25332 Three-dimensional Fluid-Structure Interaction modelling of dry wire drawing process
Richtingen: Master of Science in Electromechanical Engineering



A large number of process industries are dependent of tribology. By taking advantage of the new surface, materials and lubrication technologies for friction reduction and wear protection in vehicles, machinery and other equipment worldwide, energy losses due to friction and wear could potentially be reduced by 40% in the long term and by 18% in the short term. Besides the reduction of CO2 exhaust, an adapted lubrication regime in machinery can save until 1.4% of the Global Domestic Product annually and 8.7% of the total energy consumption in the long term. One of the application, which want to achieve friction decrease and wear reduction, is wire drawing. Moreover, it contains a challenging  technology concerning tribology. 

The process of wire drawing is a cold work hardening process. A metallic wire is pulled through a series of dies, in order to reduce its cross section, while changing the crystal structure of the material and thus the related mechanical properties as strength and hardness. In dry wire drawing, the wire is lubricated with a carrier agent and is pulled at high speed (about 10-20m/s) through a bath of dry soap granules, which may contain different additives. The application of the produced wires are highly divers, from cables used to support bridges to springs used in automotive sector.  




  1. Understand the FSI calculation of the lubricant film and the interaction with the wire in dry drawing, through extensive analysis of the two dimensional model.
  2. Build up a 3D model of the fluid film in OpenFOAM.
  3. Writing a mapping class in the in-house developed software package CoCoNuT, where the fluid has a 3D approach and the structural domain exists of two dimensions .
  4. Set up a “static case” based on an existing 2 dimensional model.
  5. A study of the behavior of different lubricants by reverse engineering in the sense of analyze the model by implementing specific lubricant parameters in the model.

??In order to achieve the different goals, first the student has to master the existing FSI 2D axisymmetric case that will be used as base with the complete mapping between the structural solver (ABAQUS) and fluid solver (OpenFOAM). In this demonstration the lubricant is approached as an incompressible flow with arbitrary values. The wire is defined as an axisymmetric rectangle.