Fluid-structure interaction modeling of dry wire drawing by coupling OpenFOAM models of lubricant film and metal wire

A steady 2D axisymmetric fluid-structure interaction model of dry wire drawing is developed to numerically investigate the interaction between the thin lubricant film and the plastically deforming steel wire. To reduce the computational cost, a layering technique is implemented in the axially moving structure. Additionally, a no-slip condition, imposed on the implemented sliding fluid-structure interaction interface, captures accurately the physics during the plastic deformation of the wire. An Arbitrary-Langrangian-Eulerian cell-centred finite volume solution methodology using pimpleFoam has been adopted to model the fluid, while a Lagrangian cell-centred finite volume solution methodology in foam-Extend executes the structural calculations. Moreover, the Python-based in-house FSI coupling code CoCoNuT performs the coupling of the flow solver and the structural solver by using the quasi- Newton IQN-ILS technique. The stresses with corresponding displacements are shown on the structure side. On the fluid side, the focus is on the behaviour of the loads of the lubricant. Additionally, the evolution of the fluid film thickness and the lubricant flow field are validated in terms of Couette and Poiseuille flow. Finally, the presented multi-physical problem shows a converged solution with a good performance of the IQN-ILS solver.