Praveen Kumar, Dr.

Geeta Agnihotri / International Journal of Engineering Research and

Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 3, May-Jun 2013, pp.988-994
Cold Drawing Process –A Review
Praveen Kumar*, Dr. Geeta Agnihotri**
*(M.Tech Scholar, Department of Mechanical Engineering, M.A.N.I.T.,Bhopal)
** (Professor, Department of Mechanical Engineering, M.A.N.I.T.,Bhopal)

ABSTRACT II. COLD DRAWING PROCESS-AN

Cold drawing is widely used metal OVERVIEW
forming process with inherent advantages like The Cold drawing is one of the oldest
closer dimensional tolerances, better surface metal forming operations and has major industrial
finish and improved mechanical properties as significance. It is the process of reducing the cross-
compared to hot forming processes. Due to the sectional area and/or the shape of a bar, rod, tube or
ever increasing competition with the advent of wire by pulling through a die. This process allows
globalization it has become highly important to excellent surface finishes and closely controlled
keep on improving the process efficiency in terms dimensions to be obtained in long products that have
of product quality and optimized use of constant cross sections. It is classified as under:
resources. In view of this different models have  Wire and Bar Drawing: Cross-section of a
been proposed and validated using experimental bar, rod, or wire is reduced by pulling it
results over a long period of time. The demands through a die opening (Fig. 1 a) .It is
in the automobile sector, energy sector and similar to extrusion except work is pulled
mining sector have led to several modifications in through the die in drawing. Both tensile
the drawing process. In this paper, process and compressive stress deforms the metal
details of cold drawing, major analytical, as it passes through the die opening.
experimental and numerical studies reported in  Tube Drawing: It is a metalworking
literature have been reviewed. The review process to size tube by shrinking a large
focuses on highlighting the developments diameter tube into a smaller one, by
associated with the drawing technology that drawing the tube through a die (Fig. 1 b). It
includes improvement in tool design, is so versatile that it is suitable for both
modification in product geometry, process large and small scale production.
optimization etc. with the use of Finite element The drawing process improvement has been an
method to achieve the process related objectives. area of extensive research over a long period of
time due to its commercial significance as it
Keywords-Cold drawing, Finite element method, offers excellent surface finish and closer
Process optimization, Product geometry, Tool dimensional control in the products.
design.

I. INTRODUCTION
Good quality and high precision products
can be produced by several metal forming methods
such as extrusion, drawing, rolling etc. Metal
forming is the large group of manufacturing
processes in which plastic deformation is used to
change the shape of metal workpieces [1].The
factors that determine the choice of
the forming or for that matter any other process are Fig.1 Types of Cold drawing (a) wire and bar
maximum utilization of resources with high quality drawing and (b) Tube drawing
output. Both extrusion and drawing are net shape
metal forming processes which have high material Earlier different analytical methods like
utilization and produces parts with superior Slab method, Upper bound method or slip line
metallurgical and material properties. This paper is theory were used for material flow and behaviour
a review on cold drawing process with a focus on analysis. In the recent years with the development in
the developments associated with the drawing Numerical techniques and with the advancement in
process that includes improvement in tool design, computers there is tremendous rise in the accuracy
modification in product geometry, process and pace of the solutions and information obtained
optimization etc. with the use of modern techniques in the researches.
like Finite element method to achieve the process
related objectives. In this context, Finite Element Method is one of the
most popular methods employed to resolve the

