An analytical approach to asymmetrical wire rolling process with finite element verification

Based on the slab method, a three-dimensional analytical solution is first proposed to calculate the rolling pressure, force, and torque in asymmetrical wire rolling where the work rolls radii, their peripheral speeds, and the interfacial frictions may be different. Since the lateral spread cannot be ignored in the wire rolling process, the plain strain condition is not applicable. Moreover, the shear and normal stresses in the vertical sides of the element are considered to be distributed linearly. The effects of process parameters such as reduction in height, rolls peripheral speed ratio, and friction factor ratio on the processes output, like pressure distribution, rolling force, and lateral spread are investigated. Moreover, the commercial finite element code, ABAQUS, is used in this study to model the asymmetrical wire rolling. The selected analytical results were compared with FEM simulation data to verify the effectiveness of the developed model. By this proposed analytical solution, it is noted that the computer expense and calculation time can be saved, and the characteristics of asymmetrical wire rolling are obtained simply and quickly.