Simulation of cross-wedge rolling process using the upper-bound method

Due to problem complexity, it is very difficult to find any analytical solutions for the cross-wedge rolling process. As yet, no finite element solution has been found. A new simplified analysis method of the cross-wedge rolling process is described in the present study. Therefore, the forming zone has been divided into several layers to be successively used for calculations similar to rotary compression processes. The upper-bound method has been used in the present study to obtain desirable solutions. As a result of numerical simulations, the diagrams were obtained for assessment of average contact pressure versus basic process parameters, i.e., forming angle alpha, spreading angle beta and relative reduction delta. Furthermore, the diagram is included, to be used for determining the limit values of relative reduction delta regarding the necking of the rod criterion. Moreover, to estimate a modelling accuracy, a comparison of the experimentally-obtained data with the theoretically-predicted results has been done.