Analysis of The Effect of Ultrasonic Excitation on The Wire Drawing Process for Aluminium Wire Using Finite Element Method

Abstract

The utilization of aluminium wires is widespread in the electrical energy transmission industry as well as in various other applications. Wire drawing are used to decrease the diameter of the wires. Simulations are conducted utilizing simulation software to imitate the drawing process of a 2.6 mm diameter Aluminium wire and reducing it to 2.2 mm through both conventional drawing methods and simulation that includes excitation of ultrasonic stimulation. The study of adding ultrasonic stimulation focuses on two critical elements, the draw force and its impact on the energy consumption during the drawing process, and the stress induced on the aluminium wire. The results of the simulation demonstrate a reduction in both the energy consumption and the stress levels on the Aluminium wire as a result of incorporating ultrasonic technique in stimulation of the drawing process.

The process of adding ultrasonic stimulation to the metal forming process works to reduce the power required for the process by reducing the drawing force. The required force for the aluminium wire metal forming process decreased by approximately 14% as a result of adding ultrasonic stimulation. Additionally, we observed an improvement in the aluminium wire through a reduction of the stresses generated during the drawing process by approximately 7% due to the addition of ultrasonic stimulation to the wire drawing die. The vibrations of the die created a gap-like effect between the inner surface of the die and the wire, which led to a reduction in the required force for the metal forming process and a decrease in the stresses generated on the wire surface.