Abstract
Flat rolling of wire is an industrial process used to manufacture electrical flat wire, medical catheters, springs and piston segments, among other products. This paper presents a 3D numerical analysis of the contact stress distributions prevailing in the roll-wire contact zone, as well as of residual stresses in the resulting flat wire, as a function of the deformation inhomogeneity induced in the material. Three different patterns in the contact pressure are clearly distinguished and discussed. As in slab-rolling process, a generalized parameter H* is proposed to quantify the deformation inhomogeneity in wire rolling. This parameter allows the characterization and prediction of the morphology of the contact and residual stress distributions.
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