Modular 3D roller straightening – A new approach to straightening and forming of spring steel wires (X10CrNi18-8)

<jats:p>Abstract. Spring steel wires are usually supplied and stored on coils. The manufacturing and coiling processes of these wires induce inhomogeneous plastic deformations that lead to undesirable residual stresses and varying wire curvatures in the semi-finished product. These residual stresses and curvatures defects are causing varying process conditions in the subsequent manufacturing processes, which have a negative impact on the product quality, leading to wastage and thus affecting the economic and ecological efficiency. Especially the curvature deviations must be compensated for the stability of the subsequent processes. This is usually realised with roller straighteners, which are set manually by the machine operators only at the beginning of a process. In this paper, we introduce a new approach with a modular straightening-machine design and a new set-up process. The more isolated deformation behaviour in a module-based straightener overcomes the complexity of interactions between the close-positioned spaced straightening rollers. This is combined with a set-up process that is independent of conventional material testing, modelling the actual and batch-specific behaviour of the wire in the straightening process. The exact knowledge and time-consuming determination of the material properties thus becomes obsolete. The experimental investigations show the influence of defined straightening strategies on the residual stress evolution and the residual forming limit of the spring steel wires (X10CrNi18-8) in the new straightening process. </jats:p>