Calculation of the rolling pressure distribution and force in wire flat rolling process

In this study a slab analysis is developed to predict the rolling pressure distribution and rolling force in the wire flat rolling process. In the slab analysis the variations of width of contact area between the rolls and wire during rolling is considered. Two differential equations are derived and solved using a modified Eulerian numerical method. The effects of friction coefficient, reduction in height and yield stress of wire on the rolling pressure distribution and rolling force are assessed. It is found that in the flat rolling of wire, there exists a maximum in the pressure distribution similar to that of the strip rolling process. Also, the effects of friction coefficient, reduction in height and yield stress on the neutral angle are investigated. It is observed that by increasing the reduction in height and friction coefficient, the neutral angle is increased and the yield stress has no effect on the neutral angle. A good agreement is found between the calculated and measured rolling force.