The effect of roll drawing process parameters on geometrical characteristics of flat roll draw wires is analyzed. Low carbon steel wires AISI 1010 are used in the experimental tests to assess the final geometry, mainly characterized by the width of flat wires, varying among several experimental levels the main process parameters i.e., initial wire dimensions, height reduction and lubrication conditions. Design of experiment technique was used to define the experimental plan and statistical techniques, such as analysis of mean (ANOM) and variance (AVOVA), were used to evaluate the effective influence of previous cited process parameters on final geometry of wire. A finite element model is developed to investigate a further process parameter i.e. the working rolls dimensions. In order to validate the finite element model, a campaign of experimental tests was conducted and the geometrical predictions of FE model were compared with experimental mea-surements with particular attention to final wire width, width of contact area and wire elongation. A linear regression analysis was performed and an empirical formulation to forecast the lateral spread of wire according to the main process parameters was developed.