Elliptical shaft has been using widely in blank forming for various kinds of precision forging and its step is mostly formed into cone shape with cross wedge rolling (CWR) process. To solve the spiral cone volume, a mathematic model was established by the analysis of rolling process for the CWR elliptical shaft, and shaping curve of oblique step was calculated with the volume invariance principle. In addition, using the finite element software DEFORM-3D, simulations of the CWR forming process for the elliptical shaft were performed to test the correctness of shaping curve, which had achieved good results. The study provides theoretical basis for shaping curve design of inside oblique step for the CWR elliptical shaft and further reduces the tool debugging time.
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