Applications of Finite Element Modeling (FEM) In Development of Cold Drawing Processes for Aerospace Fastener Feedstock

Bar and wire drawing are critical operations to Carpenter’s product lines for aerospace fasteners.  Although the cold drawing process is well researched and documented, challenging processing issues may arise that are not easily understood without extensive experimental matrices or other research and development methods.  Finite element modeling (FEM) is a computational approach that gives great insight into metal deformation processes and is well suited for usage in cold drawing applications.  Presented here are several different topics where there commercially available DEFORM^TM FEM code was used to investigate drawing processes and to predict drawing loads, design processing to achieve mechanical properties, reduce residual stress, achieve desired product geometry, and improve process efficiency.  Two and three dimensional models will be presented.  A brief discussion on model setup and limitations will be held.