This research paper describes a specifically constructed Variant A continuous dieless wire-drawing machine to experimentally determine the principal processing parameters for dieless wire drawing using extra low interstitial Ti–6Al–4V wire alloy. It was experimentally determined that the process was limited by the ratio of the ingoing and outgoing axial velocities, also known as the reduction ratio R and influenced by the primary drawing velocity V1. Reductions of up to 36% per pass wire in cross-sectional area (CSA) were achieved. However, a direct relationship between the wire diameter variation and an increase in overall achievable reduction in CSA was observed. The separation distance between the wire heating and cooling devices (S) was identified as one of the principal governing process parameters. It was found that processing in an inert gas environment led to an increased reduction on CSA of approximately 3% per pass when compared with processing in compressed air. This was attributed to a reduction in surface oxidation and stress cracking. The experimentally determined results showed excellent agreement with a proposed mathematical model. It was also determined that the calculated strain rate for the process fell within the boundaries of previously determined strain rates for this particular alloy. The successful operation of this experimental machine effectively illustrates the possible commercial validity of continuous dieless wire drawing.

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