Influence of Flaws of Wire Rod Surface, Inclusions and Voids on Wire Breaks in Superfine Wire Drawing

Abstract

By means of the finite element analysis (FEA), this study analyzed wire breaks that occurred in the drawing fine wires containing flaws on the wire surface, inclusion and void. The deformation behavior of an inclusion was examined, in which the inclusion's location is assumed to be on the center axis of the wire, and the cause of wire breaks and their prevention method were clarified. It was found that an inclusion diameter/wire diameter ratio of 0.4 or higher increases the likelihood of wire breaks occurring. When the inclusion is not assumed to be in the center axis of the wire, it was also found that necking and wire breaks appear more frequently. FEA showed that a flaw grows with each processing step, when a small circumferential flaw is placed on the wire rod surface, and eventually becomes a surface defect, which is called a check mark in practice.