Characterization of Failure Mechanisms in Cross Wedge Rolling

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A parametric finite element model will be introduced to analyze the deformation behavior of Cross Wedge Rolling (CWR) over a diverse range of operating conditions. In conjunction with the numerical simulations, extensive experiments will be conducted using a CWR prototype machine to quantify the operating conditions that lead to part failure. In addition, an experimental technique for determining the workpiece material flow and failure behavior will be developed. From the combined experimental and numerical efforts, criteria will be established for predicting the three major failure mechanisms encountered during CWR: (1) improperly formed workpiece cross section; (2) external defects on the surface of the workpiece (spiral grooves, overlapping, and necking); and (3) internal defects within the workpiece (porous voids and cracks). The experimental and numerical work represents a significant advance to an emerging manufacturing process.