Round Wire Flattening

I don't think you can do it with just a single pass through pinch rollers.

The edges won't be flat.

Best to buy flat wire to start with.

may it be 3 or 4 station passes , my question is for what is theory for calculation , of what size round will form what size flat . example if i want 3mmx 2mm flat what size round i have to input .

thanks for your comment ..

i bet you need to study geometry, regarding cross sectional area and perimeter.

It will depend on how much stretching occurs as the wire passes through any rollers or dies. The resulting cross-sectional area will be somewhat less than that of the original wire. Your example would be 12.57 input area and 12.00 output; I suspect that the real reduction (and stretching) would be more.

I suspect that this is never calculated but empirically discovered. To calculate from theory would require knowing the temperature of the wire, the wire alloy and consistency, the roller surface and alignment quality and probably a few other attributes I have not considered.

I agree.

Machine the desired rectangular groove configuration into one roll and leave the top roll smooth.

Then experiment with wire sizes. Depending on the wire composition you may have to run a larger size wire through sizing dies to get it right.

The volume of the wire must remain constant. So if the length increases by 20% during the flattening process (i.e., the final length is 1.2x the original length, the cross-sectional area will be 83.33% of what it had been prior to flattening. (cross sectional area x length = volume)

Why must the volume remain constant? I believe that there will constantly be little flakes of wire cracking off, along with oxides falling off all the time. Not to mention breakages and fraying that can also happen. It all depends on the metal that makes the wire. Gold will be closest to your ideal volume proposal. Copper and Silver will probably work similarly. The oxidation of Aluminum will pose a different set of problems. Nitinol will be a completely different challenge. Did I ever mention adhesion as a possible problem, I don't think that I did.

Well, if you can determine the losses due to flakes, etc., subtract that first.

I guess I was just trying to give a starting point for the calculation: If the volume of the wire remains essentially constant and you know the change in the length, you can easily calculate the new cross sectional area.

But, does that tell you where the rolls must be in relation to each other to get the cross section desired? I think not.

You can calculate till next week, but running wire will be the only way to determine the proper roll spacing.

And a single pair of rolls to go from round to square is a joke.

This should be directed toward the OP, but without something to calculate, it'd be lost on them.

<edit> Ga to GW