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Abstract—High carbon steel wire rods rolled by flat rolling process are used to manufacture intermediate products of various shaped wires such as a saw blade, spring wire and piano wire. To achieve a desired geometry and dimensional accuracy, it is important to predict and control the width spread amount caused by the flat rolling. This study developed the width spread model for the high carbon steel wire in the flat rolling process by using the design of experiments (DOE) and FE analysis. The process variables considered in this study were the reduction of height, roll diameter, initial wire diameter and friction coefficient. The obtained FE analysis results were fitted to a second-order polynomial equation using multiple regression analysis. The spread formula was derived by solving the second-order polynomial equation. Finally, the width spread amount predicted using the proposed spread formula was compared with experiment results. The proposed width spread model led to a good agreement with the experimental results. Therefore, the proposed model can provide a valuable guideline for the prediction of wire width spread in the actual high carbon steel wire production.