Analytical modeling of hydrodynamic lubrication in a multiple-reduction drawing die

The hydrodynamic lubrication regime is reported to exist in numerous metal forming applications, such as wire drawing and hydrostatic extrusion, but it is difficult to achieve in the drawing of large diameter rods due to the relatively low drawing speeds common for larger parts. By creating a stable fluid film between the workpiece and the die during the drawing process friction and die wear could be significantly reduced, leading to energy savings, increased achievable reductions, and increased die life. An analytical model of the hydrodynamic drawing process is proposed which considers the geometry of the workpiece and die, as well as, the material properties (including work hardening effects), and (temperature dependent) fluid properties to determine the fluid film thickness over the reduction die. This model is then used to analyze several case studies, including a multiple reduction die with high pressure lubricant supplied to the space between the dies. It is shown that a stable fluid film can be established for low drawing speeds through the combination of a multiple reduction die and a supply of lubricant at high pressures to the inlet of the dies. (C) 2017 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.