The residual stress distribution in extruded components and wires after a conventional forming process is frequently unfavourable for subsequent processes, such as bending operations. High tensile residual stresses typically occur near the surface of the wire and thus limit further processability of the material. Additional heat treatment operations or shot peening are often inserted to influence the residual stress distribution in the material after conventional manufacturing. This is time and energy consuming. The research presented in this paper contains an approach to influence the residual stress distribution by modifying the forming process for wire-like applications. The aim of this process is to lower the resulting tensile stress levels near the surface or even to generate compressive stresses. To achieve these residual compressive stresses, special forming elements are integrated in the dies. These modifications in the forming zone have a significant influence on process properties, such as degree of deformation and deformation direction, but typically have no influence on the diameter of the product geometry. In the present paper, the theoretical approach is described, as well as the model set-up, the FE-simulation and the results of the experimental tests. The characterization of the residual stress states in the specimen was carried out by X-ray diffraction using the sin²Ψ method.

在常规的成型工艺之后，在挤出的部件和金属丝中的残余应力分布通常不利于后续工艺，例如弯曲操作。高拉伸残余应力通常发生在金属丝表面附近，因此限制了材料的进一步加工性能。通常会进行额外的热处理操作或喷丸处理，以影响常规制造后材料中的残余应力分布。这是时间和精力的消耗。本文提出的研究包含一种通过修改线状应用的成形过程来影响残余应力分布的方法。该过程的目的是降低表面附近产生的拉伸应力水平，甚至产生压缩应力。为了获得这些残余压应力，在模具中集成了特殊的成型元件。成形区中的这些变化对加工性能（例如变形程度和变形方向）有重大影响，但通常对产品几何形状的直径没有影响。本文描述了理论方法，以及模型的建立，有限元模拟和实验测试的结果。通过使用正弦波的X射线衍射对样品中的残余应力状态进行表征 但通常不会影响产品几何形状的直径。本文描述了理论方法，以及模型的建立，有限元模拟和实验测试的结果。通过使用正弦波的X射线衍射对样品中的残余应力状态进行表征 但通常不会影响产品几何形状的直径。本文描述了理论方法，以及模型的建立，有限元模拟和实验测试的结果。通过使用正弦波的X射线衍射对样品中的残余应力状态进行表征² Ψ法。