The calculation specifications~(3,4) recommended for determining the tensile force requirement for straightening with roller-type straightening systems supply-in comparison with the measured results - only rough approximations that are no longer appropriate considering the optimized planning and design of straightening systems and the machinery and apparatus in which the straightening units are integrated. A new model for calculating the tensile force requirement was developed selectively on the basis of a requirements profile. It takes into account not only the straightening unit's geometrical boundary conditions-such as number of rollers, roller diameter, roller profile, pitch and adjustments-but also the properties of the process material, such as its geometrical and material data. Key elements of the model include the numerical determination of the bending moment/bend curves for the bending operations performed in the straightening unit and hence the possibility of determining the work of plastic deformation, which correlates with the tensile force requirement in accordance with the energy balance. Calculations carried out for an exemplary selection of wires using the new model display a very good correlation with the measured values. The model's future use in the wire industry is thus possible.
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