Steady-state viscoplastic analysis of metal flow during cold drawing

Abstract

The three-dimensional finite-element method is applied to the metal forming process of drawing rectangular bars from rectangular billets. The rigid-viscoplastic formulation is modified to incorporate the steady-state nature of the drawing process. Various methods of analysis of the drawing process are summarized. Application of the three-dimensional finite element method to other forming process like forging, rolling and extrusion are reviewed. Also presented is the finite element method applied to the analysis of steady-state processes. Simulations were performed under various conditions of the process parameters such as drawing velocity, die-workpiece interface friction, die angle, and area reduction. Velocity distributions, steady-state drawing loads, die-pressure distribution, flow stress, average stresses, effective strain-rates and principle stresses predicted for different simulation conditions are compared. The results are then discussed to gain insight into the mechanics of metal deformation during drawing.