Layered Model of Fluid-Structure Interaction in Dry Wire Drawing with Coupled Axial Velocity

  • Vervaecke, Mathieu (University Ghent, Faculty of Engineering)
  • Fauconnier, Dieter (University Ghent, Faculty of Engineering)
  • Degroote, Joris (University Ghent, Faculty of Engineering and)

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Dry wire drawing is a cold work hardening process employed to progressively reduce the cross-section of a wire by pulling it through a series of dies. The use of a sodium or calcium-based soap lubricant in dry wire drawing is essential to reduce the drawing forces and the corresponding power. Moreover, the thin lubricant film separates the surfaces of the wire and the die, which enlarges the service life of the die. A first attempt to simulate wire drawing with a strongly coupled partitioned Fluid-Structure Interaction (FSI) approach and a sliding interface was presented in [1]. The lubricant film was determined by the Navier-Stokes equations and the deformation was calculated by the conservation of linear momentum. However, the limited length of the wire restricted this model to achieve steady-state results. Additionally, a constant velocity was imposed on the boundary of the lubricant contacting the wire, which is not physical due to reduction in cross-section. To mitigate these issues, current work presents the implementation of a layering technique on the structure to achieve a steady-state simulation with a low computational cost [2]. Moreover, a no-slip condition is implemented, by coupling the axial velocity of the wire with the lubricant's one. However, the combination of the layering technique and the no-slip condition initially caused oscillations of the velocity along the wire, which is detrimental to get converted FSI results. This can be avoided by performing the layer addition in each time step. The obtained lubricant and wire parameters with no-slip condition are compared with the outcome of simulations where a constant velocity is imposed on the fluid boundary contacting the moving structure. Consequently, the applications of the layering technique and the no-slip condition provide a physically corrected steady 2D axisymmetric FSI modeling of dry wire drawing. References: [1] Vervaecke, M., Fauconnier, D., Degroote, J., OpenFOAM model of fluid-structure interaction in dry wire drawing, The 8th European Congress on Computational Methods in Applied Sciences and Engineering, ECCOMAS Congress, Oslo (2022). [2] Jasak, H., Tukovic, Z., Dynamic mesh handling in OpenFOAM applied to fluid-structure interaction simulations, V European Conference on Computational Fluid Dynamics, ECCOMAS CFD, Lisbon (2010).