Using Metal Additive Manufacturing for Conformal Cooling of Dies in Wire Drawing

279
USING METAL ADDITIVE MANUFACTURING FOR
CONFORMAL COOLING OF DIES IN WIRE DRAWING
A.C. VAN STADEN, G.A. OOSTHUIZEN, P.A. HUGO, D.F. TREURNICHT
UNIVERSITY OF STELLENBOSCH
Abstract
During wire drawing the die is subjected to high pressures causing frictional
heat. At elevated temperatures, wear is accelerated, and the die life is
decreased. This study investigates heat accumulation in the wire drawing die
and the reduction of this heat through the incorporation of conformal cooling
channels.Areduction in heat accumulation will help to extend the dies life and
the possibility of increased wire-drawing speeds.
Aliterature survey covers temperature development within the drawing tool.A
die casing, incorporating conformal cooling channels, is designed and
manufactured using additive manufacturing (AM) technology. Its ability to
reduce the drawing tool temperatures is tested. During experimentation the
reduction per pass and the drawing speeds are kept constant, while input and
output temperatures for each reduction pass is measured.
Experimental results, comparing the conventional standard die casing with
the conformal cooled die casing, indicate a significant temperature reduction.
It is concluded that conformal cooling is viable for temperature reduction in the
drawing die. The rate of die wear is reduced. Indications are that wire
throughput and productivity per die set can be increased.
Keywords: Additive manufacturing, conformal cooling, selective laser
melting, wire drawing
1. INTRODUCTION
The SouthAfrican (SA) manufacturing industry faces specific challenges such
as a relatively limited market, a need for reduced part count, higher design
flexibility, cost reductions from design to finishing, as well as competition from
eastern sources (e.g. China's tooling industry). Furthermore, a rising need for
customised industrial application solutions exists. Customised tools can
provide a competitive advantage allowing SA to compete on a global scale.
Customisation is not limited to application, but extends to tool geometry and
material properties. The systems, methods, and processes for tooling are
developing continuously and this, together with additive manufacturing (AM)
processes, are being concentrated on in order to improve tooling performance
(Wohlers, 2012).

280Journal for New Generation Sciences: Volume 14 Number 3
The process with which the cross section of wire is reduced by pulling it
through a die opening is referred to as drawing (Kalpakjian & Schmid, 2001),
(Schey, 1987). The construction of each individual die (nib) consists of a hard
wearing material which achieves the reduction in wire diameter, as well as a
die casing in which the die is fitted. This casing facilitates installation of the die
into the wire drawing machine. The drawing machine comprises of multiple
reduction stations where the raw wire stock is fed through a die at various
stations, progressively reducing its size.
The percentage of cross-sectional reduction, die angle, drawing speed, and
friction along the interfaces are the major variables affecting heat generation
in the drawing process (El-Domiaty & Kassab, 1998). The wire drawing
process subjects the die to high pressures and creates friction between the
wire stock and the wire-drawing die. Due to high working pressures acting on
the surface of the forming die, die wear must be considered before tool design
(Kim, Kim & Choi, 1997). The high pressure on the die surface makes
minimization of tool wear particularly important for wire drawing (Lee, Lee, &
Kim, 2012). Increased down time is the result of an increased frequency in
worn die replacement, which is caused by high wear rates. Throughput is
increased by a higher drawing speed and reduced by a shortened die life. The
temperature developed within the die is positively correlated to the operational
drawing speed (Wright, 2011). At elevated temperatures the die material's
mechanical properties are compromised, wear is accelerated, and die lifetime
is decreased. According to Lee (Lee, et al., 2012) premature die wear
accounts for more than 70% of tool replacements, mechanical fatigue for
25%, and the remaining 5% are due to plastic deformation and thermal-
mechanical fatigue.
Rapid die wear may be minimized by controlling the temperature developed
within the tool. Tool wear reduction could result in increased productivity and
hence a cost reduction. Another distinct advantage is an increase in drawing
speed capability of the drawing process. Current industry practice uses water
cooling systems by submersion of the drawing tool in a circulating water bath.
This method proves to be of limited efficiency.
An improved technique, such as conformal cooling, necessitates additive
manufacturing (AM) to achieve geometries otherwise impossible with
machined tooling (Wohlers, 2012). According to Kruth, Leu & Nakagawa,
1998) notable progress has been achieved in AM applications, making direct
metalAM technology mature enough for relatively complex applications, such
as conformal cooling.
Die cooling through the use of conventional or conformal cooling channels
offers the distinct advantage of increasing the rate of heat transfer between
the work material and the machine tool. Conformal cooling, involving intricate
channels that follow the complex shape of a part, allows for optimum and
uniform cooling design.

