Analysis of interfacial slip in cross-wedge rolling: an experimentally verified finite-element model

摘要

Friction and interfacial slip in metal forming processes are very important parameters whenconsidering tool design, tool wear, and finished product integrity. This paper investigates theinterfacial slip between the forming tool and workpiece in a relatively new metal forming process,cross-wedge rolling (CWR). After a brief description of CWR is given, a three-dimensional finite-element model (FEM) is introduced which realistically characterizes the interfacial slip that occursduring a flat-wedge CWR process. Finite-element results, which are generated for various workpiecearea reductions, are verified using experimental data obtained from a CWR prototype machine thatwas specially designed and constructed for understanding the deformations encountered in CWR.From the close agreement between the experiment and numerical results, it is shown that all of theimportant physical phenomena in the nonlinear deformation process of CWR are included in theFEM.The relevance of developing such a model, as applied to automating CWR tool design, is subsequentlydiscussed.