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The effect of the roll design on the strain distribution of the flat surface, lateral spreading, and the strain inhomogeneity of a flat-rolled wire were investigated during the flat rolling process. Oval-grooved and cambered rolls with various radii were applied to the flat rolling process based on a numerical simulation. The effective strain on the flat surface of the wire increased when using a cambered roll due to the highly intensified contact pressure on the flat surface, while the effective strain on the flat surface of the wire decreased when using an oval-grooved roll. Lateral spreading decreased when using an oval-grooved roll because the spread in the free surface area of the wire was highly restricted by the oval-grooved roll shape. In contrast, the spread in the surface area increased when using a cambered roll due to the less-restricted metal flow at the free surface. Accordingly, a cambered roll with a small radius is highly recommended in order to improve the surface quality of flat-rolled wires. This is beneficial for industrial plants because the cambered roll can be easily applied in flat rolling plants.

Effect of Cambered and Oval-Grooved Roll on the Strain Distribution During the Flat Rolling Process of a Wire