**Joong-Ki Hwang**

School of Mechanical Engineering, Tongmyong University, Busan 48520, Korea; jkhwang@tu.ac.kr; Tel.: +82-51-629-1567

Received: 20 April 2020; Accepted: 15 July 2020; Published: 20 July 2020

**Abstract:** The effect of the roll design on the strain distribution of the flat surface, lateral spreading, and the strain inhomogeneity of a flat-rolled wire were investigated during the flat rolling process. Oval-grooved and cambered rolls with various radii were applied to the flat rolling process based on a numerical simulation. The effective strain on the flat surface of the wire increased when using a cambered roll due to the highly intensified contact pressure on the flat surface, while the effective strain on the flat surface of the wire decreased when using an oval-grooved roll. Lateral spreading decreased when using an oval-grooved roll because the spread in the free surface area of the wire was highly restricted by the oval-grooved roll shape. In contrast, the spread in the surface area increased when using a cambered roll due to the less-restricted metal flow at the free surface. Accordingly, a cambered roll with a small radius is highly recommended in order to improve the surface quality of flat-rolled wires. This is beneficial for industrial plants because the cambered roll can be easily applied in flat rolling plants.

**Keywords:** roll design; flat-rolled wire; strain inhomogeneity; normal pressure; macroscopic shear bands
