• Transactions of Materials Processing
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• v.27 no.3
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• pp.154-159
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• 2018

In the rectangular bar multi-stage drawing process, the cross-section dimensional accuracy of the rectangular bar varies depending on the aspect ratio and process conditions. It is very important to predict the dimensional error of the cross-section occurring in the multi-stage drawing process according to the aspect ratio of the rectangular bar and the half die angle of each pass. In this study, a process map for improving the dimensional accuracy according to the aspect ratio was derived in the drawing process of a rectangular bar. FE-simulation of the multi-stage shape drawing process was carried out with four types of rectangular bar. The results of the FE-simulation were trained to the nonlinear relationship between the shape parameters using an Artificial Neural Network (ANN), and the process maps were derived from them. The optimum half die angles were determined from the process maps on the dimensional accuracy. The validity of the suggested process map for aspect ratios 1.25~2:1 were verified through FE-simulation and experimentation.

• Transactions of Materials Processing
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• v.24 no.3
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• pp.155-160
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• 2015

One of the most important aspects in multi-stage shape drawing is the proper design of the intermediate dies especially to provide adequate metal distribution. In the current study, a method for designing the intermediate dies has been developed to manufacture hollow linear motion guide rails by multi-stage shape drawing. The design method is based on the modified virtual die method. The effectiveness of the proposed design method was verified by FE-simulations and experiments using Mn55Cr carbon steel. From the results of the FE-simulations and the experiments, the proposed design method led to a drawn product with a sound shape. The dimensional tolerances of the product were within the allowable specified tolerances.

• Transactions of Materials Processing
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• v.24 no.3
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• pp.187-193
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• 2015

The objective of the current study is to determine cross-sectional profile of intermediate dies in order to improve the plastic strain homogeneity which directly affects not only the dimensional accuracy but also the mechanical properties of final product by redesigning the intermediate dies using the conventional electric field analysis (EFA) method. Initially, the multi-pass shape wire drawing was designed by using the equivalent potential lines from EFA. The area reduction ratio was calculated from the number of passes in multi-pass shape wire drawing but constrained by the capacity of the drawing machine and the drawing force. In order to compensate for a concentration of strain in a region of the cross section of the wire, the process for multi pass wire drawing from initial round material to an intermediate die was redesigned again using the electric field analysis. Both drawing process designs were simulated by the finite element method in which the strain distribution and standard deviation plastic strain of the cross section of drawn wires were examined.