Back tension & fill
Back tension on a passive (pull-through) stand genuinely does influence how reduction splits
between elongation and lateral spread — confirmed from direct process experience, not a public
formula. It's a real lever for adjusting corner/groove fill. This calculator doesn't quantify it;
treat it as a live process variable you control on the line, not a number this tool can give you.
Cumulative cold work & inter-anneal
Whether inter-process annealing is needed isn't just a function of total area reduction — roll
diameter changes contact arc length and therefore deformation time, which affects work hardening
independently of RA%. That's too dependent on your specific tooling for this calculator to predict
responsibly, so it deliberately doesn't try. Track cumulative cold work against your own process
experience for the actual mill geometry in use.
Scope
This is the conservation-law layer only: section geometry and the round-stock ↔ finished-profile
area/length relationship, both checked against independent methods. It does not model roll groove
design, pass-by-pass spread, or how many stands/passes a given reduction needs — that's a separate,
harder problem that would need real reference data (your own groove drawings or measured pass
results) before anything could be trusted in a live tool.
Verification loop
Since you measure thick edge and included angle inline during production, that's a direct way to
check this calculator's geometry against real output — feed in what your gauge reads and compare
to what's predicted here from the round stock and roll setup.
AbarTech