Three-dimensional elastic-plastic finite-element analysis of the flattening of wire between plain rolls

It is normal industrial practice to roll round edged flat wires from round circular wires using plain rolls. Although this is not a complex type of me tal forming process, the internal deformation is highly three-dimensional. It is important to be able to determine the lateral spread, elongation and final profile precisely. In this paper, this process has been analyzed risi ng an elastic-plastic finite element program. Firstly, algorithms for integ rating the constitutive equations, i.e., return mapping algorithms, are eva luated to determine the most accurate technique. Then, the influences of fr iction and reduction in thickness on the deformation characteristics are in vestigated. The lateral spread and the radius of curvature of the free surf ace are quantitatively in reasonable agreement with those obtained from emp irical formulas. The lateral spread increases with friction and with reduct ion. The variation of elongation in the roll bite is investigated in detail . It is found that the elongation is not uniformly distributed across the c ross section. After passing the roll gap, the distribution is compensated b y the elastic recovery of wire, otherwise it ma), cause edge waves.