Master’s Thesis in Production Engineering Examines Numerical and Experimental Study of Die Geometry Effect on Wire Drawing Process
A master’s thesis titled “Numerical and Experimental Study of die Geometry Effect on Wire Drawing Process” was discussed in the Production Engineering Department at the College of Production Engineering and Metallurgy, University of Technology.
The research, presented by student Sura Hassan Mahmoud, aimed to determine the effects of variables in wire drawing on process performance using numerical simulation alongside theoretical methods and experimental work. Three of the most widely used wire materials in industry were selected: AISI 4340 carbon steel, 6061 aluminum alloy, and C11000 copper alloy, all with an initial diameter of 3 mm. These materials were then drawn in a single pass using dies with approach angles of 12°, 15°, and 18°, and reduction ratios of 13%, 23%, and 36%. A theoretical analysis based on the Slab method was also conducted, and the mathematical model was converted into computational algorithms implemented by MATLAB to predict approximate drawing force values. ANSYS Workbench was used to create a finite element model that predicted stress distribution and simulated the drawing process.
The results showed that the process efficiency was affected by die geometry. The drawing force decreased with an increase in the approach angle. Additionally, deformation resistance and stress increase were influenced by the reduction ratios. The material behavior varied significantly when process variables were changed.
Copper was the least sensitive to changes in parameters when compared to other materials. On the other hand, steel was significantly affected by parameter changes and had an impact on work performance, while aluminum showed intermediate behavior.
The examining committee consisted of:
- Assist. Prof. Dr. Adnan Ibrahim Mohammed from the Presidency of the Republic (Chairman)
- Assist. Prof. Dr. Khalida Kadhim Mansour (Member)
- Lect. Dr. Mohammed Sattar Jabbar (Member)
- Assist. Prof. Dr. Jalil Jabbar Shukr (Supervisor)
- Dr. Raed Rashid Shuwaiyish (Supervisor)
All committee members are from the College of Production Engineering and Metallurgy at the University of Technology.
