Improving Product Quality of Wire Drawing Process Using Design of Experiments

Document Type : Research Paper

Authors

1 Department of Mechanical Engineering, Faculty of Engineering, King Abdulaziz University, Jeddah, Saudi Arabia.

2 Department of Mechanical Design and Production, Faculty of Engineering, Zagazig University, Egypt.

Abstract

The wire drawing process is an essential technique in mechanical and industrial operations in lots of applications. Therefore, the current article aims to employ different methodologies (i.e., experimental, numerical) to investigate the optimum operating conditions and lubrication type on the surface and mechanical quality of these wires. By examining the effects of die angle, drawing speed, and lubricant type on wire drawing outcomes, the research not only provides valuable insights into process optimization but also contributes to reducing defects and enhancing wire properties. Results demonstrate significant variations in tensile strength based on these parameters, highlighting the need for precise control over process variables to achieve desired outcomes consistently. Moreover, statistical analyses reveal substantial relationships between process variables and tensile strength, offering a deeper understanding of the underlying mechanisms driving wire drawing performance. Overall, this research not only advances the understanding of wire drawing processes but also offers practical insights for improving wire manufacturing techniques, ultimately bolstering product quality, reducing costs, and increasing competitiveness in the global market.

Keywords

Main Subjects

[1]          A. Kisrane-Bouzidi, M. Zidani, M.-C. Nebbar, T. Abid, A. Helbert, F. Brisset, T. Baudin, Mechanical Properties and Texture Evolution of High-Carbon Steel Wires during Wire Drawing: Strand Manufacturing, International Journal of Engineering Research in Africa, Vol. 49, pp. 130-138, 2020.
[2]          L. V. Radionova, D. V. Gromov, R. A. Lisovskiy, I. N. Erdakov, Experimental Determination and Calculation of the Wire Drawing Force in Monolithic Dies on Straight-Line Drawing Machines, Machines, Vol. 11, No. 2, pp. 252, 2023.
[3]          B. A. McGuire, 2002, Wire in Design: Modern Wire Art & Mixed Media, Penguin,
[4]          J. Larsson, A. Jansson, P. Karlsson, Monitoring and evaluation of the wire drawing process using thermal imaging, The International Journal of Advanced Manufacturing Technology, Vol. 101, pp. 2121-2134, 2019.
[5]          J.-K. Hwang, Drawing direction effect on microstructure and mechanical properties of twinning-induced plasticity steel during wire drawing, Journal of Materials Engineering and Performance, Vol. 28, pp. 2834-2844, 2019.
[6]          G. Tasevski, K. Angjushev, Z. Petreski, D. Shishkovski, Experimental measurements of system dynamics between two stages of wire drawing machine, Archive of Mechanical Engineering, pp. 61-72-61-72, 2015.
[7]          V. Laghi, M. Palermo, G. Gasparini, V. A. Girelli, T. Trombetti, Experimental results for structural design of Wire-and-Arc Additive Manufactured stainless steel members, Journal of Constructional Steel Research, Vol. 167, pp. 105858, 2020.
[8]          N. Belov, M. Murashkin, N. Korotkova, T. Akopyan, V. Timofeev, Structure and properties of Al–0.6 Wt.% Zr wire alloy manufactured by direct drawing of electromagnetically cast wire rod, Metals, Vol. 10, No. 6, pp. 769, 2020.
[9]          A. Narayan, A Computational Fluid Dynamics Study of Lubrication Flow in The Wire Drawing Process,  Thesis, University College Dublin, 2020.
[10]        G. A. Santana Martinez, W.-L. Qian, L. K. Kabayama, U. Prisco, Effect of process parameters in copper-wire drawing, Metals, Vol. 10, No. 1, pp. 105, 2020.
[11]        W. Wilson, Friction and lubrication in bulk metal-forming processes, Journal of applied metalworking, Vol. 1, No. 1, pp. 7-19, 1978.
[12]        A. Reddy, S. Rajesham, P. Reddy, T. Kumar, J. Goverdhan, An experimental study on effect of process parameters in deep drawing using Taguchi technique, International Journal of Engineering, Science and Technology, Vol. 7, No. 1, pp. 21-32, 2015.
