Experimental and numerical analysis of the deformation in mild steel wire during dieless drawing

Dieless wire drawing is the process of causing a reduction in a wire diameter without the use of conventional wire drawing dies. The wire, axially loaded with a force, is heated to an elevated temperature to initiate plastic deformation. The mechanics of this novel drawing process and a theoretical analysis of the deformation are discussed in this paper. The results of an experimental drawing programme carried out with mild steel wire at temperatures between 400 and 900degreesC are also presented. Mathematical models were developed and used to describe and predict the process deformation and both the stress and temperature distribution profile along the workpiece. A machine was designed and manufactured to facilitate an experimental programme of dieless drawing. The machine permitted continuous drawing of wire, while the reduction ratio, drawing load and temperature were automatically controlled using a personal computer. A finite element (FE) model of the wire was developed, and the results obtained from the FE analysis show good agreement with those obtained from both the experimental work and the mathematical modelling. Results obtained confirm that a complicated interdependence of the process parameters exists during the dieless drawing process.