Analysis of wire breaks during drawing of fine wire with an inclusion by FEM

The effect of the inclusion size on the wire breaks has been investigated. When copper wire used in the drawing process contains an inclusion, a complex distribution of the equivalent strain and deformation of the mesh near the inclusion are observed in the drawn wire. Furthermore, when a large inclusion passes through the die, the drawing stress increases markedly, which in turn increases the frequency of wire breaks during the fine wire drawing process. This study predicts that the frequency of wire breaks increases with increasing inclusion diameter D-j/D-o>0.4.