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Article history: The objective of this study is the design of a multi-stage wet wire drawing process for improving the
Received 23 September 2009 drawing speed for high carbon (0.72 wt% C) steel wire. In this study, the pass schedule and the design of a
Received in revised form multi-stage wet drawing machine have been executed for achieving the objective. In the high-carbon steel
30 December 2009
wet wire drawing process under high speed, the excessive rise in the wire temperature not only increases
Accepted 15 January 2010
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,
Keywords:
Wet wire drawing
a new multi-stage wet wire drawing machine is designed for carrying out a wire drawing experiment
Drawing speed to verify the new pass schedule. From the result of the experiment, the final drawing speed can be
Wire temperature approximately doubled in relation to that of the current drawing process.
Pass schedule © 2010 Elsevier B.V. All rights reserved.
Wire drawing machine
1. Introduction Skolyszewski and Paćko (1998) have studied the wire tempera-
ture of drawing process. In a multi-stage wet wire drawing process
To maximize the productivity of a wire drawing process, the at high speed for producing fine high carbon steel wire, about
drawing speed has to be increased as fast as possible without wire- 95% of the mechanical energy that is involved in the process is
breaks or deterioration of the qualities of the final drawn wire. transferred into heat that can increase the wire temperature by
In a multi-stage drawing process, using a series of dies, the wire about several hundred degrees Celsius. This adversely affects the
diameter is reduced in stages from the initial diameter to the final qualities of the final wire. As the final drawing speed increases,
diameter. The wire drawing process can be classified according to the wire temperature increases dramatically. This embrittles the
the final diameter of the wire: large wire pertains to final diame- wire and eventually causes the wire to break or weaken. Kalweit
ters of 1.5–8.0 mm, medium wire to 0.35–1.5 mm, and fine wire (1997) showed that the control of wire temperature through the
to 0.01–0.50 mm (Phelan et al., 2001). Further, the multi-stage appropriate process design is very important to control the wire
drawing process can be classified into two types according to the temperature.
drawing condition: dry drawing and wet drawing (Hollinger et al., The aim of this study is the design of a multi-stage wet draw-
2003). Generally, fine wire is manufactured by a multi-stage wet ing process to prevent the excessive rise in the temperature for
drawing process. In this process, the reduction ratio from the initial high carbon (0.72 wt% C) steel wire for increasing the final draw-
to the final wire is more than 90% and the final drawing speed is very ing speed. For this purpose, a wire-temperature calculation model
fast. Specifically, the final drawing speed for fine high carbon steel has been proposed for the multi-stage wet wire drawing process.
wire is over 1000 m/min. Therefore, if wire-breaks occur during Through the model, the wire temperature of a conventional draw-
the process, the drawing process stops and significant downtime ing process has been predicted according to the increase in the
occurs owing to the need to thread the wire through the dies. This drawing speed. Based on the calculated wire temperature, a new
causes a significant decrease in the productivity. pass schedule has been established to decrease the wire temper-
ature. Moreover, a new wet drawing machine has been designed
and manufactured for applying the newly designed pass sched-
∗ Corresponding author. Tel.: +82 51 510 2319; fax: +82 51 581 3075. ule. Finally, the effectiveness of the new pass schedule and the
E-mail addresses: o3man@pusan.ac.kr (S.-K. Lee), seonbong@kmu.ac.kr wet drawing machine has been verified through a wet drawing
(S.-B. Lee), bmkim@pusan.ac.kr (B.-M. Kim). experiment. In the experiment, it has been possible to increase
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) 776–783 777
the final drawing speed from 1100 m/min to 2000 m/min without
wire-breaks and the deterioration of qualities of the drawn wire.
Table 1
Process conditions of the wet drawing process.
Number of passes 24
Semi-die angle 5◦
Dia. of the initial wire 1.050 mm
Dia. of the final wire 0.175 mm
Bearing length 0.3Din mm (Din : inlet diameter
of wire)
Final drawing speed 1100 m/min
Initial wire temp. 20.0 ◦ C
Lubricant temp. 45.0 ◦ C
Convection coeff. of lubricant 0.005 W/mm ◦ C
Fig. 4. The reduction and machine ratios of the current drawing process.
temperature after the final pass is about 150 ◦ C. The wire tempera-
ture 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 influence of the drawing speed on the wire temperature, the
final drawing speed is increased from 1100 m/min to 2000 m/min
under the same process conditions. As shown in Fig. 6, the final wire
Fig. 7. Change in the wire temperature in the multi-stage drawing process.
temperature increases by up to 235 ◦ C. Moreover, the wire temper-
ature at the die inlet increases gradually because of the excessive
generation of heat and insufficient 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.
