Investigations on the Effects of Bonding and Forming Conditions on the Deformation Behavior of Copper–Steel Bimetallic Rods during the Cold Drawing Processes
Abstract
:1. Introduction
2. Materials and Methods
3. Deformation Behavior of the Rods under Different Initial Bonding Conditions
3.1. Distribution of Effective Strain during the Drawing Process
3.2. Material Flow during the Drawing Process
3.3. Distribution of Residual Stress after Drawing
4. Effects of the Bonding and Forming Conditions on the Core Ratio of Drawn Products
5. Drawing Experiments
6. Conclusions
- The deformation of the unbonded case was more concentrated on the sleeve compared to the bonded case under all the tested conditions.
- The initial bonding condition significantly affected the deformation behavior. In the bonded case, the core and sleeve deformed together, resulting in a more uniform strain distribution.
- When the reduction ratio increased from 10% to 25%, the axial residual stresses for both the bonded and the unbonded cases became more compressive, and the change in residual stress at the core–sleeve interface became larger for the unbonded case and smaller for the bonded case.
- The increase in the reduction ratio intensified the strain-hardening effect in the sleeve, particularly in the unbonded case, causing some deformation to be transferred to the core.
- The core ratio of drawn products depended mainly on the initial core ratio: for the unbonded case, it increased by 5–6% after drawing; for the bonded cases, it was nearly the same as the original one.
- The simulation and experimental results agreed with each other.
- Understanding the effects of bonding conditions and forming parameters on deformation behaviors helps in optimizing the cold drawing process for bimetallic rods, guiding industrial applications to achieve better control over product quality and manufacturing efficiency.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Die | Sleeve | Core | |
---|---|---|---|
Material | Tungsten carbide | C-10100 Copper | AISI-1006 Steel |
Deformation type | Rigid | Elastoplastic | Elastoplastic |
Young’s modulus [GPa] | NA | 115 | 207 |
Poisson’s ratio | NA | 0.33 | 0.3 |
Forming Parameters | Value |
---|---|
Initial outer radius of the composite rod, Ri [mm] | 5.13, 5.27, 5.42, 5.59, 5.77 |
Initial core ratio, Rci/Ri, % | 30, 40, 50, 60, 70 |
Reduction ratio, r = (Ri2 − Ro2)/Ri2, % | 5, 10, 15, 20, 25 |
Friction coefficient, µ1 | 0.01, 0.1, 0.2, 0.3, 0.4 |
Semi-die angle, α [°] | 5, 6, 7, 8, 9 |
Drawing speed, v [mm/s] | 10, 30, 50, 70, 90 |
Initial bonding condition | unbonded, bonded |
Forming Parameters | Unbonded Case | Bonded Case | Single Steel Rod |
---|---|---|---|
Initial outer radius of the composite rod, Ri [mm] | 5.27 | 5.27 | 5.27 |
Initial core ratio, Rci/Ri, % | 70 | 70 | NA |
Reduction ratio, r = (Ri2 − Ro2)/Ri2, % | 10 | 10 | 10 |
Friction coefficient, µ1 | 0.1 | 0.1 | 0.1 |
Semi-die angle, α [°] | 8 | 8 | 8 |
Drawing speed, v [mm/s] | 10 | 10 | 10 |
Initial bonding condition | µ2 = 0.3 | sticking | NA |
Forming Parameters | Value |
---|---|
Initial outer radius of the composite rod, Ri [mm] | 4.01 |
Initial core ratio, Rci/Ri | 50% |
Reduction ratio, r = (Ri2 − Ro2)/Ri2 | 12.5% |
Friction coefficient, µ1 | 0.1 |
Semi-die angle, α [°] | 8 |
Drawing speed, v [mm/s] | 10 |
Initial bonding condition | unbonded, bonded |
Simulations | Experiments | Difference | ||
---|---|---|---|---|
Initially unbonded case | diameter of the rod | 7.50 mm | 7.50 mm | 0% |
diameter of the core | 3.98 mm | 3.95 mm | 0.76% | |
core ratio | 53.07% | 52.67% | 0.76% | |
Initially bonded case | diameter of the rod | 7.50 mm | 7.50 mm | 0% |
diameter of the core | 3.76 mm | 3.75 mm | 0.27% | |
core ratio | 50.13% | 50.00% | 0.27% |
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Hwang, Y.-M.; Tsui, H.S.R.; Lu, C.-Y. Investigations on the Effects of Bonding and Forming Conditions on the Deformation Behavior of Copper–Steel Bimetallic Rods during the Cold Drawing Processes. Materials 2024, 17, 4015. https://doi.org/10.3390/ma17164015
Hwang Y-M, Tsui HSR, Lu C-Y. Investigations on the Effects of Bonding and Forming Conditions on the Deformation Behavior of Copper–Steel Bimetallic Rods during the Cold Drawing Processes. Materials. 2024; 17(16):4015. https://doi.org/10.3390/ma17164015
Chicago/Turabian StyleHwang, Yeong-Maw, Hiu Shan Rachel Tsui, and Cheng-Yu Lu. 2024. "Investigations on the Effects of Bonding and Forming Conditions on the Deformation Behavior of Copper–Steel Bimetallic Rods during the Cold Drawing Processes" Materials 17, no. 16: 4015. https://doi.org/10.3390/ma17164015