The purpose of this paper is to present an assessment of the ability of combined finite and slab element method (FSEM) for analyzing the wire flat rolling process.
Using the FSEM, the effective strain field of flat rolled wire is predicted for different reductions in height and frictional conditions. The validity of the method is assessed by performing the Vickers microhardness measurements on the flattened wire cross section. Also, the creation of macroscopic shear bands in cross section of the flat rolled wire is investigated and confirmed by microhardness and metallographic examinations. Moreover, the lateral spread and width of contact area are predicted by the FSEM for different reductions in height and frictional conditions.
The FSEM and microhardness results show the minimum and the maximum effective strains at the round edge and center of the flattened wire, respectively. Also, the results show the bands of maximum effective strain at cross section of the flattened wire, i.e. macroscopic shear bands.
This paper can be useful in rolling industries to produce electronic parts, various springs, trolley cables, piston rings, and guide rails.
The paper shows the applicability of the FSEM for calculating the effective strain field and geometry of wire after wire flat rolling process.