281
Additive manufacturing (AM) has the aptitude to manufacture such tools due
to its flexibility in material applications and its ability to produce complex
geometries.
Currently conformal cooling of wire drawing tools is not an available option
and no previous work is readily available on the use of conformal cooling
methods in wire drawing applications. As such, the application and
performance of a conformally cooled drawing tool is unexplored and forms the
objective of this paper.
2 THE WIRE DRAWING PROCESS
2.1 Wire Drawing Station
Wire in excess of several thousand meters and smaller cross-sections are
drawn by a rotating drum, also known as a capstan or bull block (Kalpakjian &
Schmid, 2001). Drawing, using blocks, is dependent on the capability of the
stock to be coiled around a capstan or bull block after being drawn. The stock
is attached to the bull block after been fed through the die as illustrated in
figure 1. Once attached the bull block rotates, pulling the stock through the die
while it coils the as-drawn wire around the bull block (Wright, 2011).
Figure 1:Acommercial multiple-block wire drawing station
Single capstan drawing is often used in manufacturing facilities; however
multiple-block systems are most commonly used as indicated in figure 1. The
stock is wrapped around each capstan a few times before it enters the
following die. The contact surface between the wrapped wire and the capstan
has enough frictional contact to transmit pulling force to the undrawn stock
(Wright, 2011). This effectively lessens the amount of pulling force required by
the bull block.

2.2 Drawing as forming technology
Wire-drawing is a bulk deformation process, pulling the work material through
the die, as opposed to being pushed through the die as in the case of extrusion
(Kalpakjian & Schmid, 2001), (Groover, 2011), (Dieter, 1961). Deformation
forces are present at the exit of the die in drawing, as opposed to the forces
being at the entrance of the die, as in the case of extrusion (Lange, 1985). In
the deformation zone, a combination of tensile and compressive stresses is
encountered (Lange, 1985).The deformation of the drawing process is often
referred to as indirect compression (Dieter, 1961), (Schey, 1987). During
drawing, the draw force should be kept lower than the strength of the drawn
wire thus limiting the attainable reduction to lower than 50% (Schey, 1987).
According to Lange (1985) the maximum achievable natural strain, φmax, is
between 0.25 and 0.3 for steels and non-ferrous metals. Schey (1987)
suggests that further limitations to the drawing process arise from a possible
non-uniformity during deformation. The compression zone depth may not be
sufficient to ensure homogeneous deformation which could potentially result
in arrowhead (or centerburst) defects in less ductile metals (Schey, 1987).
2.3 Temperature Changes
The temperature in the forming process affects the final mechanical
properties of the wire, the work required, the forces, as well as the economic
outcomes of the process (Dieter, 1961). Wire drawing at high speed, for
increased productivity, affects the heat generated (El-Domiaty & Kassab,
1998). Wright (Wright, 2011) suggests that the effect of the drawing speed, v
[m.s-1], is held within the initial wire temperature, T0 [K], rather than having a
direct influence. In a multi-pass drawing setup the heat generated with each
reduction pass is not completely removed through inter-pass cooling and thus
T0 will increase relative to each reduction pass (Wright, 2011). Convective
and conductive heat loss to air and lubricant is generally included in inter-pass
cooling. Furthermore, conductive heat loss occurs upon wire contact with the
capstan (Wright, 2011). At high drawing speeds the heat generated does not
have sufficient time to dissipate. A rise in temperature therefore results and
this has a detrimental effect on the quality of the final wire product (Kalpakjian
& Schmid, 2001), (El-Domiaty & Kassab, 1998), (Lee, et al., 2010). According
to Lee, et al. (2010) in a high speed wet wire drawing process, an excessive
rise in wire temperature increases wire breakage as well as reduces the wire
quality.
Lange (1985) presents an example based on elementary plasticity theory. He
shows that surface temperatures along the deformation zone increases with
drawing speed. Wright (2011) concludes that the wire surface temperature
rises at the die exit with an increase in drawing speed. Other factors that
influence the temperature is plastic deformation, friction at the die-material
interface, heat transfer between the tool and work material, and the heat
exchange between the die and the surrounding environment (El-Domiaty &

