Cross wedge rolling failure mechanisms and industrial application

Cross wedge rolling (CWR) is an innovative metal forming technology with several well-documented benefits over other traditional manufacturing processes. Over the past several years, CWR technology has obtained overwhelming popularity within the United States, especially in the automotive industry. Based on the authors’ academic and industrial experience, recent development techniques for the CWR process are presented. Initially, the experimental and numerical research techniques for analyzing fundamental CWR failure mechanisms are presented with particular emphasis on the finite element method. This is followed by discussion on industrial implementation of cross wedge rolling system, including the required tooling manufacturing process and major supporting systems. Finally several industrial examples are presented to demonstrate feasibility and efficiency of the CWR process with the goal of removing hesitation of US manufacturers to adopt novel CWR technology.

[1]  W. Johnson,et al.  A Survey of Some Physical Defects Arising in Metal Working Processes , 1977 .

[2]  Trevor A. Dean,et al.  Past developments, current applications and trends in the cross wedge rolling process , 1993 .

[3]  Kaveh A. Tagavi,et al.  Analysis of interfacial slip in cross-wedge rolling : an experimentally verified finite-element model , 1998 .

[4]  N. S. Cho,et al.  Analysis of the rotational compression of a cylindrical billet in the transverse rolling process , 1990 .

[5]  Qiang Li,et al.  On the critical interfacial friction of a two-roll CWR process , 2005 .

[6]  Qiang Li,et al.  The establishment of a failure criterion in cross wedge rolling , 2004 .

[7]  Kaveh A. Tagavi,et al.  Investigation of the morphology of internal defects in cross wedge rolling , 2002 .

[8]  Mike C. Tsao,et al.  Plastic Shear Properties of Metals and Alloys at High Strain Rates , 1973 .

[9]  Masujiro Hayama.  Estimation of Load and Contact width in Rotational Compression of Rod , 1974 .

[10]  Atsushi Danno,et al.  Hot forming of stepped steel shafts by wedge rolling with three rolls , 1984 .

[11]  Z. Pater.  Theoretical method for estimation of mean pressure on contact area between rolling tools and workpiece in cross wedge rolling processes , 1997 .

[12]  G. Cowper,et al.  STRAIN-HARDENING AND STRAIN-RATE EFFECTS IN THE IMPACT LOADING OF CANTILEVER BEAMS , 1957 .

[13]  Qiang Li,et al.  Predicting Critical Friction in a Two-Roll Cross Wedge Rolling Process , 2003 .

[14]  Zb. Pater.  A study of cross wedge rolling process , 1998 .

[15]  N. S. Cho,et al.  Analysis of plane-strain rotational compression using the upper-bound method , 1989 .

[16]  Masujiro Hayama,et al.  Optimum working conditions in the cross rolling of stepped shaft , 1979 .