Comparison between finite element method and analytical methods for studying wire drawing processes

Wire drawing is one of the most commonly used processes for obtaining wire used in mechanical applications such as: rivets, screws, welding wires, etc. In this work, several analytical methods have been employed in order to obtain the forces, energies, stresses and strains that are involved in the process. A comparative study between analytical methods and FEM results is presented, considering hardening strain materials. The material selected to carry out those analyses was an aluminium alloy AA-5083, whose flow stress was determined by an appropriate tension test. The geometric property of axisymmetry has been used in order to reduce the computational cost in the finite element simulations, and to simplify the equations for the rest of the methods introduced. The energies involved in wire drawing processes are also determined. Moreover, energies involved in the process are studied for both strain hardening and non-strain hardening materials.