Closer tolerances, reduced surface roughness, no scale and reduced decarburization can be realized by warm forging. However, the geometrical spectrum of warm forged parts is limited by flow stress. To overcome this geometrical limitation, innovative warm cross wedge rolling and forging processes are developed in the project presented in this paper. To investigate the effect of lower temperatures on process parameters, e. g. force, die wear and material properties in comparison to hot forming processes, Finite Element Analysis (FEA) and experimental tests using downsized model geometry were performed. In this paper the new warm cross wedge rolling process is explained and results of warm cross wedge rolling trials (e. g. work piece characteristics), FEA simulations of forming forces and material analysis are shown. The results of these analyses allow industrial application of warm cross wedge rolling for the first time.
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