Analysis of the use of variable angular parameter tools in cross-wedge rolling

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This paper proposes novel tools for cross-wedge rolling (CWR). Previously used standard tools have a flat forming surface described by two angles, i.e. the forming angle α and the wedge spreading angle β. In this study, the authors investigated whether the use of tools with modified forming surface due to the use of variable angles α and β would have a positive effect on the CWR process. Numerical modelling was employed to determine the impact of the tools with variable angles β and α on CWR. The focus was put on assessing the effect of the changed forming surface of the wedge tools on the radial and forming loads, effective strains, and damage functions determined by fracture criteria developed by Argon et al., Oyane et al. and Pater et al. Numerical results were used to design a novel wedge tool shape that would ensure a reduction of rolling forces and energy consumption as well as a reduced risk of internal cracking in the axial zone of the workpiece. Experiments were conducted using both standard and novel tools of the same size. Experimental results confirmed that the use of the proposed novel tools had a positive effect on the CWR process.