Method for forming square-wire conductor

A method for forming a square-wire conductor, comprising:

• step 1:
• providing a circular conductor with a diameter d;
• step 2:
• passing the conductor through a gap of a longitudinal calendering roller to longitudinally calender the conductor up and down to form a conductor with flat upper and lower surfaces, wherein the gap L1 of the longitudinal calendering roller is 0.911 d;
• step 3:
• longitudinally and transversely straightening the conductor;
• step 4:
• passing the conductor through a gap of a transverse calendering roller to transversely calender the conductor left and right to form a conductor with flat left and right surfaces, wherein the gap L2 of the transverse calendering roller is 0.911 d;
• and
• step 5:
• longitudinally and transversely straightening the conductor;
• wherein the method further comprises step 6:
• repeating step 2 to step 5 at least once, such that a finally obtained square-wire conductor has four corners being arc chamfers, and a radius of the arc chamfers is 0.25 L1, and the square-wire conductor has a normal specification of 0.80 mm and below;
• wherein the gap of the longitudinal calendering roller for post-processing is smaller than the gap of the longitudinal calendering roller for prior-processing, and the gap of the transverse calendering roller for post-processing is smaller than the prior-processed gap of the transverse calendering roller;
• wherein the conductor is expanded in a transverse direction during longitudinal calendering, and is expanded in a longitudinal direction during transverse calendering.