Study on Formation Mechanism of Axle Part in the New Cross-Wedge Rolling Process Based on Experiment and Simulation

Aiming at the concavity defects in the cross-wedge rolling (CWR) process, one new rolling method named as the twice closed-open joint CWR was presented to improve the use ratio of material in CWR of the axle parts. The new rolling method included three stages: the first closed rolling, the second closed rolling and the last open rolling. To investigate the flow of material in this rolling process, one 3D finite element model (FEM) of the twice closed-open joint CWR was established. The CWR process of one pump spindle part was simulated using the established 3D FEM. The formation, the flow law of metal materials and concavity defects of end were studied. In addition, the CWR experiments were carried out. The results of simulation agreed with the results of tests well. The results proved that the new method can decrease the extent of concavity and improve the material use ratio.