A new model of the antifriction effect on wiredrawing with ultrasound

Abstract This paper presents a new mathematical model of wiredrawing with ultrasonic vibration based on the nonlocal friction theorem for overcoming the inadequacy in describing the friction effect by the conventional classical Coulomb friction model. The friction stress distribution, the contact pressure distribution, and the drawing force were obtained by employing Taylor's series, von Mises yield criterion, the velocity field theorem, power balance analysis, and a numerical solution method developed in MATLAB®. The ultrasonic antifriction effects of three different wires, including a copper wire, a stainless steel wire, and a titanium wire, were evaluated. The results point out that the antifriction effect of ultrasound on the titanium wire is the most obvious and then followed by the stainless steel wire and the copper wire; the ultrasonic amplitude has observable effects on the drawing force reduction, while the drawing speed has no visible effect on the drawing force. The experimental system of wiredrawing with ultrasound was designed. The experimental results verify the validity of the modeling and the theoretical analysis. The present work provides a new methodology to predict the contact mechanics and tribology property of wiredrawing with ultrasound for metals, especially for difficult-to-draw materials.