283
Kassab, 1998), (Lee, et al., 2010). The coefficient of friction at the wire-die
interface is independent of pressure and temperature, and it may be assumed
to be constant (El-Domiaty & Kassab, 1998).
Lange (1985) presents experimental results regarding the temperature field
when a round bar is drawn. The temperature rises steeply at the material
boundary as it enters the deformation zone. Thereafter the temperature
stabilises and increases once more at the die exit. It is also clear that the
temperature does not vary significantly near the centre of the bar, even if the
drawing velocity varies (Lange, 1985).According to Lange (1985) the frictional
heat generated for all drawing velocities remains constant. Due to the time
dependence of heat conduction, however, the frictional heat will be
concentrated in a localised layer near the boundary (Lange, 1985). High
pressures in the die and the resultant friction results in accelerated die wear,
specifically when speeds are increased. Die reliability, wire dimensional
precision, and surface properties are largely determined by die wear
progression (Kim, et al., 1997), (Lee, et al., 2012), (Hillery & McCabe, 1995).
2.4 Wear during drawing
According to Kim, et al. (1997) the theory of wear can be classified according
to the contact conditions between the drawing tool and the wire product.
Amongst these wear theories the abrasive-wear theory is generally applied to
cold-forming processes and the die-wear mechanism associated with it (Kim,
et al., 1997), (Lee, et al., 2012). According to Shaw, Stableford, and Sansome
(1970) die wear, in a wire drawing process, may occur in any of the following
forms: (1) Abrasive wear and pick up can be caused by the adhesive
mechanism in which particles of the work piece material are dislodged by
subsequent material and carried down the die face; (2) Plastic deformation
can result in mechanical wear; (3) Pitting may occur as a result of cyclic
stressing of a microscopic point. The cyclic stressing could be caused by
temperature or load variations caused by unstable lubricant films; (4)
Corrosion could be a direct result of chemicals being added to the lubricant to
provide extreme pressure and/or boundary lubrication qualities. Lubricant
breakdown could also result in corrosion.
Emmens (1988) investigated the influence of surface roughness on die wear.
Generally it was found that higher values of friction are a result of higher
grades of surface roughness leading to higher rates of die wear. Frictional
forces can be explained by the welding theory (Shaw, et al., 1970). Friction is
declared as the breaking of welded junctions, between asperities of
contacting surfaces, together with a certain degree of surface ploughing
(Shaw, et al., 1970). As friction increases the temperature will rise during the
drawing process. Over long periods, dies have to be able to withstand the high
working temperatures encountered (Hillery & McCabe, 1995).

2.5 Temperature Control
In order to reduce increased temperatures in the drawing process,
improvement in the thermal management of the drawing tools is required.
Conventionally the die and casing is installed in a die box which is filled with
circulating water in order to control the operating temperatures during the
process.
Metal additive manufacturing has demonstrated the potential to fabricate tools
with complex internal conformal channels to improve the cooling uniformity
and efficiency (Xu, 1999). These channels conform to the shape of the tool
(Wohlers, 2012). In comparison, conventional tools make use of straight-line
cooling channel configurations which have lower rates of cooling than
conformal cooling channels (Wohlers, 2012).
3. ADDITIVE MANUFACTURING
Final Part properties are influenced by several additive manufacturing (AM)
process variables. Powder-based AM, specifically, involves variability in the
material, the process, and the energy source used to sinter the material
(Campanelli, 2010).
Selective Laser Melting (SLM) is based on the fusion of metallic powder
materials using a laser. Almost all metallic materials may be used and parts
are constructed on a layer-by-layer basis (Sinirlioglu, 2009). Theoretically
100%-part density is achievable through the use of a SLM technology like
Laser-Cusing. Such a dense structure yields mechanical properties as high as
(or higher than) conventionally machined parts (Sinirlioglu, 2009). Densities of
parts with conformal cooling channels are important to ensure that no
leakages will occur during operation. Part stability, the corresponding
increased part density, and the associated mechanical properties are
dependent on uniform single layers. It has been found that hatch spacing,
laser power, and scan speed are the dominant factors in determining how well
individual scan tracks are formed (Gu & Shen, 2009), (Yadroitsev, et al.,
2010).
The SLM process develops residual stresses in the material, derived from the
high thermal gradients induced in the material. Cracking, warping, uprooting,
and/or delamination are but a few defects that could result from excessive
residual stresses (Campanelli, 2010). Residual stresses can be reduced with
various heat treatments and annealing processes.
Literature and previous in-house studies have proved that SLM technologies
can successfully be used for production of conformally cooled inserts for
injection moulding. Reductions of up to 31% in cycle time have been achieved.
These inserts showed no signs of cracks, delamination or leakages during
multiple years of operation.

