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Physical and mathematical modelling of wire drawing

Başlık çevirisi mevcut değil.

  1. Tez No: 401717
  2. Yazar: ERKAN KARAOĞLU
  3. Danışmanlar: DR. RICHARD DASHWOOD, DR. HENRY MCSHANE
  4. Tez Türü: Doktora
  5. Konular: Metalurji Mühendisliği, Metallurgical Engineering
  6. Anahtar Kelimeler: Belirtilmemiş.
  7. Yıl: 2004
  8. Dil: İngilizce
  9. Üniversite: Imperial College London
  10. Enstitü: Yurtdışı Enstitü
  11. Ana Bilim Dalı: Metalurji Mühendisliği Ana Bilim Dalı
  12. Bilim Dalı: Belirtilmemiş.
  13. Sayfa Sayısı: 119

Özet

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Özet (Çeviri)

Currently the worldwide production of copper wire exceeds 10 million tonnes per year. The majority of this is produced on continuous, high speed, multi wire production lines. Each wire break causes significant downtimes and hence reductions in productivity. In order to improve the efficiency of such plants an understanding of the origin and physics of wire breaks is required. To this end a study has been conducted on over 4000 industrial wire breaks. Using scanning electron microscopy in combination with EDS techniques the source of the break has been identified and classified as a function of wire diameter and origin of feedstock. It was found that“Inclusion Breaks”and“Macroporosity + V Shape Defect Breaks”were the crucial break types constituting nearly 70% of the breaks examined. It was also found that the origin of the feed stock played a significant role in determining both the origin of the break, and the diameter at which the break occurred. In order to gain a better understanding of the break determining factors, a validated model of the wire drawing process was developed using the commercial finite element package Forge2. The model was used to study the effect of process parameters during wire drawing such as reduction ratio, friction, die bearing length and reduction angle, allowing the optimum wire drawing conditions to be determined. The model was extended to theoretically investigate the effect of deformable and undeformable inclusion and porosity presence on the wire drawing process. A drawing stress analysis was carried out for both industrial wire break samples and modelled situations. A critical ratio was determined theoretically and it was confirmed by the data which was extracted from industry. Additionally simulation results confirmed this value. Strain distributions in the wire were also analysed for different materials: - Defect free - Containing an undeformable inclusion - Containing a deformable inclusion - Containing a pore.

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