FEM simulation of wire drawing

The paper deals with the finite element simulation of wire drawing processes with focus on
unalloyed carbon steels. Based on the development of suitable material models as a basis for the simulation model, the forming processes are analyzed over several drawing stages for different drawing regimes. The simulation model is validated by comparing the simulation
results with measured values. For the description of the forming behavior, the damage
developments of the wire during the multi-stage forming are specifically analyzed.
Subsequently, forming limits are derived by correlating the calculated damage with mechanical parameters of the wires. The validation of the damage models used is made possible by an FE parameter study, within which a targeted variation of the drawing die geometry takes place at a specific drawing stage. The paper is concluded by the verification of the results obtained theoretically by practical tests on a wire drawing machine using critical drawing die geometries.