Simulation of different forming mode of wire based on thermo-mechanical coupling method

In this paper, the mathematic model of workpiece and three rolling passes, including two ellipse-round rollers, Y type three round-flat rollers and Y type three arc-flat rollers, are developed by using thermo-mechanical coupled rigid-plastic FEM. Various thermal transfer phenomena are considered in the paper, such as conduction, convection, radiation, forced water convection, inner heat conduction, and heat generation. Numerical simulations are carried out to examine the strain and temperature on the cross section, rolling force and 3D friction stress distribution. It is found that the spread and rolling force are smaller in Y type three rollers mill than those of two-roller rolling; the highest temperature and the largest deformation all occur in the core for two-roller rolling because the deformation is penetrated the core; the three-rollers rolling is very steady, which makes rolling force more uneven; and the friction stress distribution is different for three-roller rolling systems. In addition, rolling forces history for two ellipse-round rollers are simulated, which provides reasonable agreement with the measured results