The Effects of Non-Metallic Inclusion on Ductile Damage of High Carbon Steel Wire in Multi-Pass Dry Drawing Process

Abstract:

The objective of this study is to evaluate how the inclusion sizes influence the damage value and the maximum hydrostatic stress during multi-pass dry drawing process. It was well known that non-metallic inclusions can lead to material fracture during metal forming process, and be harmful to the quality of the final product. In multi-pass dry wire drawing, the temperature rise during deformation greatly decreases the quality of final product. In this study, the pass schedule in which initial diameter of 3.55 mm is reduced to final diameter of 2.115 mm was isothermally designed for the high carbon content steel. Spherical non-metallic inclusion of Al₂O₃ is located in the center of a steel rod. Influences of inclusion size, 5 μm, 10 μm, 20 μm and 50 μm in initial diameter 3.55 mm on ductile damage was investigated by FE-simulation in which material fracture was estimated using normalized Cockcroft and Latham criterion.

• Periodical: Key Engineering Materials (Volumes 622-623)
• Pages: 155-161
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.622-623.155
• Online since: September 2014
• Authors: Se In Ji, Kyung Hun Lee, Yo Sep Yang, Choong Yeol Lee, Chul Min Bae, Byung Min Kim
• Keywords: Ductile Damage, Fe-Simulation, High Carbon Steel, Multi-Pass Dry Wire Drawing Process, Non-Metallic Inclusion

References

[1] U.T. Riedel, W. Bleck, J.E. Morgan, F.J. Guild, C.A. McMahon, Finite element modelling of the effect of non-metallic inclusions in metal forming processes, Comp. Mater. Sci. 16 (1991) 32-38.

DOI: 10.1016/s0927-0256(99)00043-9

[2] K. Yoshida, FEM analysis of wire breaks in drawing of superfine wire with an inclusion, Wire J. Int. (2000) 102-107.

[3] S.B. Son, Y.K. Lee, S.H. Kang, H.S. Chung, J.S. Cho, J.T. Moon, K.H. Oh, A numerical approach on the inclusion effects in ultrafine gold wire drawing process, Eng. Fail. Anal. 18 (2011) 1272-1278.

DOI: 10.1016/j.engfailanal.2011.03.015

[4] S. Norasethasopon, K. Yoshida, Influences of inclusion shape and size in drawing of copper shaped-wire, J. Mater. Process. Technol. 172 (2006) 400-406.

DOI: 10.1016/j.jmatprotec.2005.09.020

[5] S.K. Lee, D.W. Kim, M.S. Jeong, B.M. Kim, Evaluation of axial surface residual stress in 0. 82-wt% carbon steel wire during multi-pass drawing process considering heat generation, Mater. Design 34 (2012) 363-371.

DOI: 10.1016/j.matdes.2011.06.036

[6] S.K. Lee, D.C. Ko, B.M. Kim, Pass schedule of wire drawing process to prevent delamination for high strength steel cord wire, Mater. Design 30 (2009) 2919-2927.

DOI: 10.1016/j.matdes.2009.01.007

[7] S.I. Oh, S. Kobayashi, Theories of flow and fracture in metal forming processes: part Ⅱ – A theory on ductile fracture in metal working processes, AFML-TR-76-61 (1976).

[8] S.I. Oh, C.C. Chen, S. Kobayashi, Ductile fracture in axisymmetric extrusion and wire drawing: Part 2 – Workability in extrusion and drawing, ASME Journal of Engineering for Industry 101 (1979) 22-35.

DOI: 10.1115/1.3439471

[9] S. Norasethasopon, K. Yoshida, Finite-element simulation of inclusion size effects on copper shaped-wire drawing, Mat. Sci. Eng. A-STRUCT 422 (2006) 252-258.

DOI: 10.1016/j.msea.2006.02.015

[10] H. Cho, H.H. Jo, S.G. Lee, B.M. Kim, Y.J. Kim, Effect of reduction ratio, inclusion size and distance between inclusions on wire breaks in Cu fine wiredrawing, J. Mater. Process. Technol. (2002) 130-131: 416-20.

DOI: 10.1016/s0924-0136(02)00719-7

[11] K. Hashimoto, T. Fujimatsu, N. Tsunekage, K. Hiraoka, K. Kida, E.C. Santos, Study of rolling contact fatigue of bearing steels in relation to various oxide inclusions, Mater. Design 32 (2011) 1605-1611.

DOI: 10.1016/j.matdes.2010.08.052

[12] G.L. Zhang, T.Z. Zhao, S.H. Zhang, Finite element analysis of inclusion effects on high strength steel cord wire drawing, AIP Conference Proceedings 1532 (2013) 1131-1136.

DOI: 10.1063/1.4806963

[13] S. Norasethasopon, K. Yoshida, Prediction of chevron crack initiation in inclusion copper shaped-wire drawing, Eng. Fail. Anal. 15 (2008) 378-393.

DOI: 10.1016/j.engfailanal.2007.01.003