Wire aging or failure takes place on a drawn wire because of the accumulation of residual stress which will accelerate the wire-rope failure. In this work, an attempt is made to simulate and predict the stress accumulation developed in the multi-pass system using ABAQUS CAE. A numerical technique was used as the benchmark for performing the finite element analysis (FEA). The stress distribution on the surface in the multi-pass drawing process of the steel rod was simulated with various die input angles. The rod properties including yield strength, poison ratio, and modulus of elasticity used as boundaries condition in this simulation are based on JIS G3502 steel. The stress values were high during the second (Die 2-403 MPa) and third (Die 3-446 MPa) multi-pass stages. The Cockroft and Latham criterion showed that ductile damage was high during the third (Die 3) multi-pass stages, with the highest stress values at 16° and 18° entrance angles. The results indicated that the maximum value of the stress increases with the increase of the input angle and decrease of the cross-section. In addition, the increase in the die angle leads to an increase in the maximum value of the residual stress. The maximum residual stresses possess in 16° and 18° die input angles are 446 MPa, and that is the maximum point of fracture occurrence. The numerical analysis carried out showed that raising the die inlet angle can greatly reduce residual stress that builds up in the wire after the drawing process. These findings indicated the effect of the die input angle on the stress distribution in the wire drawing process.

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