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The purpose of this paper is to determine the physical design parameters that influence the total resistance of a twisted conductor (cable). One of the physical parameters characterizing this type of structures is the uneven distribution of resistivity due to hardening, which is the result of stress exerted on the wires during the manufacturing process.

The authors have developed a method to take into account the effect of localized hardening on the inhomogeneous distribution of electrical conductivity in the distorted structures of the conductor. To achieve this goal, the authors have implemented a mechanical-electrical simulation method. The resistance characteristics have been measured as a function of mechanical stress.

As demonstrated by the results of measurements conducted on various samples and with various cable design parameters, the resistance of a given material (copper or aluminum), expressed as a function of stress, does not depend on the type of force applied. Therefore, the same characteristics may be applied to various cable designs.

The method presented in this paper enables more detailed investigation of the influence of particular design parameters on the total resistance of a cable. It also provides the ability to determine optimal settings of design parameters.

The approach is distinct from similar studies because it takes into account the deformed geometry of the conductor and the uneven distribution of the resistivity within a filament. In the literature, it is sometimes stated that the distribution of resistivity in a compacted cable is uneven, but its measurement is deemed impossible. This paper provides a method for determining such a distribution.

In the majority of devices for measuring the resistance of wires or cables, the supplying voltage is applied via some clamping arrangement. Thus, current enters the bundle of conductors through the side surface of the outside wire. The purpose of this project was to establish the distance from the supplying point after which the current may be considered to be uniform and normal to the cable cross‐section.

When current passes from one wire to another, the crucial parameter is the resistance of the contact region. The paper presents a method by which this region can be identified and relevant resistance measured. A comprehensive simulation was conducted for different types of wires and cables to assess the influence of design parameters on the current distribution and uniformity.

The distance from the current entry point (the clamps) to the position where current density may be considered uniform has been established. This has facilitated estimating recommended positions of voltage taps with reference to current taps.

The look‐up tables and graphs allow adjustments to the position of the taps and/or correction of the measured results.

The original contribution of this paper is in the way the contact region is identified where current passes from one wire to another. Original relationships have been proposed showing the relationship between contact resistance and the design parameters of the cable and mechanical stress.