Accurate Finite Element Simulation of Unidirectional and Alternate Multi-Pass Drawings, Focusing on Residual Stresses

An optimized numerical model is proposed, accompanied by an in-depth investigation of the characteristics of rod and tube drawing processes and a critical review of previous studies on tube drawing from the perspectives of practicality and accuracy. An automatic simulation framework, specifically a dual-step simulation scheme incorporating a specialized remeshing function, is presented to enhance the applicability and accuracy of simulations for rod and tube drawing processes. The effectiveness of the proposed finite element (FE) analysis model is evaluated by comparing FE-predicted results with those reported in the literature. Using typical examples of various multi-pass drawing processes, including both unidirectional and alternately driven cases, the importance of the proposed FE model and its automatic analysis capability in improving engineering productivity is demonstrated.