Dieless wire drawing—an experimental and numerical analysis

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. A theoretical analysis of the wire deformation is discussed in this paper. The results of an experimental drawing programme carried out with mild steel wire at temperatures between 400 and 900 °C are also presented. A mathematical model was 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 the experimental programme of dieless drawing. 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.