Numerical analysis of the rolling process of shaped wires for locked steel ropes

The production process of Z-shaped wires for the outer layers of locked steel ropes was studied by means of a finite element (FE) analysis of the rolling sequence as well as of a mechanical and microstructural characterization of the material at different steps of the shaping process. A satisfactory concordance between the predictions of the numerical analysis and the results of the experimental characterization was found. The FE model was then used to evaluate the effectiveness of some modifications introduced in the shaping process, aimed at improving the wire performances. In particular, considering that the non-uniform plastic strain produced in the wire section by the shaping operations strongly influences the wire mechanical performances, some indications toward the improvement of the material plastic flow during the shaping operation are proposed and discussed.