Manufacturing Technology 2025, 25(3):383-395 | DOI: 10.21062/mft.2025.041

Process Prediction and Force Measurement of Hot Rolling Process for 6061 Aluminum Alloy Wire

Jinn-Jong Sheu ORCID..., En-Hsuan Chien ORCID...
Department of Mold and Die Engineering, National Kaohsiung University of Science and Technology. No. 415, Jiangong Rd., Sanmin Dist., Kaohsiung City, Taiwan

This study examines the two-pass hot rolling process of 6061 aluminum alloy wire, focusing on forming load measurement to evaluate process stability and its effects on dimensional accuracy and mechanical property uniformity. Using response surface methodology (RSM), process parameters and forming loads were analyzed to assess their influence on mechanical property distribution and verify the applicability of load measurement in process quality evaluation. A full-factorial finite element simulation was conducted to investigate the effects of pre-forming section reduction rate, material temperature, roll speed, and friction coefficient. Experimental results indicate that forming load measurements effectively capture variations in initial wire temperature and reveal the influence of material velocity and roll speed. Load data also identify the Spike phenomenon caused by improper roll positioning, leading to abnormal load surges and reduced mechanical property uniformity. The strong agreement between experimental forming loads and FEM simulations validates the reliability of the proposed measurement method. This study provides a basis for wire rolling process design and machine learning-based quality prediction, supporting advancements in smart manufacturing applications.

Keywords: Two pass wire rolling, Bézier curve groove-shape design, Aluminum alloy 6061
Grants and funding:

This paper presents the results of project number NSTC 112-2221-E-992-081, funded by the National Science and Technology Council (NSTC) of Taiwan. The support from NSTC has been instrumental in the successful execution of this project, and we would like to express our sincere gratitude for their assistance

Received: February 27, 2025; Revised: June 2, 2025; Accepted: June 7, 2025; Prepublished online: June 7, 2025; Published: July 4, 2025  Show citation

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Sheu J, Chien E. Process Prediction and Force Measurement of Hot Rolling Process for 6061 Aluminum Alloy Wire. Manufacturing Technology. 2025;25(3):383-395. doi: 10.21062/mft.2025.041.
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