Modelling of drawing and rolling of high carbon flat wires

In order to meet customer requirements, it is necessary to develop new flat wires with a high tensile strength and a high width/thickness ratio. These products are manufactured from wire rod. The first step is to draw the wire until we have the required mechanical properties and required surface area of the section. After this, the wire is rolled from a round to a rectangular section. During the flat rolling process it can be reduced by more than 50%. Then the wire is exposed to a high level of stress during this process. Modelling allows us to predetermine this stress level, taking into account the final dimensions and the mechanical properties, thus optimising both rolling and drawing process. Forge2005 was used in order to simulate these processes. The aim of this study is to determine the value of residual stresses after drawing and so to optimise rolling. Indeed, the highest stress values are reached at this step of the process by changing the section of the wire from a round to a rectangular one. In...