Influence of process parameters on shape quality and area fraction in round-to-hexagonal composite wire drawing

This research paper shows how three of the main process parameters, the composite wire yield-stress (S), the cross-sectional area reduction (Re) and die-half-angle (α), influenced drawing stress, area fraction of the core and shape quality in the round-to-hexagonal composite wire drawing by FEM and experiment. The FEM and experimental round-to-hexagonal composite-wire drawing were conducted and compared using two metallic materials types. The Re, α, and S strongly influenced the shape quality. The Re, α, and S slightly influenced change in area fraction of core. The increasing of the area fraction of core was found by experiment. Both increasing and decreasing of the area fraction of core were found by FEM. The change in area fraction of core, which equals to zero, was obtained at a value of α and this α value increased as S increased. The Re, α, and S strongly influenced drawing stress. The Re and S directly strongly and inversely influenced optimal die-half-angle, respectively.