Analysis of curvature and width of the contact area in asymmetrical rolling of wire

•An investigation into the asymmetrical wire rolling is presented using experimental tests, finite element simulation, and some analytical formulations.•The effects of the roll speed ratio, roll diameter ratio and reduction in height on the curvature radius, and width of the contact area of a rolled wire are investigated.•Comparison of results from FEM simulation with those from experimental study, have showed good agreements.

In this paper, an investigation into the asymmetrical wire rolling is presented using experimental tests, finite element simulation, and some analytical formulations. Moreover, the effects of the roll speed ratio, roll diameter ratio, and reduction in height on the curvature radius, and width of the contact area of a rolled wire are investigated. In addition, possibility of applying a theoretical formula for calculating the width of the contact area in the symmetrical wire rolling for the asymmetrical wire rolling is also studied. A very good agreement is shown to exist between the results predicted by the FEM simulation and the experimental results.