A comparison between process parameters in die and roll drawing

Many ways to achieve the reduction of the pulling forces in the drawing process have been largely studied especially searching for such techniques capable to reduce the friction coefficient inside the die. On the other hand, the same issue has been poorly approached by developing alternative technologies. Particularly, a few knowledge is available about the roll drawing process; even though the advantages of this technology have been illustrated in some researches and the pulling forces in standard and roll drawing have been measured and compared, no mathematical or empirical relationship has been still established between these two technologies; thus the value of the pulling forces in roll drawing is unknown until the pass is physically realized. In the present paper, an industrial double pass for the production of low carbon steel wires (actually realized by standard drawing) has been analyzed by FEM techniques. Besides, the same pass has been numerically simulated adopting a roll drawing process and the pulling forces have been calculated. Subsequently, a testing bench has been realized to validate the results and to physically verify the reduction of the drawing forcers noticed in the FE models.