Fig. 11. The wire temperature of the new drawing process with a drawing speed of
2000 m/min.
then tapers down. In this study, the slip velocity rate has been set at final drawing speeds. To evaluate the surface condition of the
5%. The result of the wire-temperature analysis for the new draw- drawn wires, the surface roughness was measured by using round-
ing process with a final drawing speed of 2000 m/min is shown type roughness-measuring equipment, as shown in Fig. 14(a). The
in Fig. 11. The wire temperature increases with the pass num- surface roughness of the new drawing process is found to be
ber up to the 15th pass. The maximum wire temperature is about 0.15–0.21 m. Although the surface roughness slightly increases
167.7 ◦ C. Then, the wire temperature shows almost a uniform value with the drawing speed, the roughness under a wire speed of
of between 164 ◦ C and 167 ◦ C. Moreover, it can be inferred that the 2000 m/min is less than that of the current drawing process.
wire temperature at the die inlet drops sufficiently to the lubricant Fig. 14(b) shows a comparison of the surface roughness between
temperature of about 48 ◦ C. Therefore, it is expected that the new the current drawing process and the new drawing process under a
drawing process can prevent an excessive rise in the temperature drawing speed of 2000 m/min.
when the drawing speed is 2000 m/min. The number of torsional fractures and the occurrence of delam-
ination were evaluated through the torsion test (Raemdonck et al.,
6. Experiment in wire drawing 1994; Shimizu and Kawabe, 2002). In the drawn wire, delamina-
tion is characterized by longitudinal splitting at the wire surface
To verify the effectiveness of the new drawing process, a draw- during the early stages of plastic torsional deformation (Lee et al.,
ing experiment was carried out. The new drawing machine is 2009; Terragna, 1976). Under further torsion, the crack extends
shown in Fig. 12. along the sample length, imparting it a typical helical aspect, as
The drawing experiment was performed in relation to various shown in Fig. 15(a). The wire without delamination assumes a flat
final drawing speeds. After the drawing experiment, the diame- fracture surface aspect in the torsion test, as shown in Fig. 15(b).
ter of the wire, tensile strength, number of torsional fractures, The torsion test was carried out by using a torsion test machine
delamination, surface roughness, and the occurrence of wire- with a sample of which the length was 100 times the wire diame-
breaks were investigated. Fig. 13 shows the drawn wire for various ter. As a result of the torsion test, the number of torsional fractures
is seen to vary between 63 and 65. In all cases, there is no delami- 167.4 ◦ C to 170.6 ◦ C. Especially when the final drawing speed
nation. was 2000 m/min, the calculated wire temperature was 165.0 ◦ C.
The wire temperature of the final pass was measured by Although the difference of wire temperature was about 5 ◦ C, the
using a contact type thermometer. The temperature ranged from calculated temperature shows good agreement with the mea-
Table 2
Result of the drawing experiment.
sured temperature. No remarkable rise in the temperature is seen the range, 164.0–167.0 ◦ C. Moreover, the wire temperature at the
when the drawing speed increases. This means that it is possi- die inlet drops sufficiently to the lubricant temperature of about
ble to prevent excessive rise in the wire temperature by applying 48 ◦ C.
the new drawing process when the drawing speed increases up A new drawing machine has been designed to apply the pass
to 2000 m/min. The tensile strength of the drawn wire is found schedule with a drawing speed of 2000 m/min. A drawing experi-
to range between 2737 MPa and 2786 MPa, which are above the ment has also been carried out. From the experiments, it has been
required tensile strength of 2697 MPa. The results of the draw- possible to not only produce drawn wire without wire-breakage
ing experiment are summarized in Table 2. From the experimental and deterioration of the qualities by applying the new drawing
result, it is possible to not only produce drawn wire without wire- process but also dramatically increase the productivity.
breakage and the deterioration of the wire qualities by applying the
new drawing process but also dramatically increase the productiv- Acknowledgements
ity.
This research was financially supported by the Ministry of Edu-
7. Conclusions cation, Science Technology (MEST) and the Korea Industrial for
Advancement of Technology (KIAT) through the Human Resource
To improve the productivity of a multi-stage wet wire draw- Training Project for Regional Innovation and by the National
ing process, it is essential to increase the wire speed. In this study, Research Foundation of Korea Grant funded by Korean Government
the rise in the wire temperature has been predicted. Further, the (NRF-2006-K20601000004-09E0100-00410).
pass schedule has been executed for preventing the rise in the wire
temperature. Moreover, a new drawing machine has been designed References
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