Forming parameters optimizations with drawing force and die stress in wire rod drawing using rotating die under Coulomb friction

An optimization research is performed on the related forming parameters of wire rod drawing through a rotating die under Coulomb friction. The optimization research is conducted through finite element method (FEM) simulation combined with Taguchi method. There are two drawing characteristic optimizations have been carried out. They are the optimizations with drawing force and die stress. The forming parameters considered in this study are half die angle, frictional coefficient, die fillet, and rotating angular velocity of the rotating die. The same procedure is carried out in both optimizations. The geometrical models of the wire rod, top die and rotating die are constructed firstly in SolidWorks and imported into the FEM simulation software named DEFORM 3D. With the aid of Taguchi method, the simulation experiments are carried out. The results such as drawing force, die stress, and the corresponding signal-to-noise (S/N) ratio are obtained and compared. The influence rank of the forming parameters and the optimal combination of parameters are obtained through the response table for both optimizations. The results such as effective stress, effective strain, velocity field, drawing force, and die stress are studied. The results show that the minimizations of drawing force and die stress are successfully achieved.