Finite-element modelling of thermal and deformational processes in manufacturing high-strength wire

The paper considers simulation of thermal strain processes while high-strength wire manufacturing. Thermal strain processing (TSP) technique was studied. Processes model consisting of wire high-speed heating up to temperatures exceeding Ас3, homogenizing soaking, workpiece straining, workpiece transfer to cooling zone under controlled and stabilized temperature providing polygonised structure formation. Simulation of thermal strain induction heating, wire drawing and reduction by running in three-roll running head was performed on the basis of conceptual functional model. Induction heating thermal field is not homogeneous within the section and depends on wire diameter, inductor transfer speed and induction heating frequency. Wire drawing shows complex state of stress, the process is axisymmetric, equivalent plastic strains are slightly different from rated strains; possible tear location on leaving the die is shown. Running equivalent plastic strains are considerably different from the rate one in terms of reduction due to tangential component. Three-roll running head application may result in higher material strengthening than it has beenpredicted during technique development on the account of pre-assigned degree of strain.