Numerical simulation and optimization of cross wedge rolling parameters

Cross wedge rolling (CWR) is a metal forming process for the production of rotational parts. In this process, a cylindrical billet is plastically deformed to an axisymmetric part by two wedge tools assembled in rolls or plates. Cross wedge rolling has been used in many applications in industrial production in elongated pieces, stepped shafts and axles. These kinds of parts are mainly applied in the automotive machine and aircraft industries. CWR technology has many advantages in comparison to other metal forming methods such as high productivity, high precise product, saving in material and energy cost. In addition to the positive aspects of CWR, this method has not been widely used in industry due to the difficulties of die design. This can mainly be attributed to complexities involved in CWR tool design. The design of CWR tooling is difficult because of the many parameter alternatives that can be encountered during the CWR process.In this thesis, extensive investigation on numerical simulation have been performed to analyze the interactions of CWR parameters by using DEFORM 3D package program. Main effect plots, interactions and the contribution of the parameters were presented by the power of ANOVA and TAGUCHI methods. Prediction of the forming loads and the optimization of the parameters were also searched by ANN.Keywords: Cross Wedge Rolling, Numerical Simulation, ANOVA, TAGUCHI