A study on the corner filling in the drawing of a rectangular rod from a round bar

An important characteristic of the shaped drawing process, unlike the wire drawing process, is the corner filling which influences the dimensional accuracy of the product. In this study, therefore, in order to investigate the effect of process variables, such as the reduction in area, the semi-die angle, and the rectangular ratio to the corner filling, the drawings of a rectangular rod from a round bar have been simulated by using the three-dimensional rigid-plastic finite element method (FEM) and an artificial neural network has been introduced to reduce the number of simulations. To verify the results of the study, the experimental investigations were also carried out on real industrial products. According to the results, in the case of the irregular-shaped drawing process the main process variable on the corner filling is the combination of the semi-die angle but for the regular-shaped drawing process, the reduction in area has a significant effect on the corner filling. (C) 2000 Elsevier Science Ltd. All rights reserved.