23. - 25. 5.

2012, Brno, Czech Republic, EU

EFFECT OF DRAWING ANGLE SIZE OF A DIE ON WIRE DRAWING AND BUNCHING

PROCESS

a a b
Viktor TITTEL , Miroslav ZELENAY , Ľuboš KUDELAS
a
STU Faculty of Materials Science and Technology in Trnava, J. Bottu 25, 917 24 Trnava, Slovak Republic,
viktor.tittel@stuba.sk, miroslav.zelenay@gmail.com
b
TU Košice, Faculty BERG, Park Komenského 14, 040 01 Košice, Slovak Republic, lubos.kudelas@tuke.sk

Abstract
This paper focuses on the effect of drawing angle size of a die on the wire processing into a ropery at the
bunching of steel cords. Experiments were carried out with usage of standard dies with drawing angle size
2α = 11° and 2 α = 13°. Results of the experiments were statistically evaluated and they proved that dies
with 2α = 11° had beneficial effect. Drawn wires on dies with 2α = 11° were with lower level of hardening and
so the drawing process was better. This beneficial effect of 2α decrease was also demonstrated by the
reduction of wire fractures and lower wire scrap quantity during steel cords bunching.
Key words:
wire hardening, bunching, die, drawing angle, steel cord

1. INTRODUCTION
The basic design solution of die is realized so that by drawn wire it covers the required precision of the
dimension and the quality of surface. Unthinkable part of the die construction is its geometry [1, 2]. By steel
wire drawing the process of plastic deformation is generated and this is in consequence of the present force
effect (Fig. 1) and drawing force. Drawn steel wire and die are heated gradually. Creation of thermal energy
is caused in the result of transformation of strain work and the next reason, which causes the creation of
thermal energy, is friction between the wire surface and the die [3, 4]. The heating of surface layers of the
wire is affected by drawing speed, because it affects directly the contact time of the wire with the die.

Die

qm

.qm
d0

d1

F
2α

Wire

Fig. 1 Pressure between the die and wire [1]

where: F – drawing force, qm – pressure between die and wire, µ – coefficient of friction
 23. - 25. 5. 2012, Brno, Czech Republic, EU

The biggest plastic deformation by the process of wire drawing ranges in the interval of elected angle of
drawing cone of die 2α. By great angle of drawing cone the work for repression of secondary internal
materials movement is increasing. Magnitude of the drawing force by constant friction coefficient is then
stated by die geometry and reduction. In connection with the steel wire drawing there is a risk of drawing
wire breaking creation. The risk of wire breaking influences then workability of wire in the process of steel
cords bunching. On the basis of this fact it was realized multiple experiments with the aim of monitoring of
the dependence between the die geometry and workability of wire in the bunching process. [1, 5, 6]
Steel cords are one of the basic structural components of tires and they are compound of wires, which are
used for tire body or tire buffers at the production of tires. Technological process of steel wires production
/wire drawing/ is a difficult process that is influenced by a wide variety of factors. The basic production tool
which is used in the process of steel wire drawing is die (Fig. 1).

