Steady-state numerical modeling of size effects in wire drawing

Abstract eng:
Wire drawing processes at micron scale receive increased interest as micro wires are increasingly required in micro electrical components. At the micron scale, size effects become important and have to be taken into consideration. The goal is to optimize the semi-cone angle of the tool in terms of drawing force. The present study employs a steady-state modelling technique that omits the transient regime, thus creating a basis for comprehensive parameter studies. The steady-state procedure is based on the streamline integration method presented by Dean and Hutchinson [1]. This approach allows elastic-plastic loading/unloading to be taken into account and it is readily implemented into an existing finite element program. The numerical model deals with a time dependent material model that includes strain gradient effects according, to Fleck and Willis theory [2]. The analysis indicates that size effects reduce the optimal semi-cone angle of the tool with up to 40%.

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