Three-dimensional rigid–plastic finite element simulation for the two-roll cross-wedge rolling process

In this paper, the process of cross-wedge rolling (CWR) has been simulated and analyzed by the 3D rigid–plastic finite element method. Considering the characteristic of CWR, the static implicit FEM program DEFORM-3D is selected. To simulate all forming stages in the CWR process, dynamic adaptive remeshing technology for tetrahedral solid elements was applied. The stress distributions in the cross-section of the forming workpiece are analyzed to interpret fracture or rarefaction at the center of workpiece. The authors have also analyzed the time–torque curve and the laws of load changing.