[13]        F. Banda, L. Siaminwe, H. M. Mwenda, Aspects of die geometry influencing drawability of metals during wire drawing: a literature review, Journal for Manufacturing Science and Production, No. 0, 2014.
[14]        U. Prisco, G. A. S. Martinez, L. K. Kabayama, Effect of die pressure on the lubricating regimes achieved in wire drawing, Production Engineering, Vol. 14, No. 5-6, pp. 667-676, 2020.
[15]        I. V. Bryakin, I. V. Bochkarev, V. R. Khramshin, Diagnostics of electrical wires and cables, in Proceeding of, IEEE, pp. 1-5.
[16]        A. Egbetokun, W. Siyanbola, A. Adeniyi, Assessment of Innovation Capability in the Cable and Wire Manufacturing Industry in Nigeria: a case study approach, Micro Evidence on Innovation in developing Economies [MEIDE], May 31–June 1, 2007, UNU-MERIT, Maastricht, the Netherlands, 2007.
[17]        P. Villanueva-Rey, S. Belo, P. Quinteiro, L. Arroja, A. Dias, Wiring in the automobile industry: Life cycle assessment of an innovative cable solution, Journal of Cleaner Production, Vol. 204, pp. 237-246, 2018.
[18]        Y.-J. Bae, A six sigma project for reducing the cost copper materials of the cable manufacturing process, Journal of the Korea Safety Management & Science, Vol. 11, No. 1, pp. 121-130, 2009.
[19]        T. Broomfield, S. Willard, A. Traylor, Foil and heavy wire winding and tensioning, in Proceeding of, IEEE, pp. 245-250.
[20]        A. Stolyarov, M. Polyakova, G. Atangulova, S. Alexandrov, Effect of die angle and frictional conditions on fine grain layer generation in multipass drawing of high carbon steel wire, Metals, Vol. 10, No. 11, pp. 1462, 2020.
[21]        A. Stolyarov, M. Polyakova, G. Atangulova, S. Alexandrov, L. Lang, Effect of frictional conditions on the generation of fine grain layers in drawing of thin steel wires, Metals, Vol. 9, No. 8, pp. 819, 2019.
[22]        S.-K. Lee, S.-B. Lee, B.-M. Kim, Process design of multi-stage wet wire drawing for improving the drawing speed for 0.72 wt% C steel wire, Journal of materials processing technology, Vol. 210, No. 5, pp. 776-783, 2010.
[23]        L. Zhou, F. Fang, L. Wang, H. Chen, Z. Xie, J. Jiang, Torsion delamination and recrystallized cementite of heavy drawing pearlitic wires after low temperature annealing, Materials Science and Engineering: A, Vol. 713, pp. 52-60, 2018.
[24]        S. Gondo, R. Tanemura, R. Mitsui, S. Kajino, M. Asakawa, K. Takemoto, K. Tashima, S. Suzuki, Relationship between mesoscale structure and ductility of drawn high carbon steel wire, Materials Science and Engineering: A, Vol. 800, pp. 140283, 2021.
[25]        F. Fang, Y. Zhao, L. Zhou, X. Hu, Z. Xie, J. Jiang, Texture inheritance of cold drawn pearlite steel wires after austenitization, Materials Science and Engineering: A, Vol. 618, pp. 505-510, 2014.
[26]        J.-K. Hwang, Y.-C. Chang, Effects of Contact Conditions at Wire–Die Interface on Temperature Distribution during Wire Drawing, Processes, Vol. 11, No. 2, pp. 513, 2023.
[27]        C.-C. Yang, C.-L. Liu, Improvement of the mechanical properties of 1022 carbon steel coil by using the Taguchi method to optimize spheroidized annealing conditions, Materials, Vol. 9, No. 8, pp. 693, 2016.
[28]        J. Majta, M. Kwiecien, P. Lisiecka-Graca, S. Dymek, R. Bloniarz, C. Trujillo, K. Muszka, Microstructural effects and mechanical response of microalloyed ferrite and austenite subjected to metal forming at extremely different rates of deformation, Materials Today Communications, Vol. 28, pp. 102472, 2021.
[29]        H. G. Hosseinabadi, S. Serajzadeh, A coupled stream function-finite element analysis for wire drawing processes, The International Journal of Advanced Manufacturing Technology, Vol. 57, pp. 917-926, 2011.
[30]        J.-K. Hwang, Effect of grain size on tensile and wire drawing behaviors in twinning-induced plasticity steel, Materials Science and Engineering: A, Vol. 772, pp. 138709, 2020.
Volume 55, Issue 1
January 2024
Pages 8-25
  • Receive Date: 01 January 2024
  • Revise Date: 01 February 2024
  • Accept Date: 02 February 2024