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Technical Brief

High-Speed Drawing of Al Alloy Wire by Diamond-Coated Drawing Die Under Environmentally Friendly Water-Based Emulsion Lubrication

[+] Author and Article Information
Xinchang Wang

School of Mechanical Engineering,
Shanghai Jiao Tong University,
Mechanical Building B318, Dongchuan Road 800,
Minhang District,
Shanghai 200240, China
e-mail: wangxinchang@sjtu.edu.cn

Chengchuan Wang, Xiaotian Shen, Fanghong Sun

School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China

1Corresponding author.

Manuscript received November 1, 2017; final manuscript received September 7, 2018; published online October 5, 2018. Assoc. Editor: Yannis Korkolis.

J. Manuf. Sci. Eng 140(12), 124502 (Oct 05, 2018) (7 pages) Paper No: MANU-17-1680; doi: 10.1115/1.4041477 History: Received November 01, 2017; Revised September 07, 2018

It is environmentally friendly to use water-based emulsion instead of the oil when cold drawing Al alloy production. In this research, adopting specially prepared water-based emulsion, contact angles and tribological properties of as-selected multilayer diamond films are clarified. The contact angle on diamond film is much smaller than that on WC-Co with the same surface roughness, and tribological behaviors of the diamond film are much better. The effects of surface roughness Ra of the film, lubrication, and water content in the emulsion W are studied, indicating that the contact angle increases with W or Ra. For the diamond film, lower Ra is beneficial for reducing the coefficient of friction (COF), Al alloy ball wear and oxidation, while lower W contributes to the reduction of the COF, ball oxidation, and coated disk wear. Finally, high-speed drawing of high-quality 6021 Al alloy wires (AWs) is accomplished, proving that using coated drawing dies, the water-based emulsion (W < 80 vol %) can totally replace oil, and coated dies under the water-based emulsion lubrication present much elongated lifetime and can guarantee the production quality, compared to uncoated ones under the oil lubrication, in spite of slightly severer wire oxidation.

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Figures

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Fig. 1

Surface morphologies of the BDMC-MC-NCCD film (a) before and (b) after the polishing, and (c) cross-sectional morphology of the former one

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Fig. 2

Schematic of tribological test

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Fig. 3

Contact angles of (a) emulsions (different W) on polished disks and (b) emulsions on BDMC-MC-NCCD films (different Ra)

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Fig. 4

a-COFs for different specimens sliding against Al alloy balls (a) under different lubrications and (b) in OF01 with different W

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Fig. 5

(a) As-worn ball surface and schematic for calculating Ib; correlations between Ib and (b) lubrication condition and (c) W in OF01

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Fig. 6

(a) As-worn ball surfaces sliding against the totally polished (left, Ra < 40 nm) and unpolished (right, Ra > 120 nm) films in the water; correlations between oxygen content on the ball and (b) lubrication condition, and (c) W in OF01

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Fig. 7

(a) Typical disk wear track and schematic for calculating Id; correlations between Id and (b) lubrication condition, and (c) W in OF01

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Fig. 8

Schematic of multipass drawing machine

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Fig. 9

(a) Limited drawing speeds and (b) variations of drawing temperatures (v = 16 m/s) under typical conditions

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Fig. 10

Typical surface morphologies of (a) AWs drawn by disabled coated dies (OF01, W = 80%, v = 16 m/s), and AWs drawn by coated dies in use under (b) OF01 (W = 80 vol %, v = 16 m/s), (c) OF02 (W = 80 vol %, v = 12 m/s), and (d) oil lubrications (v = 20 m/s)

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Fig. 11

(a) Film removal in reduction zone of coated die and (b) schematic of drawing process

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Fig. 12

Surface morphologies of (a) coated die (OF01, W = 80 vol %) and (b) uncoated die (oil) in use, including elementary compositions of adhered debris (at  percentage)

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