285
3.1 Conformal Cooling Design forAM
Manufacturing constraints associated with layer manufacturing includes the
achievable channel diameter and feature angle without the use of filler or
scaffolding to support the feature. The final process/machine where an am
part will be used also poses certain geometric constraints. Cooling channels
are required to be of adequate size to achieve the desired thermal control
without compromising the mechanical properties of the tool or the functionality
of the tool (Xu, 1999).
Uniform cooling of the product yields a uniform microstructure in metal
products, ensuring an even distribution of mechanical properties within the
metal product. Better temperature control over the cooling channel is
accomplished by decreasing the distance between the cooling channels and
the tool surfaces.
4. RESEARCH METHODOLOGY& EXPERIMENTALSETUP
This study investigates the temperature reductions that could be achieved
when using conformally cooled die casings compared to conventional die
casings. All experiments were conducted at Allens Meshco (Pty) Ltd. A die
casing serves as an encasement for the die nib and serves to hold the nib in
position during the drawing process, the die nib being the tool achieving the
desired wire reduction.
The standard die casing is classified under two die wall sizes, namely thin and
thick walled. The thick walled die casing is used, in general, for medium to
small wire diameters. The thin walled die casing is used, in general, for
intermediate wire diameters. The standard die casing is used as the basis for
the proposed casing design, incorporating conformal cooling channels. The
wire drawing process used for the study involves a four stage process as
illustrated in Figure 2.
Figure 2: Four stage wire-drawing process indicating the diameter (Ø) of the
die
Stage 1 uses a rotating die box. This serves to aid the initial drawing of the wire
stock which has surface defects present due to environmental exposure and
lack of treatment prior to being drawn. These defects could potentially
damage the drawing die if a stationary die is used for the initial reduction,
resulting in surface damage to the drawn wire. Any surface damage will
potentially damage drawing dies further down the drawing line. Furthermore,

a rotating die box allows for simplified continuous inspection, improved
lubrication application, and temperature development reduction during the
initial reduction pass (Frigerio &Arnoldi, 1992).
Stage 2 is included in the drawing schedule to guide the wire. This serves to
provide stability, increase the application of lubrication to the drawn product,
and to include a greater inter-pass cooling zone before the reductions
achieved in Stages 3 and 4.
Stage 3 achieves a 13.2% reduction in wire diameter from the initial reduction
pass. This reduction pass corresponds to the low drawing speed described
previously.
Stage 4 achieves a 15.2% reduction in wire diameter from the second
reduction pass. This reduction pass corresponds to the high drawing speed
described previously.
The variability of the drawing speed is present in the rotational speed of
successive capstans. A distinction is drawn between two drawing speeds: a
low drawing speed at stage 3 and a high drawing speed at stage 4. A thin-
walled casing is used at stage 3 and a thick-walled casing at stage 4.
4.1 Die Casing Design (Conformal Cooling Layout)
Cooling channels can be placed either far from the tool surface, or close to the
tool surface. With channel placement far from the tool surface, heat generated
during tool use will progressively increase to a steady state between heat
generation and extraction. With channel placement close to the tool surface, a
reduction in thermal mass within the tool is achieved. The optimal conformal
cooling condition can be satisfied by increasing the channel diameter, using
tool materials with increased thermal diffusivity, decreasing the distance
between adjacent cooling channels and the tool surface, or increasing the
heat transfer coefficient of the coolant used.
Xu, Sachs, and Allen (2001) presented a design framework for designers
based on the diameter of the cooling channels and the length of the cooling
channels. Figure 3 clearly indicates the feasible area describing the cooling
channel diameter and length corresponding to design constraints associated
with geometry, coolant pressure drop, coolant temperature uniformity, and
manufacturing constraints. The proposed design framework has been
developed for injection molding operations; however the principles were
adapted and used here for selection of the appropriate process conditions and
geometric parameters.