2. EXPERIMENT DESCRIPTION
The experiment was in progress during 41 days of continual production and 650 t of wires of suitable quality
were made. Chemical composition, mechanical properties and metallographic parameters of used heats of
wire rod were very similar, without significant differences. In all machines it was used the same lubricating
emulsion which was balanced by technological standard. During the experiment it was judged mechanical
properties of wires, breakages and next wires processing, too.
Our experiment was implemented in drawing shop and ropery of steel cords. On fine drawing (by wet wire
drawing) it is produced the steel wire about diameter 0.300 mm in the long term. Steel wire about diameter
0.30 mm was produced from patented semiproduct about diameter 1.65 mm. This wire is using as a
semiproduct for steel cord 2x0.30 mm bunching. This construction of steel cord is at the present time very
expanded and it is using to the tire body at the production of tires for personal motor cars. The test was
implemented by using of die set with twenty dies. On fine drawing it was used dies from supplier A. Dies from
supplier A were standard supplied by die geometry with drawing angle 2α = 13° (A 13). These dies from
company A were compared with dies from supplier B that prepared dies with drawing angle 2α = 13° (B 13)
and 2α = 11° (B 11). During the experiment realization the conditions of drawing were stable. The same
lubricating emulsion was used in every machine, which was defined by technologic process. The drawn
-1
speed was v = 18 m.s . Besides within the frame of experiment it was performed the following of wire
workability in dependence on the change of drawing angle 2α from original 13° to 11°.
Wire, which is produced on fine drawing, was subsequently processed on double-twisted machines. Wire
processing was in progress by particular sorts with exclusion of mutual immixture among particular groups.
In the bunching process it was recorded amounts of produced steel cord, number of breakages, quality of
steel cord, straightness and overall curves bounce by steel cord. Besides, it was registered a scrap, this is a
wire, which was unworkable because of very high frequency of breakages. During the bunching it was from
time to time obtained sample for tests. In the process of bunching every groups of wires were processed on
the same double-twisted machines concurrently and on equal terms of double-twisted machines setting.
We can characterize the wire workability as a number of wire fractures which originates during the process of
bunching. If the number of wire breakdowns is lower, so its workability is higher and by that a number of
tense wire grows lower, which is disabled to the technological waste. From the view of other processing the
number of breakages per ton of produced cord is a very important index. This index talks about a quality of
produced wire. [7]

3. EFFECT OF DIE GEOMETRY ON WIRE WORKABILITY

The consumption of dies (Fig. 2) and assessment of mechanical properties of wires were the next
parameters which were verified within of this experiment.
 23. - 25. 5. 2012, Brno, Czech Republic, EU

Fig. 2 Die consumption in the set

At the design of experiment it was appear from the assumption that lower drawing angle 2α, lower Δ-
parameter value (and lower relative pressure die can positive influence dies consumption, mechanical
properties of wire and also entire drawing process (Fig. 3). It was also partially confirmed in our case.

Fig. 3 The wire in the die. Schematic

dm d0  d
  . sin  (1)
l d0  d
where: α – ½ drawing angle [°], d0 – diameter of wire before drawing [mm],
d – diameter of wire after drawing [mm] [8]
1
 (1  1   d ) 2 .sin  (2)
d
where: εd – calculated reduction [-] [9]
q   2  1   d (3)
m
  ln(1   d ).(1  )  .
 m   3   .(1   )
tg
d

where: qm – pressure between wire and die [MPa]

σm – flow stress, which is approximately equal to the mean value of the yield strength S 0,2 [MPa] [10]
It appears from this that in general the consumption of dies B11 was lower as the both others compared die
groups. A backset occurs at the finished dies when the value of Δ-parameter begins to increase and also a
pressure into the die. The value is more favourable (lower) for B11 dies (for a last die Δ = 3.29) against dies
 23. - 25. 5. 2012, Brno, Czech Republic, EU