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 Praveen Kumar, Dr. Geeta Agnihotri / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 3, May-Jun 2013, pp.
metal forming problems.Kopp [2] presented a report traditional section drawing method. It dramatically
that described ways for the shortening, increased the manufacturing productivity, improved
flexibilization and optimization, as important tools. the product quality, and reduced the manufacturing
Numbers of studies on the analysis of drawing time and cost.
process carried out by researchers are discussed A newly developed plug featuring a tiny
below under different criteria. boss club structure in the sizing zone was proposed
by Xu et al. [12]. It was found that when the plug
III. LUBRICATION AND COEFFICIENT OF with a tiny boss club structure is adopted, the
FRICTION contact quality is better and the larger plastic strain
Establishing friction conditions is crucial in exists on the inner surface of the tube, which is very
bulk metal forming because of the usually high crucial in improving the surface finish of the formed
contact pressure and the influence of friction on the part. The evaluation of effect of tools’ geometries on
material flow, tool stresses and the forming force the maximum possible tube deformation was studied
[3]. The friction minimization by forming processes by Bihamta et al. [13] on variable thickness tube
is reflected in: tool life increase, stagnation time drawing process with a newly developed procedure.
reduce, increase of the machining process Based on the optimum design developed by Béland
productivity, less energy consumption, less et al. [14] through a finite element model, a new tool
consumption of tools and less production costs [4]. was built which minimised the maximum stress
In the context of the same, Chuiko et al. [5] level to draw tubes in one pass.
described the development in new forms of
production lubricants and methods of oxalate V. TOOL GEOMETRY MODIFICATION
application over Stainless Steel Tube. Lubricity Modification in conventional tube
criteria of fatty-based oils (palm, groundnut and geometry like development of the Rifled Tubes etc.,
shea butter oils), an important aspect of oil as per the application requirement has also been a
selection, were qualitatively assessed by Obi and part of several researches. Rifled Tubes have high
Oyinlola [6] for friction evaluation for processes heat-transfer efficiency and therefore are used for
like wire drawing and extrusion through open dies. the furnace wall tube in the large power plant
Neves et al. [7] carried out experimental tests with a boilers. Assurance of high dimensional accuracy in
laboratory drawing bench with three different the rifle tubes was given by Yoshizawa et al. [15]
lubricants and two different lubrication conditions in with the help of a manufacturing technique
order to study their effect on drawing loads and developed through experiments. Bayoumi [16] gave
residual stresses. Similarly Byon et al. [8] performed an analytical solution for the problem of cold
Wire drawing test for four different coating drawing through flat idle rolls of regular polygonal
materials and two different lubricants as the metal tubular sections from round tube. The forming
reduction ratio increased from 10% to 30%.Results tool load in plastic shaping of a round tube into a
showed that the behaviour of drawing force varies square tubular section was determined by Bayoumi
with the lubricant-type at the initial stage of and Attia [17] both analytically and numerically by
drawing. applying finite element simulation. Parshin [18]
utilized the obtained equations in the standard finite-
1V. IMPROVEMENT IN TOOL DESIGN element program to analyse the variation in the
The profile design of die and mandrel is the shape of the eight-beam star like tubes in the course
most important factor related to forming energy and of multipass drawing.Xu et al. [12] developed an
deformation behaviour of tubular material [9]. aluminium tube with rectangular cross-section with
Gunasekera and Hoshino [10] described a new high dimensional accuracy and surface finish. High
method for obtaining optimal die shape which quality micro copper tube with straight grooves
produces minimal stress in the extrusion or the (MCTSG) with an outer diameter of 6 mm was
drawing of non-axisymmetric sections from round obtained by Yong et al. [19].The influence of
bar stock. In order to find the best geometry of die drawing parameters on the forming of micro straight
and plug to reduce the drawing force. , Neves et al. grooves was investigated based on the forming
[7] simulated the cold drawing of tubes with fixed mechanism. Bihamta et al. [20] modified the
plug by FEM with the commercial software MSC classical tube drawing process. The sinking and
Superform. Kim et al. [9] investigated the process fixed-mandrel tube drawing methods were mixed
parameters related with tool configuration. As a together to produce tubes with variable thickness in
result, the advanced mandrel shape, which can the axial direction.
effectively transmit, without generating defect,
drawing force to deforming tube, was designed. VI. EFFECT OF RESIDUAL STRESSES
Wang and Argyropoulos [11] designed, modified Residual stress and its measurement is very
and analyzed a plum-blossom-shape die for the important aspect of cold drawing process as it has a
direct cold drawing of hexagon/square-section rods significant impact on the material performance in
in order to replace a series of converging dies in the the field. Minimisation of the induced tensile

