Assessment of ductile failure models in single-pass wire drawing processes

Abstract

The present work reports a comparative study of ductile failure models applied to an Al-2011 aluminumalloy single-pass wire drawing process using different reductions. The material damage experienced in thewire after passing through the die is evaluated using the well-known Rice and Tracey, Cockcroft andLatham, Brozzo and Modified Chaouadi models. Due to the fact that nonrealistic damage predictions arefound for the highest studied wire reduction, an alternative uncoupled failure criterion combining theeffect of deformation and triaxility is proposed. The ability of these five models in predicting the formationof chevrons in the process is the main focus of this research. First, the model parameters are characterizedby means of numerical simulations of the tensile test. Then, the predictions of the numerical analysesof the drawing process are compared with available experimental results where physical evidence ofchevrons was found. Relevant variables are analyzed to determine their incidence in the formation ofcentral bursts. Finally, the performance of this new model is assessed for the full reduction scenarios.