with the approach angle 13º (B13 for a last die Δ = 3.89). In general the dies with lower Δ-value require the
better lubricant properties with a lower friction coefficient with good resistance against the dissociation. The
properties of our lubricant did not probably satisfy in full extent to these criterions and therefore the wires
hardening, which were drawn with the dies B11, were slightly more against the wires processed with dies
B13. A confirmation of this idea is slightly higher breaking force and also tensile strength against dies of
group B13. A comparison of relative die pressure and the Δ-parameter for each diameter in the die series
are listed in the table 1.
Tab. 1 Comparison of relative die pressure and Δ-parameter for each diameter in the die series
A13 B13 B11 A13 B13 B11 A13 B13 B11 A13 B13 B11
 [mm] Ø [mm]
qm/σm [-] Δ – parameter [-] qm/σm [-] Δ – parameter [-]
1.49 1.45 1.45 1.35 2.23 2.23 1.89 0.62 1.59 1.59 1.47 2.68 2.68 2.26
1.35 1.48 1.48 1.37 2.31 2.31 1.95 0.57 1.60 1,60 1.48 2.70 2.70 2.29
1.23 1.46 1.46 1.36 2.25 2.25 1.90 0.52 1.58 1.58 1.46 2.64 2.64 2,24
1.12 1.59 1.59 1.48 2.66 2.66 2.25 0.48 1.58 1.58 1.46 2.65 2.65 2.24
1.03 1.60 1.60 1.46 2.71 2.71 2.30 0.44 1.57 1.57 1.45 2.61 2.61 2.21
0.95 1.58 1.58 1.49 2.64 2.64 2.23 0.41 1.61 1.61 1.49 2.74 2.74 2.32
0.87 1.61 1.61 1.48 2.75 2.75 2.33 0.37 1.59 1.59 1.47 2.68 2.68 2.26
0.80 1.60 1.60 1.47 2.71 2.71 2.29 0.34 1.60 1.60 1.48 2.70 2.70 2.29
0.74 1.59 1.59 1.47 2.68 2.68 2.27 0.32 1.73 1.73 1.58 3.12 3.12 2.64
0.68 1.59 1.59 1.47 2.67 2.67 2.26 0.30 1.95 1.95 1.77 3.90 3.90 3.29

Within the experiment the total dies consumption from company B was lower more as twice against dies from
company A. The lower dies consumption B13 was probably influenced by the better quality of the die
treatment and accuracy of geometry keeping. At the dies B11 the Δ-parameter and so more favourable
relative die pressure played a significant role, which was lower than dies with the drawing angle 13º. The
comparison of total dies consumption is in a table 2.
Tab. 2 Comparison of total dies consumption
Dies group A13 B13 B11
Dies consumption [pieces/tonnage of production] 15.29 6.26 6.56

When we analyzed and found the dependencies between dies consumption and relative die pressure the
Wistreich´s theory was confirmed that dies consumption would increase if the relative pressure between wire
and die increased. Table 2 follows that the lower relative die pressure is the lower dies consumption is and
also a longer lifetime is. The lowest dies consumption was reached at the die dimensions, which were
calculated with the lowest relative pressure (Fig. 2).
Based on mentioned it can be supposed that it would be suitable to use different calculated reductions for
dies with drawing angle 11° that we decreased relative die pressure and so positive influenced the die
consumption. In future it can also be supposed a trend for next decreasing of drawing angle 2α at the wires
drawing at the allowance of Δ-parameter size and relative pressure.
The following of mechanical parameters were carried out continuously before starting of bunching. The each
of tested wires fulfilled the specific request of breaking force, request in tolerance limits from 180 to 230N
and wires were statistical evaluated.
 23. - 25. 5. 2012, Brno, Czech Republic, EU

m-3,00s m m+3,00s m-3,00s m m+3,00s

n = 189 24,0 n = 128
30,0 15,87
AVG = 211.1 N AVG = 205.2 N
s = 2.413 N s = 2.240 N
24,0 Ppk = 2.61 12,70 19,2 Ppk = 3.69 14,84

CELL FREQUENCY
CELL FREQUENCY

11,88

PERCENT
18,0 9,52 14,4

PERCENT
8,91
12,0 6,35 9,6
5,94

6,0 3,17 4,8

2,97

0,0 0,00 0,0 0,00

206,9 208,7 210,5 212,3 214,1 215,9 199,9 201,7 203,5 205,3 207,1 208,9
206,0 207,8 209,6 211,4 213,2 215,0 216,8 199,0 200,8 202,6 204,4 206,2 208,0 209,8
CELL BOUNDARY CELL BOUNDARY
Fitted curve is a Normal. K-S test: 0,704. Lack of fit is not significant. Fitted curve is a Normal. K-S test: 0,453. Lack of fit is not significant.

