Investigating of the production of several eccentric, non-circular cross sections using cross wedge rolling

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The aim of the proposed research project is to study the possibilities of cross wedge rolling for the simultaneous production of several non-circular eccentric cross sections. In addition to the simultaneous generation of different cross sections the orientation of the formed sections is examined as well as the limits of the process, beyond which a cross-wedge rolling due to the transitions or expressions of eccentric elliptical cross sections is no longer possible.First, the production of elliptical cross sections is examined. By locally deforming the material only in radial orientation the cross section area remains constant. The maximum expression of the elliptical cross section, the ratio of the thinnest to thickest diameter, is part of the investigations. In addition to the maximum expression, the forming behavior of the part with several elliptical cross sections will be studied. Another main point of the investigations is the orientation of two elliptical sections to each other. Different orientation results in different force effects affecting on different positions of the component. In order to keep the process stable, the contact point for the different oriented sections needs to be considered.The second aim is to study the production of eccentric sections using cross wedge rolling. The eccentric steps are carried out with a circular shape. As well as within the elliptical investigations, the cross section area stays constant so that material is only formed radial. First, the maximum possible eccentricity is examined. As a further investigation, the orientation of two eccentric sections to each other is examined similar to the studies of the elliptical cross-section.The third aim is to study the combination of elliptical and eccentric sections. With the knowledge gained from the previous studies the possibilities of combining both processes in order to produce several sections with non-circular eccentric cross sections will be investigated.The investigations are carried out first using FEM to reduce tooling costs. Using the FEM results, a modular tool will be designed. With this tool, investigating different parameter combinations are possible.