| Special-shaped wire is widely applied in the textile, automobile and machinery. Rectangular wire is a kind of it, which is shaped by die drawing traditionally. However, there are many problems when drawing it, such as fillet incomplete filling and nonhomogeneous wear of the die that reduces the life of die, thus it is hard to realize the mass production. In this paper, specified wire is regarded as the research object, and main studies are as follows:Firstly, forming characteristics of the existing methods and the deformation features of forming process are studied, and the effect of process parameters on shaping is analyzed. The combination method is brought forward to drawing rectangular wire on the basis.Secondly, taking rectangular wire with raw material for Q195 and the size for 2.3㎜×4.8㎜ as the research object, and three-dimensional finite element modeling of drawing is established according to the finite element theory. The correctness of the model is confirmed by H.G formula.Thirdly, the forming process with combination method is simulated by the finite element model and metal flow characteristics and the law of stress and strain distribution are studied. It is verified that it is available to shape rectangular wire with combination method.Last, orthogonal experiment design method is used to analyze the effect of process parameters to forming course, and the optimized combination of process parameters are obtained by employing range analysis to analyze the simulation results.The results show that, rectangular wire with raw material for Q195 and the size for 2.3㎜×4.8㎜, it is able to acquire the minimum radius of fillet 0.17㎜ with combination method. Meanwhile, it can also meet the requests for utilization and the life of die is longer due to little wear. Combination method has some for helpful references to shaping other special-shaped wire.
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