Evaluation of axial surface residual stress in 0.82-wt% carbon steel wire during multi-pass drawing process considering heat generation

In a multi-pass wire drawing process, inhomogeneous deformation through the cross section of a wire, heat generation resulting from plastic deformation, and friction generate residual stress in the drawn wire. The tensile residual stress in the wire deteriorates the mechanical properties of the drawn wire, with the maximum tensile residual stress occurring on its surface. This paper proposes a prediction model for the maximum axial residual stress that considers the inhomogeneous deformation and heat generation in a high-carbon (0.82-wt% C) drawn wire. An elastoplastic finite element (FE) analysis that considered the flow stress at a high strain range was carried out. Based on the results of this FE analysis, a stress prediction model was established. In order to verify the effectiveness of the prediction model, a multi-pass wire drawing experiment was performed. After performing the drawing experiment, the axial surface residual stress in the drawn wire was measured by X-ray diffraction. From the results, a close agreement was observed between the predicted residual stress and the measured residual stress.

► The relationship between effective strain and effective stress is defined in the high strain region. ► This makes it possible to predict axial surface residual stress accurately. ► Effect of deformation and generated surface heat caused by friction on the axial surface residual stress was investigated. ► Proposal of a prediction model for the axial surface residual stress, considering deformation and heat generated in a wire.