High-Order Groove-Shape Curve Roll Design for Aluminum Alloy 7075 Wire Rolling

Abstract

A Bézier curve groove-shape roll design method was proposed and compared to round-oval-round designs for the wire rolling process. CAE simulations were adopted to predict the rolling forces and torques required for the rolling process. The rolling torque required for the case of 28% vertical compression rate is 73% higher than the case of 12% compression rate. The curve fittings of the rolling torque and the compression force with respect to the compression rate were obtained with very high R-square values (0.99 and 0.98) in the first rolling pass. The rolling force required for the Bézier curve groove-shape design is no different compared to the oval design with the same compression rate, but the rolling torque requirement for the next rolling station is 6% less than the oval groove design. Furthermore, the equivalent strain distribution on the cross section of the product was uniform, and no fin flash defects occurred. The proposed Bézier curve groove-shape is a better design from the viewpoint of uniform product mechanical property requirement, and a larger compression rate per pass could be achieved.