A parametric study on residual stresses and loads in drawing process with idle rolls

A comprehensive study of drawing process with flat idle rolls of round wires is presented through 3D mechanical finite element simulations. An elastic–plastic model is used for the wire material and contact behavior is simulated by a sliding–sticking friction model. The results of numerical simulations are compared with measurements on wires produced with a laboratory equipment. The comparison of drawing load and some geometrical characteristics of experimental samples with numerical model predictions allowed to establish a good correspondence of model with experimental findings, thus validating the numerical model. Residual stress of flat roll drawn wires, pressure distribution on the forming rolls and drawing load are studied. The effects of main process parameters such as initial workpiece diameter, forming rolls diameter and percentage of deformation are investigated. The results present a helpful insight into the process parameters effect in wire drawing with flat idle rolls thus furnishing the basic guidelines for process design and optimization.

► The effect of main process parameters in wire drawing process with flat idle rolls are investigated.
► A finite element model of the process is developed and calibrated by means of experimental tests.
► Pressure on rolls, drawing load and path of residual stress are investigated by means of parametric study.
► Initial wire diameter, forming roll diameter and thickness reduction are involved in the analysis.