The hydrodynamic lubrication regime is reported to exist in numerous metal forming applications, such as wire drawing and hydrostatic extrusion, but it has not been achievable in the drawing of large diameter rods due to the relatively low drawing speeds common for larger parts. By creating a stable fluid film between the workpiece and the die during the drawing process friction and die wear could be significantly reduced, leading to energy savings, increased achievable reductions, and increased die life. An analytical model of the hydrodynamic drawing process is proposed which considers the geometry of the workpiece and die, as well as, the material properties (including work hardening effects), and (temperature dependent) fluid properties to determine the fluid film thickness over the reduction die. This model is then used to analyze several case studies, including a proposed multiple reduction die with high pressure lubricant supplied to the space between the dies. It is shown that a stable fluid film can be established for low drawing speeds through the combination of a multiple reduction die and elevated lubricant pressure in the inlet of the dies.
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