FEM analysis of wire breaks in drawing of superfine wire with an inclusion

Wire breaks during the drawing process of fine wires are often induced by inclusions in the wires. Using finite element method, a simulation of drawing wires containing inclusions is performed and the causes of wire breaks are investigated in terms of mechanics of plasticity. When a wire containing inclusions is drawn, the inclusions are only negligibly deformed due to their hardness, whereas the copper around the inclusions is significantly deformed. Accordingly, complex equivalent plastic deformations are distributed in the drawn wire. As a large inclusion passes through a die, drawing stress rapidly increases, inducing a wire break.