Prediction of Effective Strain Distribution in Two-Pass Drawn Wire

In the multi-pass wire drawing process, the diameter of a wire is decreased by continuously passing it through progressively smaller drawing dies. Although the deformation depends on the process variables, in most wire drawing processes, the wire deformation is concentrated on the surface by its direct contact with the drawing dies, causing a nonlinear distribution of radial direction effective strain from the center to the surface. In this study, a new model for predicting this effective strain in two-pass drawn wire was derived based on the upper bound method, and a finite element analysis and drawing experiment were conducted to validate its effectiveness. The proposed model offers a promising approach to determining and thus controlling the strain in multi-pass drawn wire.