Modeling asymmetric fracture mechanics of Mg alloy wire in drawing process

Abstract

In this study, a numerical analysis was conducted on the ductile fracture of a 2-mm diameter Mg-1Zn-0.5Mn-0.5Sr-0.1Ca alloy wire during drawing. The hexagonally close-packed crystal structure of Mg alloys causes asymmetric fracture behavior, especially in the compression region. The aim of this study is to develop a comprehensive damage model for Mg alloy wire that accurately predicts ductile fracture, with a focus on the compression region. A novel experimental method was introduced to measure the ductile fracture of Mg alloy wires under different stress states. The wire drawing process was simulated using the Generalized Incremental Stress-State dependent damage (GISSMO) Model and the Semi-Analytical Model for Polymers (SAMP) model. The damage model's prediction and the experimental results were found to be in excellent agreement, especially in determining crack initiation. Computational analysis established a safe zone diagram for die angle and reduction ratio, and experimental validation confirmed the feasibility of this approach. The proposed damage model can provide a practical and reliable analysis for optimizing the drawing process of Mg alloy wire.

Keywords

• Mg alloy
• Wire drawing
• Finite element method
• Damage model
• Safe zone diagram