Wire Die Drawing Simulation in ANSYS Mechanical
Hi everyone, this is Mingyao from Ozen Engineering. In this video, I'll be demonstrating how we can make a wire thinner by pulling it through a wire die. I have the privilege of working with a wide range of companies, and it always impresses me how complex it is to make everyday things. Today, we're going to look at pulling a wire through a die using ANSYS Mechanical.
Introduction to the Wire Die Tool
We'll be using a Fort Wayne wire die tool. This is their blue book, and I'll give a quick demonstration of how we can model wire getting pulled through this die using ANSYS Mechanical.
Modeling Process
- Start by taking a picture of the die. This will serve as the geometry for our analysis.
- Use ANSYS SpaceClaim CAD modeling tool to sketch on the xy-plane for an axis-symmetric model.
- Import the picture and align it with the background image to extract the die's shape.
- Vectorize the image and adjust the threshold to capture the die's shape accurately.
- Hide the image and select the curves to create a surface representing the die.
- Sketch the wire using the center line as the line of symmetry and adjust the geometry as needed.
Simulation Setup
- Change the analysis type from 3D to 2D axis-symmetric model.
- Define the die and wire materials: diamond for the die and platinum for the wire.
- Define the contacts manually due to the large gap.
- Set up the mesh with appropriate sizing and inflation layers for detailed analysis.
- Apply boundary conditions and forces: fixed support and displacement with a pull force.
- Enable large deflection and automatic time steps for convergence.
Analysis and Results
The simulation shows how the wire deforms as it passes through the die. Key observations include:
- Stress and strain distribution as the wire is pulled through the die.
- Plastic deformation in the contact region.
- Force required to pull the wire through the die.
Parametric Analysis
ANSYS allows for parametric analysis to optimize design parameters such as:
- Pull force
- Wire thickness
- Material properties
Conclusion
This demonstration highlights the capabilities of ANSYS Mechanical in simulating wire drawing processes. Although I'm not a wire pulling expert, these tools are valuable for the industry and are easy to use for 2D axis-symmetric examples.
If you enjoyed this video, please subscribe to our channel. For any questions, reach out to us at Ozen Engineering, Inc. Thank you and have a good day!
Hi everyone, this is Mingyao from Ozen Engineering. In this talk, I'll be discussing wire die drawing simulation in Ansys Mechanical. I have the privilege of working with a wide range of companies and it always impresses me how complex it is to make everyday things.
So today we're going to look at pulling a wire through a die that looks like this. This is a Fort Wayne wire die tool. I'll give a quick demonstration of how we can model wire getting pulled through this die using ANSYS Mechanical.
We'll start with a picture of the die and use it to create a geometry for a static structural simulation. I'll use ANSYS SpaceClaim CAD modeling tool to sketch the shape of the die on the xy-plane and extract the midline. Then, I'll create a surface that represents the curves of the die.
Next, I'll create a cable that goes through the middle of the die. I'll use the center line as the line of symmetry and trim out the excess. Then, I'll round out the sharp corners and make the cable slightly thinner. Now, we have a geometry that we can start simulating.
We'll pull the cable through the die and deform it as it goes through. We'll define the properties of the die and cable, and set up the contacts between them.
We'll adjust the initial mesh to have a smaller size on the side of the cable, and add inflation layers to refine the mesh in the contact region. Then, we'll support the cable on one side and apply a displacement in the X direction.
We'll also apply a pull force in the Y direction and let the simulation run. As the cable goes through the die, we'll see the deformation, stress, and plastic strain. Once the simulation is finished, we can look at the results and see how the cable is deformed as it goes through the die.
We can also see the equivalent stress, plastic strain, and total strain. Thank you for watching. If you have any questions, reach out to us at Ozeninc.com. Have a good day. If you liked this, please like us on YouTube and subscribe to our YouTube channel. Thank you.
