The analysis of the heating of the wire including theoretical studies showed that in the multistage drawing process a increase drawing speed causes intense heating of a thin surface layer of the wire to a temperature exceeding 1100°C, which should be explained by the accumulation of heat due to friction at the interface between wire and die. It has been shown that with increasing of drawing speed the heated surface layer thickness measured at the exit of the wire from the dies is reduced significantly and at drawing speed of 25 m/s is equal to about 68 μm. The decrease in the thickness of this layer can be explained by a shorter time of heat transfer to the wire, which causes additional heat accumulation in the surface layer. Thus fivefold increase in drawing speed caused an approximately 110% increase in the temperature in the surface layer of the wire. Experimental studies have shown that the increase of drawing speed of 5 to 25 m/s will increase the temperature of the wire after coiled on the spool more than 400%.

This paper presents research results in the field of industrial die forging, mostly related to the use of advanced measuring techniques and tools, numerical simulations, and other IT tools and methods for a geometrical analysis of the forged items as well as detection of forging flaws and their prevention, and optimization of the hot-forging processes. The results of the conducted investigations were divided into three main areas. The first area refers to the application of, e.g., optical scanners and programs related to their operation, data analysis, including the construction of virtual gauges, measurements of selected geometrical features of both the manufactured forgings and their physical and virtual models, as well as an analysis of the durability of the forging tools based on the proprietary reverse scanning method. The second area presents the results of measurements and analyses performed with the use of finite element modeling and by means of some special functions in the calculation packages, such as contact, flow lines, trap, or fold, for the detection of forging defects and an analysis of the force parameters. In turn, the third area presents a combination of different methods of measurement and analysis, both FEM and scanning, as well as other IT methods (physical modeling, image analysis, etc.) for the analysis of the geometry and defects of the forgings. The presented results point to the great potential of these types of tools and techniques in forging industry applications as they significantly shorten the time and increase the accuracy of the measurement, as well as providing a lot of valuable information, physical variables, and technological parameters that are difficult or impossible to determine either analytically or through experimental means. The use and development of these techniques and methods are fully justified, both in the aspect of science and the increased effectiveness and efficiency of production.

The paper presents the impact of the drawing method on the microstructure and corrosion resistance of galvanized steel wires. The microstructural tests confirmed that, in the drawing speed range v = 5–20 m/s, the use of hydrodynamic dies creates more favorable conditions for the deformation of the soft zinc coating on the hard steel core. The increase in friction at the wire/die interface in the conventional method, as compared to the hydrodynamic method, contributed to the decrease in coating thickness and the increase in the diffusion layer, and the higher the drawing speed, the greater the differences between the analyzed drawing methods. In the conventional method, while drawing at high speeds v = 20 m/s, there was a two-way diffusion and complete remodeling of the ζ phase in δ₁. In the hydrodynamic method, at the speed of 20 m/s, in the analyzed micro-areas, places showing the presence of the ζ phase, partially dispersed in the layer with pure zinc, were observed. A corrosion tests comparison between conventionally and hydrodynamically drawn wires showed an improved behavior of the latter. The greater mass in the surface layer of pure zinc, a substrate for the corrosion product in hydrodynamically drawn wires, reacted, creating insulation from the white corrosion produced. The compressive stresses in the hydrodynamic dies caused by the high pressure of the lubricant on the circumference of the wire closed the microcracks on its surface, which additionally sealed the zinc coating.

This paper discusses experimental studies aiming to determine the effect of the drawing method on the lubrication conditions, zinc coating mass and mechanical properties of medium-carbon steel wires. The test material was 5.5 mm-diameter galvanized wire rod which was drawn into 2.2 mm-diameter wire in seven draws at a drawing speed of 5, 10, 15, 20 and 20 m/s, respectively. Conventional and hydrodynamic dies with a working portion angle of α = 5° were used for the drawing process. It has been shown that using hydrodynamic dies in the process of multi-stage drawing of zinc-coated wire improves the lubrication conditions, which leads to a reduction in friction at the wire/die interface. As a consequence, wires drawn hydrodynamically, as compared to wires drawn conventionally, are distinguished by a thicker zinc coating and better mechanical and technological properties.