The development of new markets by expanding the applicability of flat wire products addresses the need to increase the forming capacity of high-strength semi-finished steel products. However, this deformation capacity is reduced in conventional straightening processes due to the large number of forming operations, and reduced deformation capacity prevents optimum utilisation of the semi-finished product in subsequent production processes. This reduces the efficiency of material utilisation considerably in some cases.

A promising solution to the challenges mentioned is the reduction of deformation by means of self-correcting straighteners. To achieve this goal, the development of an innovative 3D straightener based on the intelligent straightener from the previous project (IGF no.: 19799 N / FOSTA P 1273) is being sought. This will be realised by means of an innovative tool design in which the straightening modules are arranged so that they can rotate around the wire to be straightened. The possibility of controlling the individual straightening modules in their roller feed and also orientating them continuously in relation to each other means that, in addition to bending curvature, sabre curvature and helix formation can also be counteracted. The forming capacity available for the actual forming process and therefore also the efficiency of material utilisation, particularly of high-strength steel materials, can be significantly increased in this way.