287
Figure 3: A design framework defined by cooling channel diameter and
cooling channel length (Adapted from Xu, et al., 2001)
Designing for coolant pressure drop involves determining the desirable
combination of coolant flow rate, cooling channel diameter, and cooling
channel length to ensure a resultant pressure drop lower than the given
pressure budget. Maintaining coolant temperature change within a specified
range is essential. An unusually high change in coolant temperature results in
insufficient heat being transported away from the production tool. The
designer may reduce the change in coolant temperature by increasing coolant
flow, using a coolant with a high specific heat, decreasing the length of the
cooling channels, or previously stated by decreasing the distance between
the adjacent cooling channels and tool surfaces.
The current cooling system operating at Allens Meshco (Pty) Ltd. provides
coolant for a multitude of drawing lines, as well as other production processes
and more is than capable of supporting any high pressure requirements. The
proposed die casing designs will have a negligible pressure drop and
pressure drop was excluded as a design constraint in this study.
The die box in which the drawing tool is fitted is standardized throughout the
entire facility at Allens Meshco (Pty) Ltd. The cylindrical characteristic of a die
casing required the channels to take the shape of a coil, revolving around a
single axis. The final conformal cooling channel parameters are summarized
inTable 1.

Table1: Design parameter summary of the die casings
Conventional Cooled Die Casing Conformal Cooled Die Casing
DESIGN PARAMETERS
Thin Walled
Casing
Thick Walled
Casing
Thin Walled
Casing
Thick Walled
Casing
Channel Diameter [mm] - - 4 4
Pitch [mm] - - 8 8
No. of Coil Revolutions - - 2.5 2.75
Figure 4 & 5 shows the resultant die casings designed, incorporating 2.5
channel rotations in stage 3 and 2.75 channel rotations in stage 4. Structural
integrity of the die sleeves are ensured with sufficient material between
adjacent channels. Standard nibs, consisting of hard wearing materials, are
used in each casing during the process.
4.2 Die Casing Manufacture
The two die casings are manufactured on a SLM machine, namely a M2
Laser-Cusing Machine, from Concept Laser as illustrated with its
specifications in figure 6. Both parts are printed in one build in a time of 12
hours using 30µm layers.

289
Figure 6: M2 Laser-Cusing machine used to manufacture the conformally
cooled die casingsToolsteel 1.3970 (CL50WS) is used and the building
chamber flooded with nitrogen. Parts are built directly onto a toolsteel building
plate and removed from the plate afterwards by means of wire-cutting.1.1
Experimental Setup
Only temperatures in and out of stage 3 and 4 are considered for the study in
order to directly compare the conventional and conformally cooled die
casings. A Raytek MX4 TD infrared thermometer is used with DataTempMX
software. Data is captured at 4 temperature readings per second. Three
intervals of 10 minutes each are recorded. The drawing machine is set up and
operated according to standard operational specifications. This procedure is
followed for both the standard and proposed die casings.
M2 Laser-Cusing Machine:
A large variety of Metals
including Re-Active Materials
likeTitanium andAluminium
Chamber flooded with Gas
(Nitrogen orArgon)
250 x 250 x 280 Building
Envelope
• 20 – 50 µm layers
200 W Fibre-Laser
•
•
•
Figure 7: Experimental setup: (a) Temperature recording into each die and (b)
out of each dieThe thermometer is positioned to record the temperature of
wire surface as it enters and exits each drawing stage. The thermometer is
placed approximately 200mm from the wire surface, as per the operational
specifications of the recording equipment. Figure 7 illustrates this
experimental setup.

Figure 2 indicates the temperature points at each stage.
4.4 Equipment validation
The Raytek MX4 TD infrared thermometer is validated by testing it on a block
of ice. A reference temperature of 0°C (or 273.15 K) is used for ice. A block of
ice, approximately 2199.115cm3 in size, is used for this purpose. The
thermometer is set up to record the temperature of the ice at 4 temperature
readings per second. Three intervals of 10 minutes each are recorded. The
results are shown in Figures 8-10 below.
Figure 8: Temperature
development recorded
for validation
measurement
1.measurement 2.
Figure 9: Temperature
for validation
measurement 2.
Figure 10:
Temperature
for validation
measurement 3.
The graphs show a consistent temperature measurement throughout the
validation process for all three measurements. The results indicate a steady
temperature measurement between -0.2 and 0.2 ºC with a median value of
0.03ºC. This corresponds, within a reasonable range, to the expected
temperature value for ice as stated by Cengel and Boles (2008).
5. EXPERIMENTALRESULTS
In order to confirm the feasibility of the proposed die casing designs, the
averaged results for the standard die casings are graphed together with the
averaged results for the proposed die casing.
5.1 Temperature measurement into stage 3
Stages 1 and 2 remain unaltered for both experimentation phases. This
implies that the temperature coming out of stage 2 (the temperature going into
stage 3) should be similar in value for both the standard and conformally
cooled die casings.

