The paper presents a complete numerical model of a helical-wedge rolling process for producing balls. The model was designed in Finite Element Method (FEM)-based Forge NxT v.1.1 that enables the simulation of both forming and separating balls. A comparison of numerical results with experimental findings revealed a very high agreement in both qualitative and quantitative terms. The developed numerical model was used to investigate the effect of flange shape on the helical-wedge rolling process for producing balls with a diameter of 125 mm. Three types of flange tools were investigated, and the best results were obtained for a wedge-shaped flange.
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