Abstract
A comprehensive research on the flat rolling deformation characterization of microwire has been conducted systematically through finite element simulation and testified by the results from the experimental analysis. The obtained results are compared in terms of lateral spread, geometrical characteristic, contact area width and surface roughness considering the effects of pass reduction and initial wire diameter. The size effect has been identified and surface layer modeling has been set up based on surface grain share and grain size distribution. The numerical method combined with varied flow stress has been verified by experimental value with a maximum difference of 3.7% for the 1.5 mm wire. With the increase of the height reduction, the curvature radius is decreased while the lateral spread and contact area width are increased. Surface roughness evolution in the range of 0.52–0.85 µm for the rolled wire has also been investigated.
Highlights
During cold rolling, microwire with a circular cross-section is flat-rolled at room temperature through two rolls to gain the required ratio of thickness-to-width under one or several passes with a specific cross-section due to the barreling effect
The shear band idea has been used to calculate the contact area width, and the lateral spread and the rolling load can be predicated by slab analysis [5], where the investigation on the effects of height reduction on the effective strain field during flat wire rolling had been conducted and the evolution of the shear bands was predicted as well
In the flat rolling process of wire, the existence of friction between the wire and rolls will cause the formation of two dead metal zones, resulting in the macroscopic shear bands, which are observed in metallographic cross-section of wire
Summary
Microwire with a circular cross-section is flat-rolled at room temperature through two rolls to gain the required ratio of thickness-to-width under one or several passes with a specific cross-section due to the barreling effect. The edge rounding and lateral spreading are two key factors that are related to the rolled wire quality. Inhomogeneous deformation occurs during the wire flattening rolling deformation process under different height reduction, which influences the contact stress distribution and the deformation force. The shear band idea has been used to calculate the contact area width, and the lateral spread and the rolling load can be predicated by slab analysis [5], where the investigation on the effects of height reduction on the effective strain field during flat wire rolling had been conducted and the evolution of the shear bands was predicted as well. The relationship between contact stress distributions and the deformation homogeneity has been identified in flat wire rolling [7,8,9]
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