Investigations on the effects of forming conditions on the deformation behaviors of copper-steel bimetallic rods during cold drawing processes

Abstract

Abstract Metal composites are widely used in different industries owing to their significant improvement in material properties such as mechanical strength, electrical conductivity, and corrosion resistivity compared to traditional metals. Such composites can be manufactured and processed in different ways to achieve the desired geometry and quality, among different metal forming techniques, drawing is the one that can be used to produce metal composites from raw materials or as a secondary processing method for metal composites. The drawing processes of the two cases are basically the same except for the initial bonding conditions of the billets. In this paper, bimetallic rods with AISI-1006 Low Carbon Steel core and C10100 Oxygen-Free Electronic Copper sleeve are modeled using finite element software DEFORM. The simulation models are verified by drawing experiments. The effects of initial bonding conditions, initial core ratio, reduction ratio, semi-die angle, drawing speed, and friction on the plastic deformation behaviors of the bimetallic rods are investigated. The results indicate that the initial bonding conditions have a great impact on the deformation behaviors of the billets in terms of strain distribution, material flow, residual stress, and final core ratio. With the aid of these analyses, the drawing process and the quality of the products can then be controlled more easily.