291
The similarity assumption stated previously is confirmed by Figure 11. The
difference in the median values for the average temperatures measured into
stage 3 is small. This indicates a correct replication of the experimental
procedure for both the conventional and new casings at stage 3.
5.2 Temperature measurement out of stage 3
The average output temperatures measured for stage 3 are presented here.A
significant rise in temperature can be seen from the input to the output
temperatures.
Figure 11: Average temperatures measured into stage 3.
40.00
41.00
42.00
43.00
Standard Casings Proposed Casings
Temperature[ºC]
Casing Type
66.00
68.00
70.00
72.00
74.00
76.00
78.00
80.00
82.00
84.00
86.00
88.00
Temperature[ºC]
Casing Type
Figure 12: Average temperatures measured out of stage 3.

Figure 12 presents the average temperatures measured out of stage 3.Aclear
reduction in temperature is visible. The conformally cooled die casing design
achieves a 13.08 ºC (or 15.54%) reduction in median temperature from the
standard operating condition.
5.3 Temperature measurement into stage 4
Upon exiting stage 3 the wire product temperature decreases as a result of
inter-pass cooling. The input temperature for stage 4 is, however,
considerably higher than the input temperature associated with stage 3.
60.00
62.00
64.00
66.00
68.00
70.00
72.00
74.00
76.00
78.00
80.00
Temperature[ºC]
Casing Type
Figure 13: Average temperatures measured into stage 4.
Figure 13 presents the average temperatures measured into stage 4 for both
die casing types. The accumulated effect of the conformal cooling
mechanism, as well as the inter-pass cooling mechanism, results in a
temperature reduction of 14.87ºC (or 19.41%) in median temperature from the
standard operating condition.
5.4 Temperature Measurement out of stage 4
The effect of heat accumulation on the temperature exiting Stage 4 is evident
in the experimental results. A substantial increase in temperature occurs
during the final drawing stage that could potentially degrade the die life more
rapidly and have a detrimental effect on the final wire product, as opposed to
the associated die life and product quality for the wire drawing tools in previous
drawing stages.

293
A significant reduction in the accumulated and developed temperatures, as
measured out of Stage 4, is evident for the conformally cooled dies presented
in figure 14. The conformal cooling system accomplishes a 33.27 ºC (or
24.21%) reduction in median temperature from the standard operating
condition.
5.5 Wire Surface Roughness
A total of six wire samples were taken during the process and their
microscopic images are shown in Figure 15. The die wear development can
evidently be seen over the length of the wire.
Figure 14: Average temperatures measured out of stage 4.
95.00
100.00
105.00
110.00
115.00
120.00
125.00
130.00
135.00
140.00
145.00
Temperature[ºC]
Casing Type
Sample 1 Sample 2 Sample 3 Sample 4 Sample 5
ConventionalDie
Casing
ConformalCooled
DieCasing
Figure 15: Wire Surface Roughness for 6 Samples Taken

The degree of wire surface degradation is more prominent for the standard die
casing as illustrated by the sixth samples. This indicates that a decrease in the
temperatures developed within the drawing tool results in a decreased rate of
die wear development.
6. CONCLUSION
The purpose of the study was to understand the degree conformally cooled
die casings would reduce heat during certain stages of a wire-drawing
process.
Additive manufacturing was successfully used to build the two die casings for
stage 3 and 4 of the process in toolsteel. No cracks, delamination or leakages
are observed during operation of the system.
Conformal cooling proves to be exceptionally effective as a method to control
thermal heat formation during the wire-drawing process. The temperature
reduction indicates a possible increase in the die life as well as the ability to
increase the operational drawing speed of the process. The reduction in
median temperature values (per reduction stage) at stage 3 was 13.08 ºC (or
15.54%) and 33.27 ºC (or 24.21%) at stage 4.
The effect that the die surface roughness, non-uniform lubrication and initial
wire surface roughness has on temperature development was excluded from
this study.These factors should be included in future studies.
Further studies should be carried out to determine by how much the tool life
could be extended and how this will relate to increased wire-drawing speeds
and wear.
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