angle. This effect is illustrated in 7F