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 Praveen Kumar, Dr. Geeta Agnihotri / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 3, May-Jun 2013, pp.
residual stresses was investigated by Karnezis et al. observations of defects developed during flow
[21]. Elices [22] showed that how stress-relaxation forming of high strength SAE 4130 steel tubes. The
losses, environmental assisted cracking and fatigue major defects observed were fish scaling, premature
life of cold-drawn pearlitic wires are influenced by burst, diametral growth, micro cracks, and macro
residual stresses. Elices [22] further discussed that cracks. When we consider the micromechanical
residual stresses due to cold-drawing are known to point of view, it is a known fact that the drawing
be detrimental to the mechanical performance- process influences the microstructure of the material
particularly as regards to creep, fatigue and in the form of progressive trend towards a closer
ductility.A numerical model using the code packing and a more oriented arrangement [33].
ABAQUS was developed by Atienza et al. [23] to Anisotropic fracture behaviour is exhibited by
study the residual macro stress state generated by prestressing steel wires (heavily drawn) in air and in
drawing. Phelippeau [24] identified and discussed aggressive environments promoting stress corrosion
the mechanisms controlling the elongation to failure cracking in several forms as was reported by
of cold drawn steel wires and examined, in Toribio et al. [33] .
particular, the role of residual stresses. Nakashima et
al. [25] patented a method to produce seamless tubes Camacho et al. [34] used the Finite
in such a way that the residual stress generated Element Method to study the effect of drawing
during the stage of correction after cold working is variables on defects. Shinohara and Yoshida [35]
limited to 30 MPa and scattering thereof is 30 MPa carried out a three-dimensional finite element
or less, when measured by Crampton method. In the analysis (FEA) that investigated the growth of
similar context, Ripoll et al. [26] proposed two surface defects due to wire drawing. They stated that
methods for reducing the residual stresses during superior wires without flaws could be obtained by
wire drawing, namely applying an advanced die removing the flaws before drawing and by multi-
geometry and performing an inexpensive post- pass drawing.Weygand et al. [36] analysed the
drawing treatment based on targeted bending drawing process with a finite element model to
operations. Kuboki et al. ([27] examined the effect determine the factors that are responsible for defects
of a plug on residual stress in tube drawing by both called splits. The effect of residual stresses due to
numerical analysis and laboratory experiment. The the cold-drawing process on the fatigue crack
typical variation in residual stresses from tensile to propagation in a metallic cracked round bar with a
compressive was seen across the drawn gold wire V-shaped circumferential notch was examined by
cross section in the experiment carried out by Carpinteri et al. [37]. The crack propagation under
Narayanan et al. [28]. Results of residual stress cyclic tension combined with the residual stresses
measurements and simulation were also presented was analysed by taking into account the SIF values
by Pirling et al. [29] .A three dimensional finite and the actual stress ratio. Toribio et al. [38]
element model was developed to calculate the numerically analysed the role of drawing-induced
change in wall thickness, eccentricity, ovality and residual stresses and strains in the performance of
residual macro-stress (RS) state for cold drawn cold drawn prestressing steel wires under conditions
tubes. A prediction model for the maximum axial of hydrogen embrittlement (HE). The results of the
residual stress was proposed by Béland et al. [14] study carried out by Tang et al. [39] illustrated the
through a finite element method that considers the damage evolution of the drawn wire in each of the
inhomogeneous deformation and heat generation in eight passes and the damage distribution along axial
a high-carbon (0.82-wt% C) drawn wire . and circular directions. Wire breakage is expected to
occur in those areas of the drawn wire where
VII. DEFECTS IN DRAWING fractures most possibly initiate [39]. Furthermore,
The misapplication of the manufacturing the numerical analyses contributed a new approach
process or lack of control at any stage may introduce for the optimization of the drawing parameters.
defects and residual stresses that can affect the
performance of structure in service, making it VIII.INFLUENCE OF THE OPERATING
susceptible to failure. The surface flaw of a drawn PARAMETERS
wire has a significant influence on the quality of De Castro et al. [41] investigated the
product [30]. The defects of cold drawn wire effects of die semi-angle on the mechanical
inherited from the wire rod may be divided into two properties of round section annealed copper
groups: those due to metallurgical processes; and bars.The FEM calculations of the drawing stress and
those due to rolling. The first group is formed in the effective strain distributions in the tube sinking
steel smelting and casting; the second is formed in process were performed by Sadok et al. [42]. The
heating and deformation in the course of rolling calculations were done for various process
[31]. Same is true for drawn tubes. In this context parameters, including different profiles of the
considerable amount of research has been carried working part of the die. Chen and Huang [43]
out, some of which is reviewed below.Rajan and employed the finite element method and the Taguchi
Narasimhan [32] presented experimental methods to optimize the process parameters of the

