Roll profile design for shaped wire rolling with high aspect ratio

For a shape rolling process of products with a high aspect ratio, its width does not spread sufficiently, frequently resulting in the unfilling phenomenon in the width direction. This paper proposes a roll profile design for the shape rolling process; this design method improves the dimensional accuracy of a shape wire with a high aspect ratio. From among the products produced by the shape rolling process in industrial sites, those with aspect ratios of ≥ 3.3 were selected in this study, and finite element (FE) simulation of the shape rolling process was conducted to verify the effectiveness of proposed method. The results of the FE simulation showed that the proposed design method was effective in performing the rolling process for shapes with high aspect ratios. In addition, the effectiveness of the proposed method was verified by conducting an experiment for bridge-valve wire by using plasticine. The experimental results showed that target shapes were obtained with an unfilling rate as low as 0.23 % for the cross-sectional area.