Analysis of Intermediate Die Profile in Multistage Shape Drawing Process Based on Two-Dimensional Electric Field Analysis: Results for Trapezoidal-Shaped Wire

In this study, the design method for intermediate die profiles has been developed to manufacture trapezoidal-shaped wires in the multistage shape drawing process based on the two-dimensional electric field analysis (2D-EFA). The intermediate die profiles are extracted from the numerous equivalent potential lines generated by the electric field between an initial material and a product profile. In order to reduce the localized strain distribution, the asymmetric intermediate die profiles are replaced by symmetric die profiles through the additional 2D-EFA. Deformation analysis was performed to compare the general and the advanced 2D-EFA methods including the minimized number of asymmetric intermediate dies. Furthermore, experiments designed by the advanced 2D-EFA method were carried out to evaluate the dimensional accuracy of trapezoidal-shaped wires. Analytical and experimental results indicate that the proposed design method could be widely used to design the multistage shape drawing process for the trapezoidal-shaped wire.