Kinematics of cross wedge rolling

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Cross wedge rolling is a process that involves the rotary compressive forming of a rotationally symmetric workpiece using driven rolling tools that move in opposite directions. This technique displaces material along the workpiece's axis of rotation, resulting in high productivity. The partial tool contact reduces tool load, enhancing the longevity of the forming tools. Additionally, the process is easily automated and has a low environmental impact, minimizing vibrations and lubricant use. Its basic applications include producing intermediate shapes for further forming of long parts and creating basic shapes for machining. The forming mechanism in cross wedge rolling is complex, primarily due to the spatial material flow caused by the axial displacement of the wedge-shaped die and the simultaneous rotation of the workpiece. This investigation aims to model the kinematics between the workpiece and tool during cross wedge rolling, focusing on both the unsteady deformation phase—where the rolling wedges penetrate the workpiece to achieve the desired diameter reduction—and the subsequent quasi-stationary phase, characterized by axial material displacement. The modeling will help identify and calculate the dimensions of the contact surfaces that arise during the process.