Cross wedge rolling (CWR) is an innovative metal forming technology with several well-documented benefits over other traditional manufacturing processes. Over the past several years, CWR technology has obtained overwhelming popularity within the United States, especially in the automotive industry. Based on the authors’ academic and industrial experience, recent development techniques for the CWR process are presented. Initially, the experimental and numerical research techniques for analyzing fundamental CWR failure mechanisms are presented with particular emphasis on the finite element method. This is followed by discussion on industrial implementation of cross wedge rolling system, including the required tooling manufacturing process and major supporting systems. Finally several industrial examples are presented to demonstrate feasibility and efficiency of the CWR process with the goal of removing hesitation of US manufacturers to adopt novel CWR technology.
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