03.08.12 14:10
Group A13 03.08.12 14:11
Group B13
m-3,00s m m+3,00s
CHART1: Tabu¾ka spôsobu priebehu : NOSNOST.QDB - Nosnost A13 CHART2: Tabu¾ka spôsobu priebehu : NOSNOST.QDB - Nosnost B13
24,0 n = 130 18,46
AVG = 208.8 N
s = 3.698 N
19,2 Ppk = 1.91 14,77
CELL FREQUENCY

PERCENT
14,4 11,08

9,6 7,38

4,8 3,69

0,0 0,00
204,3 207,3 210,3 213,3 216,3 219,3
202,8 205,8 208,8 211,8 214,8 217,8 220,8
CELL BOUNDARY
Fitted curve is a Normal. K-S test: 0,708. Lack of fit is not significant.

03.08.12 14:12 Group B11

CHART3: Tabu¾ka spôsobu priebehu : NOSNOST.QDB - Nosnos•B11
Fig. 4 Breaking force histograms of drawn wire (Ø 0.300 mm)

Tab. 3 Tensile strength of drawn wire  0.300 mm

Dies group A13 B13 B11
Tensile strength of drawn wire  0.300 mm [MPa] 2963.2 2898.7 2947.3

The overview of wire workability in the ropery can be seen in next table 4.
Tab. 4 Overview of wire workability in the ropery (SC production, fractures and scrap) [7]
Standard production (A13) Production (B13) Production (B11)
Production Scrap Fractures Production Scrap Fractures Production Scrap Fractures
[kg] [%] [n/t] [kg] [%] [n/t] [kg] [%] [n/t]
362313 3.614 7.558 185146 4.17 10.77 113411 0.92 4.70
[kg/day] 8234 [kg/day] 4208 [kg/day] 2577

From presented results of the experiment it is visible the quality fluctuation and workability of wires in the
ropery. One of the reasons of this fact is that till 5% of dies had in the first phase damaged core and from this
reason the surface of drawing wire was grooved on the surface.
This damage of wire influences the load capacity of steel wire only in minimal measure, but its negative
influence shows by wire loading with torsion moment. From reason that this type of loading is by the
production of wires on double-twist machines, in some phases of production it was excessive high increase
of the number of wires breakages and by that it comes to the increased deletion of material. On the basis of
this it is possible to state the assumption that the surface damage of wire supports directly the creation of
breakages by the bunching process. This statement relates to double-twist machines above all.
 23. - 25. 5. 2012, Brno, Czech Republic, EU

It can see from the table 4 that the best results in the bunching process were achieved at the wire processing
which was drawn with dies of B11 group. The number of fractures per tons of production was calculated only
4.70 at the processing evaluation of this wire. Maximum level was defined on 5.50 of fractures per production
tons. Workability of wires from the groups A13 and B13, i.e. drawn with dies which had drawing angle
2α = 13º, was essentially worse as from wires of B11 group. Expressive scrap elimination from 3.6% at A13
against 0.92% at B11 was achieved by the reduction of fractures number and by the drawing process
enhancement.

4. CONCLUSION
It was demonstrated and confirmed by the experiment the influence of dies geometry dies consumption. The
influence on the mechanical properties (in our case on the breaking force) was not entire confirmed. At the
same drawing conditions if we change die geometry we can reach more than twice lower dies consumption
what we can see in the table 2. From experiment it is followed that the dies consumption can also be
influenced by the quality and accuracy of dies geometry making up. It was also demonstrated if we change
dies geometry we can achieve better workability in the ropery.
Based on mentioned in this experiment can be globally evaluated as experiment with an enormous benefit
because it demonstrated a way for the next routing at the steel cord wires production. The main direction
should be focused on the drawing angle decreasing, accuracy of die geometry making up and correction of
calculated reductions for new die geometry.

ACKNOWLEDGEMENTS

Paper was made under grant support Grant agency of the Ministry of Education of the Slovak
Republic (VEGA) No. 1/0922/12.

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