Background: The telescopic fork is mainly used for suspension purposes in the different devices to absorb the vibration and disturbances from the road or mechanical devices. Factors such as die angle, drawing velocity, lubrication, and area reduction per pass significantly affect the drawing loads and residual stresses formed in the drawn tube during the tube marking process.
Objective: Instantaneous transverse crack was found on the pipe's outer surface during the drawing process in the current work, and the key challenges were to reduce the percentage of pipe rejection.
Methodology: In this work, optimum drawing die designs were proposed by using the finite element method (FEM). A FEM solving tool called Abaqus has been used for simulating and solving the cold-rolled process. The FEM model of the cold drawing process is generated in Abaqus with the same boundary condition (Axial load and constrain) as using on the actual wire drawing machine.
Result: There was a substantial reduction in the area; axial stress (Tensile) along the die side is 672 MPa which is 23 % lower than the current die axial stress value of 877 MPa. A 48 % plastic strain was found along the purposed die side, which was 17 % lower than the existing strain of 64%. Finally, reduced the area by changing the die geometry from ~52% to 35 to 40 %.
Conclusion: It was possible to abolish transverse crack on the pipe's outer surface to reduce the area reduction (35 to 40 %) in the output tube and strain (17 %). As part of the optimization of the FEM work process, this work gives us encouraging results. Further research will be considered for future positions.