INVESTIGATION OF THE EFFECTING PARAMETERS ON LOAD REQUIREMENT OF CROSS WEDGE ROLLING DIE DESIGN

Cross wedge rolling (CWR) is a process that a cylindrical workpiece is plastically deformed into another axisymmetric shape by the action of two wedge tools moving relative to each other. As a result of the process, initial profile is transformed into round profile by the wedges mounted on the die. In order to perform the defect free process, rolling loads should be well determined in accordance with the movement. Otherwise, instead of rotation around its own axis workpiece may slide and also necking and internal cracks may occur. In this work, the most important process parameters influencing the loads such as stretching angle (beta), forming angle (alpha), reduction ratio (delta) and die velocity (V) are determined as varying parameters. Within this work, different cross wedge rolling conditions have been simulated and analyzed by DEFORM 3D package program. It is realized that two most important zones are knifing and stretching zones. Considerable effort has been paid for the analysis of these two zones. Load requirement of knifing and stretching zones has been successfully identified by its radial and tangential components. Results are discussed by using analysis of variance (ANOVA) method to manifest the interactions of the parameters.