Muthanna Journal of Engineering and Technology
Volume (13), Issue (3), Year (2025), Pages (43-55)
DOI:10.52113/3/eng/mjet/2025-13-03-/43-55
Research Article By:
Salam Adil ALI Al Rufaye
Corresponding author E-mail: salamadil750@gmail.com
ABSTRACT
Reliable drawing dies are crucial for successful modern wire production. If these parts fail, repairs can be time-consuming and costly. This study examines how drawing speed affects die reliability within a standard commercial range of 50 to 400 m/min. We tested 750 tungsten carbide dies using various methods, including Weibull reliability analysis. Fifty dies were tested at each of 15 different speeds. Our results show a strong inverse relationship between die lifespan and drawing speed, and a significant direct relationship between operating temperature and wear rate. As drawing speed increased from 50 to 400 m/min, the average die life decreased by 65%, the wear rate increased exponentially, and the average operating temperature rose linearly. We identified three failure zones: a moderate wear phase (50–150 m/min), a rapid failure stage (300–400 m/min), and a period of accelerated degradation (150–300 m/min). In each zone, different wear mechanisms may occur. These findings help manufacturers extend die life, improve efficiency, implement predictive maintenance, and develop new die technologies that could reduce costs by 15–25%.
Keywords:
Drawing dies, Wire drawing, Reliability analysis, Drawing speed, Wear mechanisms, Tungsten carbide.