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 Praveen Kumar, Dr. Geeta Agnihotri / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 3, May-Jun 2013, pp.
wire drawing process. Neural networks were used the drawing process by different methods. Thin-
by Dwivedi et al. [44] to model relationships walled tubes drawing through conical convergent
between controlled and uncontrolled process dies with fixed inner, conical or cylindrical, plug
parameters and the yield. In most cases emphasis is was analysed by Rubio et al. [57]using the upper
given on one process parameter at a time and its bound method. Analytical formulations were
individual effect is studied on the product. extensively used by Gur’yanov [58]. He calculated
Dekhtyarev et al. [45] carried out a research to the limiting extension per drawing pass using six
demonstrate the combined effect of these parameters different formulas in order to determine the axial-
on final properties of the product and production stress increment in the working cone of the die.
process as a whole. Rocha et al. [46] analysed Similarly tension in the drawing process was
distortion for a typical manufacturing process of determined by Gonza´ lez et al. [59] via free body
pre-straightened, cold drawn and induction hardened equilibrium method to solve the drawing problem
AISI 1045 cylindrical steel bars using DoE (Design for dies of axisymmetric or symmetric sections. As
of Experiments). Celentano et al. [47] assessed the opposed to the classical slab method, solution of the
influence of specific operating conditions, such as equations obtained through this method accounted
the decrease of the number of wire reductions and for internal material distortion.An extension of an
the presence of back tension, on the material upper bound solution developed earlier was
response during the whole process numerically. proposed by Bui et al. [60] to predict the drawing
During the same period, Bourget et al. [48] studied stress field. Rubio [61] analysed tube drawing using
the effects of time, temperature, and furnace heating analytical methods, i.e. Slab Method (SM), with and
rate in order to identify an optimized heat treatment without friction effects and the Upper Bound
for tubes with different cold work levels. Method (UBM).

The variable thickness tube drawing was X. CONCLUSIONS

parameterized by Bihamta et al. [49]. Haddi et al. To keep up with the ever demanding
[50] studied the influence of drawing conditions on customer needs the industries have to keep on
temperature rise and drawing stress in cold drawn improving in terms of product quality, minimum
copper wires. From the experimental results, a product development cycle time, optimized usage of
relationship between temperature rise, drawing resources and incorporation of modern methods,
stress and friction coefficient was built. Bui et al. technologies to achieve the aforementioned goals.
[51] carried out a study in which experiments were This paper is a review on literature
conducted to evaluate the effect of cross section published in the context of cold drawing process;
reduction. Nagarkar et al. [52] simulated drawing of which is used for manufacturing high quality
round tubes while passing through the sink pass, products that have wide variety of applications in
using ANSYS software to study the effect of various different sectors of engineering. It helped in
parameters like die angle on the product quality. understanding the developments and research
Cetinarslan [53] determined the effects of some carried out over a period of time for different
drawing parameters like deformation ratio and problems associated with cold drawing and different
drawing speed on wire drawing. It was observed that approaches involved in problem solving ranging
these variables significantly affect the tensile and from analytical methods to Finite Element Method.
torsion strength of the ferrous wires.
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