Finite Element Analysis of Stress and Strain in Two-Wedge Cross Wedge Rolling Step-Shaft Part

Two-wedge Cross Wedge Rolling (TCWR) is a metal processing technology in which a heated cylindrical billet is plastically deformed into an axial part by the action of two wedges dies moving tangentially relative to the work piece. The metal deformation process is more complicated in TCWR than in single-wedge CWR. In this paper, a new and innovative numerical model of TCWR was developed, using advanced explicit dynamic finite element method (FEM). The whole TCWR process was simulated successfully, the three-dimensional nonlinear deformation process including stress and strain variation among the whole stages was analyzed at length, and 4 different principal stresses, including the first, second, third and von Mises equivalent stresses, at different billet centers are presented serving as a TCWR design guideline. Experimental result proves that the finite element simulation in TCWR process is true and this fundamental investigation provides a multi-wedge guideline in selecting CWR tool parameters and tool manufacturing.