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Three-roll rolling technology has been widely used in rolling process of nonferrous metal bar and wire. However, due to complex deformation during three-roller rolling, there is a large deviation by conventional calculating method for mechanical parameters. Based on a three-roll rolling deformation characteristics of bars, calculating models for mechanical parameters with three-roller rolling were deduced by the principle of upper limit method. The kinematically admissible velocity field was established through crooked triangle theory, total power of plastic deformation of bar and wire was obtained, and rolling torque and rolling force were calculated. Experiments of rolling bar and wire TC4 were done on three-roller mills with multi-line pass, and rolling torque and rolling force of each pass were indirectly calculated by detecting to obtain the change of the current. The results show that the theoretical values are greater than the measured value for mechanical parameters, the deviation of the rolling force is within the range of 1.25% to 5.13%，and the deviation of the rolling torque is within the range of 4.07% to 7.45%. The values of experiment and calculation are in good agreement, which can meet the actual needs. So it is more convenient to get accurate rolling force parameters by the upper limit method in calculating the complex three-roll pass.
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