A numerical study on residual stresses in drawn wires

Based on finite element modeling of the wire drawing process, the effects of several process parameters on the drawing process and the final state of residual stresses in drawn wires were studied. These parameters include die geometry, back tension and friction coefficient. The parametric study indicated that the bearing length of the die has a significant influence on the residual stresses in drawn wires. A longer bearing length causes less tensile stresses at the surface, and a smaller die inlet angle reduces the level of residual stresses. No significant change in either magnitude or distribution of residual stresses due to back tension with certain bearing length was found. Also the influence of friction coefficient on residual stresses under certain bearing length can be neglected, at least if no temperature effects are considered. The initial stresses in the raw materials do not influence the final residual stresses very much.